Development and Validation of an Electromagnetic Induction-Based Thermal Propagation Test Method for Large-Format Lithium-Ion Battery Systems

This study establishes a standardized framework for thermal propagation test in nickel-7 lithium-ion battery systems through a high-frequency electromagnetic induction heating method. The non-intrusive triggering mechanism enables precise thermal runaway initiation within two seconds through localized eddy current heating (>1200 °C), validated through cell-level tests with 100% success rate across diverse trigger positions. System-level thermal propagation tests were conducted on two identical battery boxes. The parallel experiments revealed distinct propagation patterns influenced by system sealing quality. In the inadequately sealed system (Box 01), flame formation led to accelerated thermal propagation through enhanced convective and radiative heat transfer. In contrast, the well-sealed system (Box 02) maintained an oxygen-deficient environment, resulting in a controlled sequential propagation pattern. The testing methodology incorporating dummy modules proved efficient for validating thermal protection strategies while optimizing costs. This study contributes to a deeper understanding of thermal runaway propagation mechanisms and the development of standardized testing protocols for large-format battery systems.