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Volume 12
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Article

Modeling Analysis of Thermal Runaway Propagation and Mitigation in a Large-Format Lithium-Ion Battery Module

by
Xinghuan Xia
1,
Chaohui Shi
1,
An Tao
1,
Lei Zhang
1,
Sen Hu
1,
Keshang Jiang
2 and
Huang Li
2,*
1
PowerChina HuaDong Engineering Corporation Limited, Hangzhou 311122, China
2
Institute of Advanced Technology, University of Science and Technology of China, Hefei 230000, China
*
Author to whom correspondence should be addressed.
Batteries 2026, 12(5), 184; https://doi.org/10.3390/batteries12050184
Submission received: 21 March 2026 / Revised: 30 April 2026 / Accepted: 9 May 2026 / Published: 21 May 2026
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Abstract

A thermal abuse model of a single lithium-ion battery, coupling the electric–chemical reaction model and heat transfer model condition, is presented in this work to predict the battery’s thermal response. This model was validated by the experimental results, and it was found that it can predict the battery’s thermal runaway in adiabatic conditions well. It was found that a local hot spot is formed first on the cell nearest the air gap inside the battery. A thermal runaway propagation model was constructed based on this thermal abuse model of a single battery. In addition, the effect of four different modes on the mitigation of thermal runaway propagation is also discussed, including the air gap, cooling plate and insulation layer. The thermal runaway propagation event is successfully prevented when the aerogel is placed between adjacent batteries. However, low-thermal-conductivity insulation material has a negative effect on the heat sink of the battery in thermal runaway, which may aggravate this behavior. This study demonstrates that the model can be used to predict thermal runaway propagation event in battery modules with different prevention measures, and also contributes to the design of safe lithium-ion battery systems.
Keywords: lithium-ion battery safety; electrochemical–thermal model; thermal runaway propagation; air gap; heat insulation lithium-ion battery safety; electrochemical–thermal model; thermal runaway propagation; air gap; heat insulation

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MDPI and ACS Style

Xia, X.; Shi, C.; Tao, A.; Zhang, L.; Hu, S.; Jiang, K.; Li, H. Modeling Analysis of Thermal Runaway Propagation and Mitigation in a Large-Format Lithium-Ion Battery Module. Batteries 2026, 12, 184. https://doi.org/10.3390/batteries12050184

AMA Style

Xia X, Shi C, Tao A, Zhang L, Hu S, Jiang K, Li H. Modeling Analysis of Thermal Runaway Propagation and Mitigation in a Large-Format Lithium-Ion Battery Module. Batteries. 2026; 12(5):184. https://doi.org/10.3390/batteries12050184

Chicago/Turabian Style

Xia, Xinghuan, Chaohui Shi, An Tao, Lei Zhang, Sen Hu, Keshang Jiang, and Huang Li. 2026. "Modeling Analysis of Thermal Runaway Propagation and Mitigation in a Large-Format Lithium-Ion Battery Module" Batteries 12, no. 5: 184. https://doi.org/10.3390/batteries12050184

APA Style

Xia, X., Shi, C., Tao, A., Zhang, L., Hu, S., Jiang, K., & Li, H. (2026). Modeling Analysis of Thermal Runaway Propagation and Mitigation in a Large-Format Lithium-Ion Battery Module. Batteries, 12(5), 184. https://doi.org/10.3390/batteries12050184

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