Research on Lithium-Battery Electrolyte Safety

Lithium-battery electrolyte safety is a core research focus in battery technology, as traditional liquid electrolytes (composed of lithium salts dissolved in organic solvents like ethylene carbonate and dimethyl carbonate) are highly flammable and prone to leakage—posing fire and explosion risks, especially in high-temperature or mechanical abuse scenarios (e.g., EV collisions or overcharging). Recent research aims to address these risks through electrolyte formulation optimization, the development of alternative electrolyte types, and the integration of safety-enhancing additives, ensuring lithium batteries meet strict safety standards for consumer electronics, EVs, and energy storage systems.

Electrolyte formulation optimization focuses on improving the thermal stability and flame resistance of liquid electrolytes. Researchers are replacing highly flammable solvents with less volatile or flame-retardant alternatives, such as fluorinated carbonates (e.g., fluoroethylene carbonate, FEC) or ionic liquids (salts that are liquid at room temperature). Fluorinated solvents have higher flash points (over 150°C vs. 100°C for traditional solvents) and form a stable protective layer on the anode (solid electrolyte interphase, SEI), reducing solvent decomposition and gas generation. Ionic liquids, meanwhile, are non-flammable, non-volatile, and thermally stable up to 300°C—making them ideal for high-temperature applications like EV batteries. For example, a lithium-ion battery using an ionic liquid electrolyte (e.g., 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide) can withstand temperatures up to 180°C without catching fire, compared to 120°C for conventional electrolytes.

Additive integration is another key safety strategy. Small amounts of additives (0.5–5% by weight) are added to electrolytes to enhance safety without compromising electrochemical performance. Flame-retardant additives (e.g., triphenyl phosphate, TPP) suppress combustion by releasing radical scavengers that stop flame propagation; tests show that electrolytes with 3% TPP have a 70% lower burning rate than pure electrolytes. Overcharge protection additives (e.g., biphenyl) polymerize at high voltages (above 4.5V), forming an insulating layer on the cathode that blocks current flow, preventing electrolyte decomposition and thermal runaway. SEI-forming additives (e.g., vinylene carbonate, VC) promote the formation of a dense, stable SEI layer, reducing solvent consumption and gas generation—critical for preventing battery swelling and leakage.

The development of solid electrolytes represents a transformative approach to electrolyte safety. Solid electrolytes (e.g., ceramic oxides like Li7La3Zr2O12, LLZO; or polymer electrolytes like polyethylene oxide, PEO) are non-flammable, non-leaking, and mechanically robust, eliminating the risk of liquid electrolyte-related fires. Ceramic electrolytes have high ionic conductivity (10–3 S/cm at room temperature) and wide electrochemical stability windows (up to 6V), enabling high-energy-density batteries with lithium-metal anodes. Polymer electrolytes, meanwhile, are flexible and compatible with existing battery manufacturing processes, making them suitable for thin-film batteries in wearable devices. Recent breakthroughs, such as garnet-structured LLZO ceramics with improved ionic conductivity, have brought solid-state batteries closer to commercialization—with some EV manufacturers planning to adopt them by 2030.

Safety testing methodologies are also advancing to evaluate electrolyte performance under real-world abuse conditions. Researchers use techniques like accelerating rate calorimetry (ARC) to measure heat release during thermal runaway, and nail penetration tests to simulate mechanical damage. These tests show that advanced electrolytes (e.g., solid electrolytes or flame-retardant liquid electrolytes) reduce the maximum heat release rate by 50–80% and delay thermal runaway by 2–5 minutes—providing critical time for safety systems (e.g., battery management systems, BMS) to mitigate risks.

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