Preventing Thermal Runaway Propagation in Lithium-Ion Batteries: A Holistic Review of Materials, Systems, and Predictive Strategies

Thermal runaway (TR) propagation in lithium-ion batteries (LIBs) poses significant safety risks in applications such as electric vehicles (EVs) and grid-scale energy storage systems. This comprehensive review synthesizes current research on TR mechanisms encompassing mechanical, electrical, and thermal abuse scenarios and evaluates mitigation strategies, including thermal barrier materials and advanced cooling systems. Experimental and computational studies underscore the efficacy of materials like aerogels, ceramic fibers, and phase-change composites, as well as active cooling methods such as liquid cooling and heat pipes, in suppressing TR propagation. Challenges in scalability, cost, and standardization are critically analyzed, with recommendations for interdisciplinary collaboration to bridge gaps between laboratory innovations and commercial deployment. Emerging solutions, including bio-derived aerogels, hydrogel composites, and hybrid cooling systems, are highlighted as sustainable pathways for next-generation battery safety.