Safe or Slow? The Illusion of Thermal Stability Under Reduced-Velocity Nail Intrusion

Abstract

This study investigates the effects of nail penetration speed on the safety outcomes of large-format automotive lithium-ion pouch cells. Through six controlled tests varying the speed of nail insertion, we observed that lower penetration speeds did not induce thermal runaway; instead, the cells exhibited self-discharge while the nail remained embedded. These findings suggest that penetration speed is a critical factor in the onset of thermal runaway, providing valuable insights for the development of safer battery systems and more effective safety testing protocols.