How are Different Types of Lithium-Ion Batteries Tested to Determine and Verify Optimal Containment?

Understanding Battery Capacity and Containment Solutions

When it comes to lithium batteries, accurate testing is essential for developing effective containment and suppression solutions. Each battery is unique, and its Battery Management System (BMS) can alter its performance.

For example, a battery rated at 3 volts at the cell level may have its charging limited to 2.5 volts by the BMS. This restriction helps extend battery life and improve safety, but when testing for thermal runaway containment, we always evaluate the battery at its full capacity—not just what the BMS allows. Testing at worst-case conditions ensures that our containment solutions can handle the most extreme scenarios.

At Americase, as a custom container manufacturer, we tailor each solution based on our customers’ needs. Some clients only need protection against smoke, while others require full containment of fire, shrapnel, and hazardous gases. Testing batteries at their maximum state of charge allows us to determine the most effective solution for each scenario.

How We Conduct Battery Testing

To fully understand a battery’s performance and risks, we use charge-discharge and monitoring equipment to test batteries in multiple conditions. Our process includes:

Charging the battery through the BMS to verify its manufacturer-stated capacity.
Removing BMS restrictions and testing based on the battery’s actual capabilities.
Cycling the battery (charging and discharging fully) to measure watt-hours, amp-hours, and milliamp-hours.
Pushing the battery to 100% state of charge to simulate worst-case thermal runaway conditions.

By running these tests, we gather critical data that informs how we design containment and suppression solutions for each battery type.

Key Testing Conditions for Thermal Runaway

Many people think testing conditions are limited to temperature, humidity, or lab environments—but there’s much more to it. While we control environmental factors, we also evaluate:

• Battery condition: Is it a brand-new OEM battery, or has it been damaged (e.g., from a recall or vehicle crash)?
• External stressors: Has the battery been exposed to excessive heat before testing (simulating real-world conditions like sitting in the sun)?
• Worst-case scenarios: Do we allow cell-to-cell propagation, or do we force every cell into simultaneous thermal runaway to see the worst possible outcome?

These considerations ensure that our testing accurately replicates real-world risks, allowing us to engineer the safest possible containment solutions.

Meeting Regulatory Standards for Safe Transport

Lithium batteries are classified as hazardous materials, meaning their transportation is regulated by various safety standards. We design packaging solutions that comply with:

1. 49 CFR Regulations

The Code of Federal Regulations (CFR 49) outlines shipping requirements for lithium batteries. Any containment solution must meet these regulations to ensure legal compliance.

2. Special Permits for Unique Situations

In some cases, standard regulations don’t cover certain battery shipping needs. In these situations, we help clients obtain special permits.

For example, we developed Special Permit SP16011, which allows the shipment of batteries under 100 kWh in a damaged, defective, or recalled (DDR) condition without requiring hazmat training for the shipper. This was crucial for a customer needing to transport thousands of recalled units from multiple locations.

Each special permit is different, and we work closely with clients to customize packaging solutions that comply with these unique exemptions.

3. Customer-Specific Requirements

Since we specialize in custom packaging, we design our containment solutions based on:

• The client’s specific needs (e.g., reducing weight, minimizing costs, or meeting international shipping regulations).
• Bypassing limitations (e.g., allowing the shipment of batteries above 30% state of charge).
• Future-proofing packaging to accommodate battery technology advancements.

By balancing regulatory requirements with custom solutions, we help clients achieve safe, compliant, and scalable packaging.

How We Verify Containment & Suppression Solutions

One of the most critical aspects of our work is verifying that our solutions perform as expected. To do this, we rely on:

AS6413 Testing – This standard, developed by the SAE G27 subcommittee, ensures that a battery containment system can:

• Withstand 100% state-of-charge thermal runaway events.
• Prevent flames, shrapnel, and hazardous particles from escaping.
• Contain all hazardous gases without risk of explosion.

Spark Ignition Chamber Testing – We evaluate gases released during a thermal runaway to ensure they do not ignite, further verifying the effectiveness of containment.

Rigorous Pass/Fail Criteria – Regulators often require 3 out of 5 passes, but we aim for 3 out of 3 or even 5 out of 5 to ensure higher safety margins. This results in faster approvals for special permits.

Ensuring Repeatable, Reliable Test Results

Since battery packaging solutions must perform consistently, our testing approach ensures:

• Controlled, repeatable thermal runaway events – Every test must yield reliable results to validate containment.
• Worst-case scenario preparation – By pushing batteries to their limits, we ensure that future battery advancements won’t outgrow our containment solutions.
• Future-proofing packaging solutions – Instead of testing at the current watt-hour capacity, we test well beyond, so clients can use the same packaging for years.

For example, if a 100-watt-hour battery is expected to grow to 300 watt-hours in future models, our packaging is tested beyond that threshold to ensure long-term compliance.

Final Thoughts: The Future of Lithium Battery Containment

At Americase, we take a comprehensive approach to battery containment and transport safety. By combining worst-case scenario testing, regulatory compliance, and future-proof packaging solutions, we provide safe, scalable, and reliable containment solutions for lithium batteries in all industries.

As battery technology continues to evolve, so will our methods and solutions—ensuring that businesses, manufacturers, and consumers can safely transport and store lithium batteries without risk.

If you’re looking for a custom containment solution or need guidance on regulatory compliance and special permits, reach out to our team at Americase. Let’s build a safer, more sustainable battery future together.