Assessing Lithium-Ion Battery Safety Under Extreme Transport Conditions: A Comparative Study of Measured and Standardised Parameters

The safety of lithium-ion batteries during transportation is critically important. However, current standards exhibit limitations, as their environmental testing parameter thresholds fail to fully encompass actual transportation conditions. To enhance both safety and standard applicability, in this study, we focused on four representative environmental conditions: temperature, vibration, shock, and low atmospheric pressure. Field measurements were conducted across road, rail, and air transport modes using a self-developed data acquisition system based on the NearLink communication technology. The measured data were then compared with the threshold values defined in current international and national standards. The results reveal that certain measured values exceeded the upper limits prescribed by existing standards, indicating limitations in their applicability under extreme transport conditions. Based on these findings, we propose revised testing parameters that better reflect actual transport risks, including a temperature cycling range of 72 ± 2 °C (high) and −40 ± 2 °C (low), a shock acceleration limit of 50 gn, adjusted peak frequencies in the vibration PSD profile, and a minimum pressure threshold of 11.6 kPa. These results provide a scientific basis for optimising safety standards and improving the safety of lithium-ion battery transportation.