Developing safe and high-performance lithium-ion batteries: Strategies and approaches

Abstract

Lithium-ion batteries (LIBs) as an effective low carbon technology provide a solution for achieving NetZero emissions, in line with the Sustainable Development Goals set by the United Nations. Research efforts have been devoted to increasing the energy density and efficiency of LIBs. However, large-scale deployment of LIBs is challenged by thermal runaway and safety problems, particularly under abusive conditions. To tackle this challenge, we must gain insight into the safety features of batteries and design durable strategies by fundamentally analyzing battery thermal runaway processes. In this review, we systematically summarize the abusive indicators that may trigger the thermal issues at the macroscopic level from thermal, chemical, and mechanical perspectives, and point out failure mechanisms that correlate with each component, e.g., cathode, anode, separator, electrolyte and current collector. Beyond material innovations, we emphasize the importance of optimizing industrial-scale manufacturing, integrating regulatory frameworks through advanced battery management systems, and enhancing safety engineering from an battery external perspective. Moreover, we systematically evaluate the contributions of theoretical and computational approaches to battery safety, critically comparing physics-based, machine learning, and hybrid models, and proposing targeted improvements. The broader implications of these safety strategies are considered in the context of environmental sustainability and recycling. Finally, we present design principles for safer, high-performance batteries and outline emerging research and industrial directions through a critical synthesis of thermal runaway mechanisms and mitigation strategies.