Physics of Battery Thermal Runaway: What Actually Happens Inside EV Batteries
Electric vehicles have transformed transportation, yet one persistent risk continues to capture headlines and engineering attention: battery thermal runaway. This is not simply “the battery catches fire.” It is a rapid, self-accelerating sequence of chemical and physical events that can turn a stable lithium-ion cell into a source of intense heat, gas, and flame within seconds. Understanding the hidden physics behind it is essential for safer battery design and more informed public discussion.
Thermal runaway begins when a lithium-ion cell is pushed beyond its safe operating window. Triggers include external heat, mechanical crush, internal short circuits from manufacturing defects, or overcharging.
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