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Ask Me Anything About LFP Batteries and More! – Industry insider at top EV firm

My question: any thoughts on the "my house burned down" thread relating to the stationary LFP battery that burned down someone's home and what should have been done differently?

Also curious if you have any opinion or insight on Sakuú's new dry-printed metal-free cells that stack rather than requiring inter-cell connectors?
 
My question: any thoughts on the "my house burned down" thread relating to the stationary LFP battery that burned down someone's home and what should have been done differently?

Also curious if you have any opinion or insight on Sakuú's new dry-printed metal-free cells that stack rather than requiring inter-cell connectors?
Maybe I missed them, but I don't recall reading any threads where it was the actual battery cells that caused the fires due to thermal runaway. Most of the threads I remember reading it was things like faulty connections, wiring, or fuses that overheated and caused the fire.

That's the thing about safety engineering that I think is often overlooked. Safety is only as good as the weakest link in the overall system. IMO the DIY community gets overly focused on the potential for battery cell safety issues and as a result often overlook more likely safety issues in other parts of the system. If you're building a battery with lots of interconnects and bus bars and such, then every single connection requires close attention for torque of fasters to specific specs and checking resistances and such. In a commercial setting, none of that would ever be done by hand, it would be done by automated equipment that would keep a record of all torque specs and record of every test done to ensure quality and safety. Or because all that's a lot of work, manual connections would be completely avoided because it's too costly and unreliable to guarantee quality and safety.

Working in the industrial products industry and as a result being involved with a lot of automotive, defense, and aerospace post failure analysis activities, it was interesting to see how the often mundane details ended up causing the majority of issues. It's also interesting to see the rigor of analysis methods developed by large sub-system suppliers such as Bosch and their peers.
 
Maybe I missed them, but I don't recall reading any threads where it was the actual battery cells that caused the fires due to thermal runaway. Most of the threads I remember reading it was things like faulty connections, wiring, or fuses that overheated and caused the fire.

That's the thing about safety engineering that I think is often overlooked. Safety is only as good as the weakest link in the overall system. IMO the DIY community gets overly focused on the potential for battery cell safety issues and as a result often overlook more likely safety issues in other parts of the system. If you're building a battery with lots of interconnects and bus bars and such, then every single connection requires close attention for torque of fasters to specific specs and checking resistances and such. In a commercial setting, none of that would ever be done by hand, it would be done by automated equipment that would keep a record of all torque specs and record of every test done to ensure quality and safety. Or because all that's a lot of work, manual connections would be completely avoided because it's too costly and unreliable to guarantee quality and safety.

Working in the industrial products industry and as a result being involved with a lot of automotive, defense, and aerospace post failure analysis activities, it was interesting to see how the often mundane details ended up causing the majority of issues. It's also interesting to see the rigor of analysis methods developed by large sub-system suppliers such as Bosch and their peers.
Ignition source and failure of cells are independent factors. From the thread we know what things could have prevented the fire, but we don't know what could have caused the cell failure that underlies the fire event.
 
Ignition source and failure of cells are independent factors. From the thread we know what things could have prevented the fire, but we don't know what could have caused the cell failure that underlies the fire event.
We don't know if it was a cell failure. It is presumed a cell failed, it could have been any number of failures.
 
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So I've seen pictures of honkin huge 560 and 770ah cells that I'm sure are aimed at ESS systems and grid storage. It seems they're the same thing as what we have just bigger, so my question is do you see anything in the works (in the lab at least, not just on paper) that can crack the energy density issue that batteries have? The whole world wants to push electrification without the infrastructure and that is what keeps fossil fuels on the table, the fact that batteries can't beat it kilogram per kilogram. Is there any hope in breaking this or are we going to have to find an unknown alien element on a far away planet to mine?
 
@battery_professional

So I've seen pictures of honkin huge 560 and 770ah cells that I'm sure are aimed at ESS systems and grid storage. It seems they're the same thing as what we have just bigger, so my question is do you see anything in the works (in the lab at least, not just on paper) that can crack the energy density issue that batteries have? The whole world wants to push electrification without the infrastructure and that is what keeps fossil fuels on the table, the fact that batteries can't beat it kilogram per kilogram. Is there any hope in breaking this or are we going to have to find an unknown alien element on a far away planet to mine?
Makes me wonder how high up in the periodic table they are experimenting for cathode materials?

Cesium seems much more reactive than lithium or sodium. Our chemistry teacher claimed to have put a pea size piece of cesium in a aquarium full of water, it blew the tank up.

Maybe though the breakthroughs will come from a new way of arranging atoms of the same elements currently used. Regular charcoal, diamond, and graphene are all just carbon, arranged differently.
 
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