Feature: Batteries


Lithium-ion battery handling By Grant Gibbs, Senior Manager for Energy Storage, TÜV SÜD


L 18 June 2025 www.electronicsworld.co.uk


ithium-ion batteries are found in all types of electrical and electronic devices, including consumer products, wearable medical devices, vehicles and


advanced industrial equipment. However, the widespread use of lithium-ion batteries has also brought to the forefront concerns about their safety. While technology development has


advanced over the last few decades, it has also presented new fire and explosion risks. Normally safe under most use conditions, lithium-ion batteries that are poorly designed or which consist of low-quality materials, or which have been assembled incorrectly or have been damaged can overheat and even explode, potentially resulting in catastrophic consequences involving life and property. As well as many benefits, there are


potential safety risks related to thermal stability and internal short circuits with lithium-ion batteries. Safety problems


arise due to poor design, the use of low- quality materials, incorrect assembly, or damage. Even for lithium-ion batteries with integrated safety features, an unanticipated breach in the battery separator material can result in a high current that overheats the battery’s electrolyte. While battery manufacturers and


developers are continually improving lithium-ion battery design and performance, this can make them more vulnerable to small manufacturing defects or internal damage from the physical impact with another object. Variations in battery design, and the quality of materials and manufacture can also cause potential safety risks. Of course, this problem will be


magnified if large quantities of batteries are stored on-site or transported between industrial and commercial facilities. Fortunately, there are important steps that operators of such facilities can take to reduce the risks. For example, idle


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