Lithium-Ion Battery Handling and Safety 330

adhesives

A substance used to join two or more materials without welding or mechanical fasteners. Adhesives include glues, resins, and epoxies.

anode

The negative electrode in a battery. The anode in a lithium-ion battery is usually made of carbon.

battery management system

BMS. A computer that monitors, regulates, and coordinates the operations of a battery pack. The battery management system helps to prevent overheating and thermal runaway.

battery packs

A group of battery cells connected together to produce large amounts of electrical energy. Battery packs may also include components such as sensors and battery management systems.

BMS

Battery management system. A computer that monitors, regulates, and coordinates the operations of a battery pack. The BMS helps to prevent overheating and thermal runaway.

carbon monoxide

A colorless, odorless, poisonous gas made of carbon and oxygen. Carbon monoxide may be released by burning Li-ion batteries.

cathode

The positive electrode in a battery. The cathode in a lithium-ion battery is made from a lithium compound.

cell

A single unit of a battery. A cell contains a cathode, an anode, and an electrolyte solution.

chain reaction

A sequence of events that occurs when the results of one reaction trigger more reactions of the same type. Chain reactions like thermal runaway in Li-ion batteries can create serious safety hazards.

coolant

A liquid used to decrease the temperature of a battery pack or other system. Liquid coolant lowers temperature more efficiently than air-based cooling mechanisms.

cooling mechanism

A device that removes heat from an electrical system in order to regulate temperature. Cooling mechanisms in battery packs work by circulating either air or liquid coolant.

corrosive

Capable of irreparably harming living tissues or damaging material upon contact. Corrosive chemicals include acids and certain organic materials.

coveralls

Protective clothing that covers the entire body from the wrists to the ankles. Coveralls provide good general protection for the skin.

cycle life

The total number of times a secondary cell battery can be discharged and recharged before it must be replaced. Cycle life depends on the battery's design, materials, and operating conditions.

diagnostics

A set of computer instructions that helps users or technicians investigate or analyze the cause or nature of errors or failures. Diagnostics performed by a BMS can help identify the cause of problems such as overheating.

dielectric boots

Insulating rubber footwear that protects the feet and lower legs from electric shock. Dielectric boots may be worn by themselves or over other footwear.

discharge

To release electrical energy. Discharging electrical components is often necessary for safe maintenance and repair work.

electric shock

The flow of electricity through the body. Severe electric shock can be fatal.

electric vehicles

EVs. A vehicle that is propelled by an electric motor that draws its power from a battery. Electric vehicles require high-energy, lightweight, rechargeable batteries.

electrolyte

A conductive solution containing an acid, an alkaline, or a salt. The electrolyte in a battery connects the two electrodes.

energy capacity

The total amount of electricity that a battery can supply over the course of one discharge cycle. Energy capacity in batteries is measured in watt-hours (Wh) or kilowatt-hours (kWh).

energy density

The amount of energy that a battery can supply per unit of volume. High energy density allows small batteries to supply large amounts of energy.

EVs

Electric vehicles. A vehicle that is propelled by an electric motor that draws its power from a battery. EVs require high-energy, lightweight, rechargeable batteries.

face shield

A rigid, transparent plastic sheet worn over the face to protect against dust, sparks, and splashes. Face shields do not protect against impacts, so they are often worn with safety goggles.

first aid

Short-term medical treatment that is administered immediately after an injury or health event. First aid, such as bandaging small cuts or treating minor burns, requires little technology or training to administer.

flammable

Capable of easily igniting and starting a fire. Flammable liquids are often used as electrolytes in lithium-ion batteries.

graphite

A soft, black form of carbon. Graphite is highly conductive.

hard hat

A lightweight, protective head covering used to protect the head from impacts. Hard hats may also be insulated to protect against electric shock.

hearing protection

A type of personal protective equipment specifically designed to prevent hearing damage. Earplugs are the most common form of hearing protection.

high-voltage interlock loop

HVIL. A low-voltage circuit that runs in parallel through a system of high-voltage connections and becomes disconnected if any of those connections are loosened or damaged. High-voltage interlock loops trigger an alert when disconnected and are used in devices such as EVs.

housing

A protective cover designed to contain the cells, modules, and all the circuitry and sensors required for a battery pack to function. A battery housing can be rigid metal or plastic.

hydrofluoric acid

A colorless liquid made of hydrogen and fluorine that is highly toxic and highly corrosive. Exposure to hydrofluoric acid should be treated as a serious medical emergency.

insulated

Covered in a material that prevents the passage of electricity. Insulated gloves, boots, and hard hats are common PPE for electrical work.

International Electrotechnical Commission

IEC. An international organization that prepares and publishes standards for electrical, electronic, and related technologies. The International Electrotechnical Commission develops standards that are applied in the European Union and many other countries.

ions

A charged atom or molecule. An ion can be either positive or negative depending on whether it has a shortage or surplus of electrons.

job briefings

A meeting during which supervisors and employees prepare for an upcoming task by reviewing job duties, risks, safety measures, and other important information. Job briefings are a required part of preparing for energized electrical work.

laptops

A small, portable personal computer with an attached keyboard. Laptops typically use lithium-ion or lithium polymer batteries.

LCO batteries

Lithium cobalt oxide batteries. A type of lithium-ion battery with a cathode made of lithium cobalt oxide. LCO batteries have high specific energy but low specific power and are commonly used in portable electronics.

LFP batteries

Lithium iron phosphate batteries. A type of lithium-ion battery with a cathode made of lithium iron phosphate. LFP batteries have high thermal stability but low specific energy.

Li-ion battery

Lithium-ion battery. A type of secondary cell battery that uses a lithium compound as a cathode and usually graphite as an anode. Li-ion batteries are widely used in portable electronics and electric vehicles.

lithium

A lightweight, silver-white metal that is highly reactive. Lithium is often used in batteries because it is extremely energy-dense.

lithium-ion batteries

Li-ion batteries. A type of secondary cell battery that uses a lithium compound as a cathode and usually graphite as an anode. Lithium-ion batteries are widely used in portable electronics and electric vehicles.

LTO batteries

Lithium titanate batteries. A type of lithium-ion battery with an anode made of lithium titanate. LTO batteries have high thermal stability but low specific energy.

manual service disconnect

A plug or switch that electrically isolates the battery pack from the rest of an EV's electrical systems when activated. The manual service disconnect, also called the service disconnect, should be activated before beginning maintenance or repair work.

module

A unit that contains several battery cells connected in either series or parallel. Modules are usually surrounded by a hard plastic case.

National Fire Protection Association

NFPA. An organization devoted to eliminating deaths, injuries, and damage caused by fires. The National Fire Protection Association also publishes standards for electrical safety.

NCA batteries

Lithium nickel cobalt aluminum oxide batteries. A type of lithium-ion battery with a cathode made of lithium nickel cobalt aluminum oxide. NCA batteries have high specific energy and higher specific power than LCO batteries.

NFPA

National Fire Protection Association. An organization devoted to eliminating deaths, injuries, and damage caused by fires. The NFPA also publishes standards for electrical safety.

NFPA 70E

The standard for electrical safety in the workplace. NFPA 70E is used by OSHA to provide work safety guidelines for those working with electricity.

NMC batteries

Lithium nickel manganese cobalt oxide batteries. A type of lithium-ion battery with a cathode made of lithium nickel manganese cobalt oxide. NMC batteries have high specific energy and higher specific power than LCO batteries.

Occupational Safety and Health Administration

OSHA. A government agency under the U.S. Dept. of Labor that sets the standards for working conditions in the United States. The Occupational Safety and Health Administration ensures that employees work in safe and healthy environments.

OSHA

Occupational Safety and Health Administration. A government agency under the U.S. Dept. of Labor that sets the standards for working conditions in the United States. OSHA ensures that employees work in safe and healthy environments.

personal protective equipment

PPE. Any article of clothing or device worn or used to minimize exposure to hazards and prevent injury. Common personal protective equipment includes safety glasses, hard hats, and gloves.

polymer

A material made of long chains of molecules, making it tough and elastic. Polymers include plastics, rubber, polyester, nylon, and many other natural and synthetic materials.

portable fire extinguishers

A tank of extinguishing agent that sprays out of a hose, horn, or nozzle when a lever is squeezed. Portable fire extinguishers should be visually inspected once a month and given a full inspection once a year.

power

The rate at which a device converts energy from one form to another, such as converting electrical energy into light or movement. Power is measured in watts (W).

PPE

Personal protective equipment. Any article of clothing or device worn or used to minimize exposure to hazards and prevent injury. Common PPE includes safety glasses, hard hats, and gloves.

respirator

A breathing device worn to prevent inhalation of hazardous substances. Respirators may purify air or supply clean air for the wearer.

risk assessments

A documented process that an organization uses to evaluate and plan for possible safety hazards. Risk assessments for electrical work include evaluations of the risks of electric shock and arc flash.

robots

A machine that can be programmed to automatically perform complicated and repetitive tasks. Robots often perform work more precisely and consistently than humans.

safety data sheet

SDS. A document of mandatory information that must accompany almost every chemical in the workplace. Safety data sheets include details such as the hazards, precautions, and first aid procedures associated with a chemical.

safety goggles

Tight-fitting eye protection that completely covers the eyes and the area surrounding the eyes. Safety goggles protect against sparks and flying debris.

secondary cell batteries

A battery that can be recharged. Secondary cell batteries are charged by running electrical current back through them to restore their chemical energy.

sensors

A device that detects a change in physical or environmental conditions and sends or stores data about that change. Sensors inside battery packs track conditions such as temperature and voltage.

service disconnect

A plug or switch that electrically isolates the battery pack from the rest of an EV's electrical systems when activated. The service disconnect, also called the manual service disconnect, should be activated before beginning maintenance or repair work.

service life

The length of time a battery is expected to operate before it must be replaced. The service life of a rechargeable battery is determined by its materials and operating conditions.

smartphones

A mobile device able to connect to and send data across the internet. Smartphones are used for phone calls, texting, internet browsing, and many other functions.

SoC

State of charge. The charge level of a battery. State of charge is usually given as a percentage, with 100% indicating a fully charged battery and 0% indicating a completely discharged battery.

specific energy

The amount of energy that a battery can supply per unit of weight. High specific energy allows lightweight batteries to supply large amounts of energy.

state of charge

SoC. The charge level of a battery. State of charge is usually given as a percentage, with 100% indicating a fully charged battery and 0% indicating a completely discharged battery.

thermal burns

An injury caused by contact with fire, heated objects, or hot liquids or gases. Thermal burns can range from minor to potentially fatal burns.

thermal imagers

A thermal inspection device that uses infrared technology to produce a visual representation of temperature conditions. Thermal imagers are also called infrared cameras.

thermal interface materials

TIMs. Any material that dissipates or conducts heat between two or more contacting surfaces. Thermal interface materials are used to made include cushions, adhesives, seals, and other components in battery packs.

thermal runaway

The process of a defective or damaged battery cell overheating and damaging nearby cells, causing them to also overheat. Thermal runaway can cause fires or explosions.

thermal stability

The ability of a material to resist changes in physical shape or size as its temperature changes. Batteries with low thermal stability can malfunction or catch fire as their materials warp at high temperatures.

toxic

Poisonous or harmful. Toxic substances can cause a range of illnesses and must be handled carefully.

troubleshoot

The systematic process of solving problems quickly and efficiently. Troubleshooting often involves a logical process of elimination to identify the source of a problem.

Underwriters Laboratories

UL. A private company that is certified to perform product safety testing and certification by OSHA and other government agencies. Underwriters Laboratories publishes safety testing standards for Li-ion batteries.

ventilation

A means of providing fresh air. Ventilation helps prevent employees from inhaling chemicals.

voltage

The electrical force or pressure that causes current to flow in a circuit. Voltage is also known as electromotive force and is measured in volts (V).

volts

V. A unit of measurement that indicates the amount of electrical force or pressure in a circuit. Volts measure voltage, which is also known as electromotive force.