Thermal Runaway Propagation in Pouch-Type Lithium-Ion Battery Modules: Effects of State of Charge and Initiation Location

Abstract

The widespread adoption of lithium-ion batteries (LIBs) in electric vehicles (EVs) and energy-storage systems (ESSs) has raised growing concern about fire hazards caused by thermal runaway (TR). While many studies have examined cell-level TR mechanisms, investigations at the module level remain limited despite their importance for safety design. In this study, TR propagation was experimentally analyzed in a 12-cell (2p6s) pouch-type LIB module with EV-grade cells. The state of charge (SOC) and initiation location were the main variables. TR was initiated by a surface-mounted Kapton heating film, with power increased stepwise from 63 W to 141 W at 5-min intervals. Temperature, voltage, and heat release rate (HRR) were continuously monitored. Results showed that higher SOC led to earlier TR onset, shorter vent-to-ignition delay, and stronger combustion with jet flames. Center initiation produced rapid bidirectional propagation with a peak heat release rate (PHRR) of 590 kW and a propagation time of 107 s, whereas edge initiation caused slower unidirectional spread with a PHRR of 105 kW and a propagation time of 338 s. These results demonstrate that both SOC and initiation location critically control TR severity and propagation, providing essential data for EV fire safety evaluation and module design.