Exponent Burn Box Report 3 - Prba

Failure Analysis Associates

US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds Addendum—Prismatic Battery Packs and Pressure Measurements

Doc. no. SF34041.001 C0T0 0605 CM01

US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds Addendum—Prismatic Battery Packs and Pressure Measurements Prepared for David B. Weinberg, Esq. Wiley Rein & Fielding LLP 1776 K Street NW Washington, DC 20006 Prepared by Celina Mikolajczak, P.E. Alex Wagner-Jauregg Exponent 149 Commonwealth Drive Menlo Park, CA 94025 June 2, 2005 Exponent, Inc.

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Contents

Page

List of Figures iii

List of Tables vi

Acronyms and Abbreviations vii

Executive Summary viii

Introduction 1

Experimental Set-Up 2

Pressure Transducer 2

Cells and Battery Packs 5

Results 6

Temperature and Heat Flux Results 11 Individual Prismatic Battery Pack Tests: Manufacturer D 11 Tests of Prismatic Cell Phone Battery Packs as Packaged for Bulk Shipment—Manufacturer D 16

Cargo Liner Integrity Tests: Manufacturer D 18

Halon 1301 Suppression Tests: Manufacturer D 20

Pressure Measurement Results: Manufactures B, C, and D 23

Conclusions 26

References 27

Appendix A Data from Testing A-1

Appendix B Post Testing Photographs B-1

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List of Figures

Page

Figure 1. Typical pressure measurement data: Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data. 4

Figure 2. Summary of peak ceiling temperatures for all tests described in original report and this addendum. 8

Figure 3. Summary of peak 5-second averaged heat flux at the ceiling for all tests described in original report and this addendum. 9

Figure 4. Summary of peak temperatures measured 12 in. above the floor of the chamber for all tests described in original report and this addendum. 10

Figure 5. A stack of 16 battery packs as prepared for testing. 12

Figure 6. A stack of 16 battery packs after testing. 13

Figure 7. Compilation of temperature data for all Manufacturer D bare pack tests. 14

Figure 8. Compilation of 5-second averaged heat flux at the ceiling for all Manufacturer D bare pack tests. 14

Figure 9. Compilation of temperature data for all bare cell and prismatic pack tests described in the original report and this addendum. 15

Figure 10. Compilation of 5-second averaged heat flux at the ceiling for all bare cell and prismatic pack tests described in the original report and this addendum 16

Figure 11. Six Manufacturer D individually packaged battery packs before testing. 17

Figure 12. Manufacturer D packs and packaging after testing. 17

Figure 13. Front and back of Cargo Liner A after testing with 4 Manufacturer D packs. 19

Figure 14. Front and back of Cargo Liner B after testing with 4 Manufacturer D packs. 19

Figure 15. 4 Manufacturer D cells, before and after Halon 1301 suppression testing. 21

Figure 16. Tests with 4 Manufacturer D cells, without suppression (top), and with Halon 1301 application after cells began to vent (bottom). 22

Figure 17. Detailed view of 1Hz pressure trace for Manufacturer D 16 pack test. 25

Figure A-1. Calibration Test 3/31/05, 5 in. Pan, 100% vent area. A-1

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Figure A-2. Calibration Test 5/12/05, 5 in. Pan, 100% vent area. A-2

Figure A-3. Manufacturer D, single battery pack, 50% SOC, 5 in. pan. A-3

Figure A-4. Manufacturer D, single pack, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate. A-4

Figure A-5. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan. A-5

Figure A-6. Manufacturer D, 4 packs, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data. A-6

Figure A-7. Manufacturer D, 16 battery packs, 50% SOC, 5 in. pan. A-7

Figure A-8. Manufacturer D, 16 packs, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, inset shows maximum peak recorded at 4 kHz sampling rate. A-8

Figure A-9. Manufacturer D, 6 packs in packaging material, 50% SOC, 5 in. pan. A-9

Figure A-10. Manufacturer D, 6 packs in packaging material, 50% SOC, 5 in. pan, 4 kHz pressure data for pressure peak. A-10

Figure A-11. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner A. A-11

Figure A-12. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner B. A-12

Figure A-13. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Halon 1301 applied after approximately 1 minute 20 seconds. A-13

Figure A-14. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Halon 1301 applied after approximately 1 minute 20 seconds, 4 kHz pressure data for pressure peaks. A-14

Figure A-15. Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded. A-15

Figure A-16. Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data. A-16

Figure A-17. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded A-17

Figure A-18. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, inset shows maximum peak recorded at 4 kHz sampling rate. A-18

Figure A-19. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded. A-19

Figure A-20. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data. A-20

Figure B-1. Manufacturer D, single battery pack, 50% SOC, 5 in. pan. B-1

Figure B-2. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan. B-2

Figure B-3. Manufacturer D, 16 battery packs, 50% SOC, 5 in. pan. B-2

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Figure B-4. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner A. B-3

Figure B-5. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner B. B-4

Figure B-6. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Halon 1301 applied after approximately 1 minute 20 seconds. B-4

Figure B-7. Manufacturer D, 6 battery packs with packaging, 50% SOC, 5 in. pan. B-5

Figure B-8. Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded. B-5

Figure B-9. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded. B-6

Figure B-10. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded. B-6

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List of Tables

Page

Table 1. Tested lithium ion cell and battery pack styles 5

Table 2. Summary of completed testing 6

Table 3. Summary of individual battery pack tests 12

Table 4. Summary of cargo liner integrity tests 18

Table 5. Summary of Halon 1301 suppression tests 20

Table 6. Summary of pressure measurement tests 24

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Acronyms and Abbreviations

in. Inches BTU British Thermal Unit DOT Department of Transportation Exponent Exponent Failure Analysis Associates FAA Federal Aviation Administration ft3 cubic foot Hz Hertz (1/second) kHz kilohertz (1000/second) LH left hand RH right hand mL milli-liters PRBA Portable Rechargeable Battery Association psig pounds per square inch over environmental pressure (gage pressure) SOC State of Charge

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Executive Summary

Exponent Failure Analysis Associates (Exponent) conducted additional testing in a 64-ft3 test chamber similar to that described in the Federal Aviation Administration’s (FAA) report entitled, “Flammability Assessment of Bulk-Packed, Nonrechargeable Lithium Primary Batteries in Transport Category Aircraft.” Exponent’s initial testing in this chamber is described in the April 15, 2005 report entitled, “US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds.” In the current study, Exponent describes the results of flame attack tests on single and multiple cell-phone-style (prismatic) lithium ion battery packs and dynamic pressure measurements obtained during flame attack tests on 18650-style lithium ion cells.

Based on the testing conducted, Exponent has concluded the following:

1. Tested prismatic battery packs performed comparably to previously tested 18650 cells with regard to heat release and effectiveness of suppressant. Since prismatic cells are often designed to vent through a case rupture mechanism, frequent case rupture events were observed in the prismatic battery pack testing.

2. Direct flame impingement on small, unpackaged quantities of prismatic battery packs can lead to internal thermal runaway of individual cells and venting of gases. The vent gases are generally ignited by the pre-existing flame, increasing the total heat flux produced by the fire.

3. Halon 1301 is very effective in controlling burning lithium ion prismatic battery packs.

4. The aircraft cargo liner material used in the testing, which is commercially available and which we believe is typical, is capable of withstanding the tested flame impingement from burning gases vented by lithium ion prismatic battery packs subjected to external heating.

5. When lithium ion cells vent they release gases. However, the magnitudes of measured dynamic pressure pulses, associated with venting of 18650 cells and prismatic battery packs, were small: less than 0.08 psi. In a scenario representative of a cargo hold that is not airtight and where cells vent sequentially, we observed only a negligible additive pressure rise within the chamber.

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Introduction

At the request of the Portable Rechargeable Battery Association (PRBA), Exponent Failure Analysis Associates (Exponent) conducted additional tests on lithium ion (secondary or rechargeable) cells and battery packs at 50% of full charge. The test setup and procedures are similar to those described in the Federal Aviation Administration’s (FAA) report [1] entitled, “Flammability Assessment of Bulk-Packed, Nonrechargeable Lithium Primary Batteries in Transport Category Aircraft” (FAA report). Exponent’s initial testing in this chamber is described in the April 15, 2005 report entitled, “US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds” (original report) [2]. In particular, Exponent conducted flame attack tests on single and multiple prismatic lithium ion battery packs. These tests were conducted first on various numbers of packs, then on packs in the presence of cargo hold liner material, and finally repeated with Halon 1301 application after venting began. Exponent also conducted tests on 18650-style lithium ion cells and measured pressures in the chamber. This addendum describes the results of the additional Exponent testing.

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Experimental Set-Up

The apparatus used in this testing has been previously described in the April 15, 2005 Exponent report entitled, “US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds.” Briefly, testing was conducted in a 64-ft3 chamber that was constructed to be as similar as possible to the 64-ft3 chamber described in the FAA Report.

Pressure Transducer For the testing described in this addendum, a pressure transducer was installed in the left hand (LH) wall of the 64-ft3 chamber; centered and up 12 in. from the chamber floor. The installed transducer had a range of 0 to 2.5 psig1.

Because of the rapid nature of a cell-venting event, initially two data acquisition systems were utilized for this phase of the testing. A Personal Daq system (described in the original report) recorded the chamber temperatures, heat flux and pressure data at a rate of 1 scan per second (1Hz), while a second high-speed data acquisition system2 simultaneously recorded the pressure at a rate of 4,000 scans per second (4 kHz). The average pressure versus time trace from the 1Hz system was used to identify the individual venting events (and is directly comparable to temperature and heat flux measurements), while the high-speed data acquisition system (4 kHz system) was used to capture more accurate representations of the transient pressure peaks. The high-speed data acquisition was configured to automatically trigger when the chamber pressure exceeded 0.025 psig and record for a period of 0.125 seconds prior to the trigger, and 2 seconds after the trigger.

After several tests, we noticed that a number of false triggers of the 4 kHz data acquisition system were occurring. These were likely caused by the relatively low-pressure level used for the high-speed data acquisition trigger, the proximity of high voltage transmission lines to the test site, and interaction between the two data acquisition systems. (Note that recorded pressure events that did not produce a definitive pressure rise and decay were not used in the calculation of the peak measured pressure in the early tests). To avoid this problem for the remainder of the tests, the data acquisition system was more thoroughly grounded, and only 4 kHz data was recorded. The two pressure measurement methods used produced comparable results, though the 2nd method resulted in fewer false triggers and a cleaner signal.

1 PX800-002GV pressure transducer. S/N: 1499266. Omega Engineering, Inc., One Omega Drive, Stamford, CT

06907. 2 Daq/216B PC-card data acquisition system. S/N: I16H2306. IO Tech Inc., 25971 Cannon Road, Cleveland, OH

44146.

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Figure 1 shows a typical 1Hz (slow speed) pressure trace. Note that it indicates that multiple pressure changes occurred during the course of the test. This is consistent with sequential venting of cells. The corresponding 4 kHz system data for two venting events is inset into the same chart.

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PRBA Li-Ion TestingManufacturer B - 4 Cells - 50% SOC, Trial 2

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Cells and Battery Packs Testing was conducted on lithium ion cells and packs provided by three manufacturers, designated as B, C, and D. Manufacturer B and C cells were cylindrical 18650 model cells: these were the same model cells as used in the initial report. Tests were conducted at 50% SOC (state of charge) with cells of 2.2 Amp hour capacities.3

Manufacturer D provided prismatic battery packs for testing. These packs each contained a single, prismatic (rectangular) cell. The cell dimensions were approximately 5mm x 34mm x 50mm. The cells had a nominal capacity of 0.82 Amp hours (820 mAhr). They were tested at 50% SOC.3

Note that throughout this report, the cell shrink-wrap color in the figures has been adjusted to maintain confidentiality.

Table 1. Tested lithium ion cell and battery pack styles

Manufacturer Cell Style Configuration Tested Test SOC Average Test Voltage

Manufacturer B 18650 (cylindrical) Cells (bare and bulk packaged) 50% 3.82

Manufacturer C 18650 (cylindrical) Cells (bare) & Laptop-style packs 50% 3.82

Manufacturer D 5mm x 34mm x50 mm (prismatic) Prismatic battery packs 50% 3.81

3 Published cell capacities are nominal capacities for a typical cell model. Individual cell capacities may vary

slightly from the nominal value. The 50% SOC description is based on the voltage of an average cell with 50% of its capacity remaining.

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Results

Exponent conducted additional tests in the 64-ft3 chamber on lithium ion cells and battery packs at 50% SOC. Exponent conducted flame attack tests on single and multiple prismatic lithium ion battery packs. These tests were conducted first on various numbers of packs, then on packs in the presence of cargo hold liner material, and finally repeated with Halon 1301 application after venting began. Exponent also conducted tests on 18650-style lithium ion cells and measured pressures in the chamber. Table 2 summarizes the completed tests. Data plots from each test can be found in Appendix A, and photographs of the post-test cells can be found in Appendix B. Detailed discussion of the results of each type of test follows.

Figure 2 through Figure 4 summarize data from the tests described in the original report and this addendum. Figure 2 shows the measured peak ceiling temperatures from all tests conducted as a function of the number of cells involved in each test. This figure shows that peak ceiling temperatures for the tests that involved cell venting, rather than burning of packaging materials only, stayed within the range of peak temperatures measured for the 5 in. and 11 in. fire pans alone (calibration tests).4 The prismatic battery pack performance fell within the range of 18650-cell performance.

Figure 3 shows the peak 5-second average of the heat flux measured at the ceiling of the chamber: the highest value measured for bare cells was 2.0 BTU/ft2 second. Again, the prismatic battery pack performance fell within the range of 18650-cell performance.

Figure 4 shows the peak temperature measured approximately 12 in. above the chamber floor. All results except for the 150 cells in packaging test and one of the prismatic pack tests,5 cluster in the range of 1000-1500°F (a slightly wider range than observed in testing reported in the original report). These temperatures are consistent with those produced by burning normal combustibles such as packaging materials.

Table 2. Summary of completed testing

Manf. Cell Style & Test Configuration

Cell SOC

Cells Tested

Pan Size (in)

Peak Ceiling Temp. (F)

5-second-Average Heat

Flux Peak

(BTU/ft2-sec)

Peak Measured Pressure 4 kHz capture (psig)

B 18650 cells Pressure tests 50% 4 5 554 1.36 0.05

C 18650 cells 50% 4 5 462 0.94 0.07

4 As previously reported, peak ceiling temperature did exceed the range of those produced by the 11” fire pan

alone in tests of 50, 60, and 150 cells in bulk shipment packaging. However, it is important to note that no cells vented in these tests, so the energy released in these tests was from the 11” fire pan and the burning packaging material only.

5 The box or pack arrangements in these tests, and the rapid Halon application in the prismatic pack test may have reduced the reading at 12”.

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Cell SOC

Cells Tested

Pan Size (in)



Flux Peak

(BTU/ft2-sec)


Pressure tests 50% 4 5 470 1.20 0.03

1 5 313 0.44 None available

4 5 431 0.86 < 0.025 5mm x 34mm x 50mm 50%

16 5 411 0.73 0.03

5mm x 34mm x 50mm With individual

packaging 50% 6 5 434 0.77 0.05

5mm x 34mm x 50mm Halon application late in

test 50% 4 5 372 0.85 0.03

4 5 466 .96 None available

D

5mm x 34mm x 50mm Cargo hold liner tests 50%

4 5 492 .95 None available

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5" Pan Calibration Range

Box of Facial Tissue


Empty Packaging Box

Tests run with packaging. None of the cells in these tests vented so the results are based on the packaging burning only.

Figure 2. Summary of peak ceiling temperatures for all tests described in original report and this addendum.

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Empty Packaging Box

Tests run with packaging. None of the cells in these tests vented so the results are based on the packaging burning only.

Figure 3. Summary of peak 5-second averaged heat flux at the ceiling for all tests described in original report and this addendum.

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Figure 4. Summary of peak temperatures measured 12 in. above the floor of the chamber for all tests described in original report and this addendum.

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Temperature and Heat Flux Results

Individual Prismatic Battery Pack Tests: Manufacturer D

A series of tests were conducted on prismatic battery packs that were not electrically connected in any way, though the packs were often taped together to allow stacking on the test grate to ensure that all of the packs would be exposed to the flames from the pan below (Figure 5). A summary of the packs tested in this way can be found in Table 3

In each test, all of the pack external wrappers and plastic components were consumed, and all of the cells swelled and vented electrolyte (Figure 6). The resulting weight loss was approximately 3 to 5 grams. Although the cells were not opened, the resulting weight losses are consistent with pyrolysis of the cell separator and carbon active material in addition to loss of electrolyte.

A typical test proceeded as follows:

1. The propanol was ignited.

2. Flames impinged upon, and often surrounded, the test sample.

3. After 1 minute or less the cell vents began to open, releasing flammable vapor (electrolyte and plastic decomposition products) and producing a hissing sound.

4. The vapors were ignited by the burning propanol, which resulted in flames emanating from the cells for times on the order of a few seconds.

Note that cell vents on prismatic cells are often designed to open the cell case and allow expulsion of cell contents (a case rupture mechanism). This occurred routinely in the prismatic cell tests.

Figure 7 shows all ceiling and 12 in. temperature measurement data overlaid for the prismatic pack series of tests. It is evident that the ceiling temperature measurements fall within a fairly narrow band. The maximum measured ceiling temperature for these tests was 431°F. The 12 in. temperatures are more variable, reflecting the thermocouple proximity to flames. The maximum measured temperature at 12 in. above the floor was 1383°F.

Figure 7 shows all ceiling 5 second averaged heat flux measurement data overlaid for the prismatic pack series of tests. The 5 second averaged heat flux values also fall within a fairly narrow band. The maximum measured 5 second averaged ceiling heat flux was 0.86 BTU/ft2-sec.

Figure 9 shows all of the ceiling and 12 in. temperature measurement data overlaid for the bare cell and prismatic pack tests described in the original report and this addendum. The chart indicates that the temperatures measured during the prismatic pack tests are comparable to those measured during the bare cell tests. Figure 10 shows all of the ceiling 5 second averaged heat flux measurement data overlaid for the bare cell or pack tests described in the original report

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and this addendum. The chart indicates that the heat fluxes measured during the prismatic pack tests are comparable to those measured during the bare cell tests.

Table 3. Summary of individual battery pack tests

Manf. Cell Style & Test Configuration Cell SOC Cells

Tested Pan Size

(in) Peak Ceiling

Temp. (F)

5-second-Average Heat Flux Peak (BTU/ft2-sec)


1 5 313 0.44 None available

4 5 431 0.86 < 0.025 D 5mm x 34mm x 50mm 50%

16 5 411 0.73 0.03

Figure 5. A stack of 16 battery packs as prepared for testing.

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Figure 6. A stack of 16 battery packs after testing.

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PRBA Li-Ion TestsManufacturer D - 1, 4, & 16 Pack Tests - 50% SOC


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Figure 7. Compilation of temperature data for all Manufacturer D bare pack tests.

PRBA Li-Ion Tests

Manufacturer D - 1, 4, & 16 Pack Tests - 50% SOC5" Pan, 100% Vent Area

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Figure 8. Compilation of 5-second averaged heat flux at the ceiling for all Manufacturer D bare pack tests.

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PRBA Li-Ion TestsManufacturers A, B, C, & D - 1, 2, 4, 8, & 16 Cell& Prismatic Pack Tests - 50% SOC


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Figure 9. Compilation of temperature data for all bare cell and prismatic pack tests described in the original report and this addendum.

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Figure 10. Compilation of 5-second averaged heat flux at the ceiling for all bare cell and prismatic pack tests described in the original report and this addendum

Tests of Prismatic Cell Phone Battery Packs as Packaged for Bulk Shipment—Manufacturer D

A test was conducted on 6 prismatic battery packs that were individually packaged in plastic cases (Figure 11). This type of packaging is a first level of packaging for shipment. A pack in a plastic case might then be packaged with other packs or with cell phone components in various styles of boxes.

The packaging material (plastic) was consumed during the test, and all of the cells vented during the test (Figure 12). The test produced similar peak temperatures (434 F at the ceiling, 1443 at 12 in.) and heat fluxes (0.77 BTU/ft2 sec.) as the bare pack tests.

PRBA Li-Ion TestsManufacturers A, B, C, & D - 1, 2, 4, 8, & 16 Cell & Prismatic PackTests - 50% SOC


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Figure 11. Six Manufacturer D individually packaged battery packs before testing.

Figure 12. Manufacturer D packs and packaging after testing.

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Cargo Liner Integrity Tests: Manufacturer D Tests were conducted with Manufacturer D’s battery packs in close proximity to samples of aircraft cargo hold liner.6 A summary of the pack tests can be found in Table 4. The battery packs were not electrically connected, but were taped together so that they could be arranged on the test grate. The cells were positioned so that jetting flames from venting cells would impinge upon the cargo liner materials. Tests of Manufacturer D’s packs were conducted twice: once with each style of cargo hold liner material.

No test caused ignition or burn through of either cargo hold liner material. Generally, soot deposits on the front face of the cargo liner were observed after testing, and some blistering was observed on the corresponding reverse side of the panel (Figure 13 and Figure 14). In one case, the front face coating of the liner was consumed in the region of flame impingement; however, the remaining layers of the liner were not consumed and the liner retained its integrity. This testing shows that the tested aircraft cargo liner material, which is commercially available, and believed to be typical, is capable of withstanding the tested flame impingement from burning gases vented by prismatic lithium ion cells subjected to external heating.

Table 4. Summary of cargo liner integrity tests

Manf. Cell Style & Test Configuration Cell SOC

Number of Cells Tested

Pan Size (in)

Peak Ceiling Temp.

(F)


Flux Peak (BTU/ft2-sec)

4 5 466 0.96 D

Prismatic battery packs

Cargo hole liner tests50%

4 5 492 0.95

6 As in the original report, Cargo Liner A was Gilliner 1066 Laminate, and Cargo Liner B was Gillfab 1367A

Laminate. Both materials were purchased from M.C. Gill Corporation.

SF34041.001 C0T0 0605 CM01 19

Figure 13. Front and back of Cargo Liner A after testing with 4 Manufacturer D packs.

Figure 14. Front and back of Cargo Liner B after testing with 4 Manufacturer D packs.

SF34041.001 C0T0 0605 CM01 20

Halon 1301 Suppression Tests: Manufacturer D A Halon 1301 suppression test was conducted with four prismatic battery packs at 50% SOC (Table 5). The packs were not electrically connected, but were taped together so that they could be arranged on the test grate (Figure 15).

Halon 1301 was applied late in the test, once cells had begun to vent with burning jets. Within seconds of application, all flames were extinguished and no additional flaming was observed for the continuing duration of the test. When Halon 1301 was applied, there was a precipitous drop in the chamber temperatures and heat flux measurements. This was entirely consistent with flame suppression. Chamber temperatures and heat fluxes remained low for the duration of the testing. Thermal runaway of individual cells and cell venting continued to occur after Halon 1301 was applied. However, with Halon 1301 present, this process did not result in flaming combustion.

When the data taken during the Halon 1301 suppression test was compared to data from a similar test where suppression was not used, the effect of Halon 1301 was evident (Figure 16). Halon 1301 application effectively suppressed the fire.

Table 5. Summary of Halon 1301 suppression tests


Cell SOC

Cells Tested

Pan Size (in)



Flux Peak

(BTU/ft2-sec)


D 5mm x 34mm x 50mm

Halon application late in test

50% 4 5 372 0.85 0.03

SF34041.001 C0T0 0605 CM01 21

Figure 15. 4 Manufacturer D cells, before and after Halon 1301 suppression testing.

SF34041.001 C0T0 0605 CM01 22

Manufacturer D - 4 Packs - 50% SOCNo Suppression

0

200

400

600

800

1000

1200

1400

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Hea

t Flu

x (B

TU/ft

^2-s

ec)

Temp-12"Temp-24"Temp-36"Temp-48" (Ceiling)Flux, topFlux, top (5 sec avg.)Flux, low sideFlux, low (5 sec avg.)

Manufacturer D - 4 Packs - 50% SOCHalon applied after appoximately 1 minute 20 seconds

0

200

400

600

800

1000

1200

1400

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Halon Applied

Figure 16. Tests with 4 Manufacturer D cells, without suppression (top), and with Halon 1301 application after cells began to vent (bottom).

SF34041.001 C0T0 0605 CM01 23

Pressure Measurement Results: Manufactures B, C, and D Tests with pressure measurements were conducted on both 18650-style lithium ion cells (Manufacturers B and C) and prismatic battery packs (Manufacturer D). A summary of tests that included pressure measurement and the peak pressures measured can be found in Table 6. Typical pressure data is shown in Figure 1, and all of the collected pressure data can be found in Appendix B.

The Exponent measurement method captured both the dynamic pressure pulses associated with individual cell venting incidents, and any average rise in chamber pressure. The magnitude of measured dynamic pressure pulses was small: less than 0.08 psig. These pulses were also brief, such that their peaks did not always register in the 1Hz data. Nor did all cell venting instances cause pressure pulses that exceeded 0.025 psig and triggered the 4 kHz data acquisition system. The measured average pressure rises within the chamber were negligible, less than 0.008 psig. For example, Figure 17 shows the pressure trace from the 16 Manufacturer D battery pack test. The trace indicates that there were multiple, small pressure pulses (associated with cell venting), however only one of these pulses was large enough to trigger the 4 kHz data acquisition system. That pulse had a peak of just over 0.025 psig. Average pressure rose steadily within the chamber, to 0.006 psig.

Per the FAA Report [1], an aircraft cargo compartment is constructed to withstand a 1 psi pressure differential before blow-out panels activate. FAA’s tests of lithium primary batteries in an airtight, 10 cubic meter chamber resulted in pressure rises in the range of 1.1 psi to 2.6 psi depending upon the number of cells tested. FAA’s tests with an aerosol can simulator in the same size airtight chamber [3] resulted in pressure rises of 28.2 to 32.2 psi. The tests of lithium ion cells and battery packs conducted by Exponent were done in the 64-ft3 chamber with vent ports. These various tests are therefore not directly comparable. The 64-ft3 chamber tests capture the sequential nature of cell venting as a result of fire attack and the effect of a non-airtight cargo hold. These two factors prevent a purely additive pressure rise within the chamber.

SF34041.001 C0T0 0605 CM01 24

Table 6. Summary of pressure measurement tests


Cell SOC

Cells Tested

Pan Size (in)



Flux Peak

(BTU/ft2-sec)


B 18650 cells Pressure tests 50% 4 5 554 1.36 0.05

50% 4 5 462 0.94 0.07 C 18650 cells

Pressure tests 50% 4 5 470 1.20 0.03

4 5 431 0.86 < 0.025 5mm x 34mm x 50mm 50%

16 5 411 0.73 0.03

5mm x 34mm x 50mm With individual

packaging 50% 6 5 434 .77 0.05 D

5mm x 34mm x 50mm Halon application late in

test 50% 4 5 372 0.85 0.03

SF34041.001 C0T0 0605 CM01 25

PRBA Li-Ion TestingManufacturer D - 16 Packs - 50% SOC


-0.002

0.000

0.002

0.004

0.006

0.008

0.010

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure 17. Detailed view of 1Hz pressure trace for Manufacturer D 16 pack test.

SF34041.001 C0T0 0605 CM01 26

Conclusions

At the request of PRBA, Exponent conducted additional tests on lithium ion (secondary or rechargeable) cells and battery packs at 50% of full charge. The test setup and procedures are similar to those described in the Federal Aviation Administration’s (FAA) report [1] entitled, “Flammability Assessment of Bulk-Packed, Nonrechargeable Lithium Primary Batteries in Transport Category Aircraft” (FAA Report). Exponent’s initial testing in this chamber is described in the April 15, 2005 report entitled, “US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds” (original report) [2]. In the current study, Exponent conducted flame attack tests on single and multiple prismatic lithium ion battery packs. These tests were conducted first on various numbers of packs, then on packs in the presence of cargo hold liner material, and finally repeated with Halon 1301 application after venting began. Exponent also conducted tests on 18650-style lithium ion cells and measured dynamic pressures in the chamber. Based on the testing conducted, Exponent has concluded the following:

1. Tested prismatic battery packs performed comparably to previously tested 18650 cells with regard to heat release and effectiveness of suppressant. Since prismatic cells are often designed to vent through a case rupture mechanism, frequent case rupture events were observed in the prismatic battery pack testing.

2. Direct flame impingement on small, unpackaged quantities of prismatic battery packs can lead to internal thermal runaway of individual cells and venting of gases. The vent gases are generally ignited by the pre-existing flame, increasing the total heat flux produced by the fire.

3. Halon 1301 is very effective in controlling burning lithium ion prismatic battery packs.

4. The aircraft cargo liner material used in the testing, which is commercially available and which we believe is typical, is capable of withstanding the tested flame impingement from burning gases vented by lithium ion prismatic battery packs subjected to external heating.

5. When lithium ion cells vent they release gases. However, the magnitudes of measured dynamic pressure pulses, associated with venting of 18650 cells and prismatic battery packs, were small: less than 0.08 psi. In a scenario representative of a cargo hold that is not airtight and where cells vent sequentially, we observed only a negligible additive pressure rise within the chamber.

SF34041.001 C0T0 0605 CM01 27

References

1. Webster, Harry, “Flammability Assessment of Bulk-Packed, Nonrechargeable Lithium Primary Batteries in Transport Category Aircraft,” U.S. Department of Transportation, Federal Aviation Administration, DOT/FAA/AR-04/26, June 2004.

2. Mikolajczak, C. J., and A. Wagner-Jauregg, “US FAA-Style Flammability Assessment of Lithium Ion Cells and Battery Packs in Aircraft Cargo Holds” Exponent Failure Analysis Associates Report, April 15, 2005.

3. Reinhardt, J.W, D. Blake, and T. Marker, “Development of a Minimum Performance Standard for Aircraft Cargo Compartment Gaseous Fire Suppression Systems,” U.S. Department of Transportation, Federal Aviation Administration, DOT/FAA/AR-00/28, September 2000.

SF34041.001 C0T0 0605 CM01

Appendix A Data from Testing

A-1

SF34041.001 C

0T0 0605 CM

01

Appendix A Data from Testing

PRBA Li-Ion Tests 5" Pan Calibration - 3/31/05

1-Propanol 100% Vent Area

0

200

400

600

800

1000

1200

1400

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Time (minutes)

Tem

pera

ture

(F)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

Hea

t Flu

x (B

TU/ft

^2-s

ec)

Temp-12"Temp-24"Temp-36"Temp-48" (Ceiling)Flux, topFlux, top (5 sec Avg.)Flux, low sideFlux, low (5 sec Avg.)

Figure A-1. Calibration Test 3/31/05, 5 in. Pan, 100% vent area.

A-2

SF34041.001 C

0T0 0605 CM

01

PRBA Li-Ion Tests 5" Pan Calibration - 5/12/05

1-Propanol 100% Vent Area

0

200

400

600

800

1000

1200

1400

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Time (minutes)

Tem

pera

ture

(F)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

Hea

t Flu

x (B

TU/ft

^2-s

ec)

Temp-12"Temp-24"Temp-36"Temp-48" (Ceiling)Flux, topFlux, top (5 sec Avg.)Flux, low sideFlux, low (5 sec Avg.)

Figure A-2. Calibration Test 5/12/05, 5 in. Pan, 100% vent area.

A-3

SF34041.001 C

0T0 0605 CM

01

PRBA Li-Ion TestsManufacturer D - 1 Pack - 50% SOC


0

200

400

600

800

1000

1200

1400

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Time (minutes)

Tem

pera

ture

(F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-3. Manufacturer D, single battery pack, 50% SOC, 5 in. pan.

A-4

SF34041.001 C

0T0 0605 CM

01

PRBA Li-Ion TestingManufacturer D - 1 Pack - 50% SOC


-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-4. Manufacturer D, single pack, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate.

A-5

SF34041.001 C

0T0 0605 CM

01



0

200

400

600

800

1000

1200

1400

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-5. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan.

A-6

SF34041.001 C

0T0 0605 CM

01



-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-6. Manufacturer D, 4 packs, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data.

-0.020

-0.015

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0 0.5 1 1.5 2 2.5

Time (seconds)

Cham

ber P

ress

ure

(psi

g)

-0.015

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0 0.5 1 1.5 2 2.5

Time (seconds)

Cham

ber P

ress

ure

(psi

g)

A-7

SF34041.001 C

0T0 0605 CM

01



0

200

400

600

800

1000

1200

1400

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-7. Manufacturer D, 16 battery packs, 50% SOC, 5 in. pan.

A-8

SF34041.001 C

0T0 0605 CM

01



-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-8. Manufacturer D, 16 packs, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, inset shows maximum peak recorded at 4 kHz sampling rate.

-0.015

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0 0.5 1 1.5 2 2.5

Time (seconds)

Cham

ber P

ress

ure

(psi

g)

A-9

SF34041.001 C

0T0 0605 CM

01

PRBA Li-Ion TestingManufacturer D - 6 Packs with Packaging - 50% SOC


0

200

400

600

800

1000

1200

1400

1600

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-9. Manufacturer D, 6 packs in packaging material, 50% SOC, 5 in. pan.

A-10

SF34041.001 C

0T0 0605 CM

01

-0.010

0.000

0.010

0.020

0.030

0.040

0.050

0.060

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-10. Manufacturer D, 6 packs in packaging material, 50% SOC, 5 in. pan, 4 kHz pressure data for pressure peak.

A-11

SF34041.001 C

0T0 0605 CM

01


Cargo Liner A5" Pan, 100% Vent Area

0

200

400

600

800

1000

1200

1400

1600

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Time (minutes)

Tem

pera

ture

(F)

0.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-11. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner A.

A-12

SF34041.001 C

0T0 0605 CM

01


Cargo Liner B5" Pan, 100% Vent Area

0

200

400

600

800

1000

1200

1400

1600

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Time (minutes)

Tem

pera

ture

(F)

0.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-12. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner B.

A-13

SF34041.001 C

0T0 0605 CM

01


Halon applied after appoximately 1 minute 20 seconds5" Pan, 100% Vent Area

0

200

400

600

800

1000

1200

1400

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Halon Applied

Figure A-13. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Halon 1301 applied after approximately 1 minute 20 seconds.

SF34041.001 C0T0 0605 CM01 A-14

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r Pre

ssur

e (p

sig)

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-14. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Halon 1301 applied after approximately 1 minute 20 seconds, 4 kHz pressure data for pressure peaks.

A-15

SF34041.001 C

0T0 0605 CM

01



0

200

400

600

800

1000

1200

1400

1600

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-15. Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded.

A-16

SF34041.001 C

0T0 0605 CM

01



-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-16. Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data.

-0.010

0.000

0.010

0.020

0.030

0.040

0.050

0 0.5 1 1.5 2 2.5

Time (seconds)

Cham

ber P

ress

ure

(psi

g)

-0.020

-0.010

0.000

0.010

0.020

0.030

0.040

0.050

0.060

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r P

ress

ure

(psi

g)

A-17

SF34041.001 C

0T0 0605 CM

01

PRBA Li-Ion TestingManufacturer C - 4 Cells - 50% SOC, Trial 2


0

200

400

600

800

1000

1200

1400

1600

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Time (minutes)

Tem

pera

ture

(F)

0.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-17. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded

A-18

SF34041.001 C

0T0 0605 CM

01



-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-18. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, inset shows maximum peak recorded at 4 kHz sampling rate.

-0.060

-0.040

-0.020

0.000

0.020

0.040

0.060

0.080

0.100

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r Pr

essu

re (p

sig)

A-19

SF34041.001 C

0T0 0605 CM

01



0

200

400

600

800

1000

1200

1400

1600

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Tem

pera

ture

(F)

0.0

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

Hea

t Flu

x (B

TU/ft

^2-s

ec)


Figure A-19. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded.

A-20

SF34041.001 C

0T0 0605 CM

01



-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

Time (minutes)

Cha

mbe

r Pre

ssur

e (p

sig)

Figure A-20. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded at 1Hz rate, insets show corresponding 4 kHz data.

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0 0.5 1 1.5 2 2.5

Time (seconds)

Cham

ber

Pre

ssur

e (p

sig)

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r P

ress

ure

(psi

g)

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0 0.5 1 1.5 2 2.5

Time (seconds)

Cham

ber P

ress

ure

(psi

g)-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0 0.5 1 1.5 2 2.5

Time (seconds)

Cha

mbe

r P

ress

ure

(psi

g)

SF34041.001 C0T0 0605 CM01

Appendix B Post Testing Photographs

SF34041.001 C0T0 0605 CM01 B-1

Appendix B Post Testing Photographs

Figure B-1. Manufacturer D, single battery pack, 50% SOC, 5 in. pan.

SF34041.001 C0T0 0605 CM01 B-2

Figure B-2. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan.

Figure B-3. Manufacturer D, 16 battery packs, 50% SOC, 5 in. pan.

SF34041.001 C0T0 0605 CM01 B-3

Figure B-4. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner A.

SF34041.001 C0T0 0605 CM01 B-4

Figure B-5. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Cargo Liner B.

Figure B-6. Manufacturer D, 4 battery packs, 50% SOC, 5 in. pan, Halon 1301 applied after approximately 1 minute 20 seconds.

SF34041.001 C0T0 0605 CM01 B-5

Figure B-7. Manufacturer D, 6 battery packs with packaging, 50% SOC, 5 in. pan.

Figure B-8. Manufacturer B, 4 cells, 50% SOC, 5 in. pan, pressure recorded.

SF34041.001 C0T0 0605 CM01 B-6

Figure B-9. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded.

Figure B-10. Manufacturer C, 4 cells, 50% SOC, 5 in. pan, pressure recorded.

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