What Happens When a Lithium-Ion Battery Fails?

The Hidden Danger of Lithium-Ion Batteries: Fire Risks and Toxic Gas Emissions

Lithium-ion batteries power our modern world—from e-scooters and e-bikes to power tools and household electronics. However, these powerful energy sources also pose significant fire and explosion risks when damaged or improperly handled.

But what exactly happens when a lithium-ion battery fails? Let's dive into the science behind thermal runaway, toxic gas emissions, and the fire hazards associated with these batteries.

What Happens When a Lithium-Ion Battery Fails?

When a lithium-ion battery is damaged (due to overcharging, puncture, overheating, or internal failure), it can undergo a process called thermal runaway—an uncontrollable temperature increase leading to gas release, fire, or even an explosion.

Each 18650 lithium-ion cell (commonly found in e-mobility devices) can release between 2 to 8 liters of toxic gases. Now, consider that:

• An electric drill battery contains at least 10 cells
• An e-scooter battery holds at least 20 cells
• An e-bike battery contains at least 50 cells

That means a malfunctioning e-bike battery could release over 400 liters of hazardous gases!

What Toxic Gases Are Released?

Research on lithium-ion battery fires has identified the following primary gases:

🔴 Carbon Dioxide (CO₂) – Up to 50% of the gas mixture, formed from electrolyte breakdown.
⚫ Carbon Monoxide (CO) – A deadly gas, even in small concentrations.
💨 Hydrogen (H₂) – Highly flammable and explosive.
🔥 Hydrocarbons (Methane, Ethane, Ethylene, Propane) – Flammable compounds contributing to fire hazards.
☠️ Hydrogen Fluoride (HF) – One of the most dangerous emissions; highly toxic and corrosive, even in trace amounts.

Why Are These Gases Dangerous?

1️⃣ Toxicity & Corrosiveness – Gases like HF can cause severe chemical burns and respiratory distress.
2️⃣ Explosion Risk – Hydrogen and hydrocarbons form explosive mixtures in the air.
3️⃣ Carbon Monoxide Poisoning – CO is odorless, colorless, and deadly in enclosed spaces.
4️⃣ Fire Propagation – Lithium battery fires are self-sustaining and extremely difficult to extinguish.

How to Stay Safe?

✅ Safe Storage & Transport – Store batteries in fireproof containers or certified protective covers.
✅ Prevent Mechanical Damage – Avoid impacts, punctures, or exposure to high temperatures.

Fireproof Covers: Essential Protection for E-Mobility Devices

Given the risks, using eWesta fire-resistant covers is one of the best ways to mitigate fire hazards. These covers help:

✔️ Contain fires if a battery ignites.
✔️ Reduce toxic gas exposure by limiting oxygen access.
✔️ Prevent fire spread to surrounding objects.

With the rising popularity of e-bikes and e-scooters, it's crucial to prioritize fire safety solutions for homes, businesses, and transport.

Final Thoughts

Lithium-ion battery failures are not just a hypothetical risk—they are a growing real-world problem. As e-mobility expands, understanding and mitigating these dangers is essential.

Investing in fireproof storage solutions can mean the difference between a minor incident and a catastrophic fire.

👉 Stay safe. Protect your batteries. Choose eWesta fireproof covers.

Sources

1️⃣ Research on Thermal Runaway in Li-Ion Batteries, Battery Safety Science
2️⃣ International Fire Protection Association (IFPA) Reports
3️⃣ Lithium-Ion Battery Fire Case Studies, Fire Engineering Journal