Safety First: Design Lessons from an Exploding Battery

Imagine a seemingly harmless device harboring a fiery secret within its tiny battery. That’s the potential consequence for designers who overlook safety, especially when products end up in explosive environments like oil tankers. This blog post dives deep into a cargo ship battery explosion and exposes the crucial role designers play in preventing such disasters.

We’ll crack the case of the exploding battery, analyze the official report, and explore how designers can step up to prevent similar incidents in the future. Buckle up as we navigate the world of:

What Went Wrong? Cracking the Case of the Cargo Ship Battery:
- Unveiling the details behind the oil tanker incident.
Design Duty Calls: How Designers Can Prevent the Next Blas:
- Essential design considerations to prioritize user and environmental safety.
Beyond the Manual:
- User Guides for a Safer Future: Crafting user manuals that empower users with clear and effective safety information.
Lesson Learned:
- Key takeaways to ensure your designs don’t become ticking time bombs

This blog post is a wake-up call for designers everywhere. Let’s prioritize safety and prevent the next potential disaster from unfolding!

What Went Wrong? Cracking the Case of the Cargo Ship Battery

Background Information:

11.13, lower Mississippi River, Louisiana, USA
800-foot-long cargo vessel (oil tanker)
No injuries and no pollution were reported. The estimated damage to the vessel was $3 million.
The communication table is on fire.

There was no damage noted to any of the lower decks in the superstructure. The navigation systems, communication systems, and alarm systems were damaged beyond repair.

Summary of Marine Investigation Report

The vessel operator provided video footage from the accident, which detected fire on the communication table.

The cause was a Radio’s battery charging failure. 2 types of batteries were used in these radios: lithium-ion type (with 2 cells) and nickel-metal hybrid (with 6 cells) batteries. Of the remains of the fire, the experts found: 6 pcs nickel-metal cell in 1 charger, 2 pcs lithium-ion cell in another charger and a lithium-ion battery in the charger without cells.

The report stated:” the cause of this fire was determined to be an energetic event [explosion] involving a lithium-ion battery located on the navigation [communication] desk.” The report also noted that there was a second explosion from within the ensuing fire on the communications table.

The report’s lesson learned chapter details the following:

„Crews can help prevent thermal runaways and ensuing fires by doing the following:

follow manufacturers’ instructions for the care and maintenance of lithium-ion batteries,
properly dispose of damaged batteries,
avoid unsupervised charging, and
keep batteries and chargers away from heat sources and flammable materials.”

How can we, as designers, prevent situations like this? We can’t put the responsibility entirely on the user, as the report summarizes. Let’s check some major design rules to avoid these kinds of dangerous situations.

Design Duty Calls: How Designers Can Prevent the Next Blast

The following criteria are based on my own experiences and opinions, drawn from my background as a design engineer in Ex product design, my involvement in certification process support tasks, and my perspective as an engineer who reviews the consumer products I purchase and use myself. Some engineers from another discipline may have different points of view about the same topic. But I hope I will be able to give you useful tips and another point of view.

Beyond the Manual: Product Documentation for a Safer Future

Effective product documentation is essential for user safety and satisfaction. From the outset, user manuals should comprehensively cover the product, including the battery and charger. Consider your most recent product purchase: does the user manual provide all the information you need? Unfortunately, most user manuals are often sparse, focusing only on legal requirements, manufacturer protection, and technical specifications. While these are important, they often lack a customer-centric approach, leaving users feeling undervalued.

As a designer, it is crucial to anticipate potential hazards associated with the product and user. However, the wording should be carefully chosen to avoid patronizing the user. Here are several key points to consider:

Understanding the User

Designers must have a thorough understanding of the target user base, including their age, abilities, and potential limitations. For example, a portable device with a rechargeable battery intended for elderly users should have an easily accessible battery compartment and clear, simple instructions for safe recharging.

Clear Instructions and Warnings

Even the safest product can be misused. Designers should ensure that instructions and warnings are clear and easy to understand.

User Manual

User manuals should offer clear instructions and warnings for safe product use, maintenance, and disposal. The language should be simple and tailored to the user’s expected knowledge level.

Compliance Documentation

This includes certificates or reports that prove the product (especially the battery) meets relevant safety regulations, ensuring both legal compliance and user safety.

By prioritizing comprehensive, user-focused documentation, designers can significantly enhance the safety and user experience of their products.

Boom! Battery Exploding on Oil Tanker: Why Product’s Design Matters More Than Ever

Imagine this: you’re designing a simple device, but its tiny battery holds the potential for disaster. For designers, especially when products end up in volatile environments like oil tankers, safety is paramount. Designers are the unsung heroes preventing million-dollar meltdowns and worse.

A good designer is a hazard-hunter, anticipating every way a battery could malfunction, overheat, or cause problems during use, rough handling, or disposal. It’s not just about user satisfaction; it’s about crew safety and preventing catastrophic fires.

In hazardous environments, the stakes are even higher. A faulty phone battery might be annoying, but on an oil tanker, it could spell disaster. That’s why robust safety features are crucial. Think smart circuits to prevent overcharging, fireproof compartments, and clear user instructions.

Rechargeable batteries introduce unique safety considerations. Here’s what designers should focus on to create safe products with rechargeable batteries:

Power Up Your Design with Safer, Longer-Lasting Batteries

The right battery cells are the DNA of your battery’s success. Pick wisely! While traditional lithium-ion batteries are a common choice, solid-state batteries offer significant advantages:

Unmatched Safety: Solid-state batteries eliminate the risk of fire and explosion, even in extreme scenarios like punctures or crushing. Unlike lithium-ion batteries, which can become dangerous (immediately set on fire or even explode) when damaged, solid-state batteries vent safely, minimizing risks.
Extended Lifespan: Solid-state batteries boast a longer lifespan compared to lithium-ion batteries. This translates to fewer replacements and a more sustainable product.
Superior Capacity: Solid-state batteries pack more power into a smaller space. This allows for increased range in electric vehicles, longer runtimes for electronics, and more efficient use of space in your design.

Traditional lithium-ion batteries are more common but come with inherent safety risks. ADOTT Solutions has pioneered the use of solid-state cell technology in our battery designs. This innovative approach delivers unmatched safety, withstanding even punctures and maintaining functionality – a feat impossible with lithium-ion cells. With solid-state cells and a rugged design, you can create a safer, more reliable, and higher-performing product for your customers.

Traditional lithium-ion batteries are more common but come with inherent safety risks. ADOTT Solutions has pioneered the use of solid-state cell technology in our battery designs. This innovative approach delivers unmatched safety, withstanding even punctures and maintaining functionality – a feat impossible with lithium-ion cells. With solid-state cells and a rugged design, you can create a safer, more reliable, and higher-performing product for your customers.

Electrical Safety

Overcharge and Over-discharge Protection: Implement electronic circuits to prevent the battery from being overcharged or over-discharged, extending battery life and reducing the risk of overheating or cell damage.
Short Circuit Protection: Design the product to prevent short circuits between battery terminals, using fuses, circuit breakers, or proper insulation to minimize fire risk.
Thermal Management: Consider heat dissipation during charging and use, employing appropriate materials and ventilation to prevent overheating of the battery and surrounding components.

User Interface and Instructions

Clear Charging Indicators: Provide visual or audible indicators to show charging status (charging, complete, low battery), helping users avoid overcharging or using a depleted battery.
Safe Charging Practices: Include clear instructions in the user manual on safe charging practices, such as using the provided charger and avoiding extreme temperatures during charging.
Battery Maintenance and Disposal: Educate users on proper battery maintenance (e.g., cleaning terminals) and disposal procedures to avoid environmental hazards.

Compliance and Testing

Battery Safety Standards: Ensure the product adheres to relevant safety standards for rechargeable batteries, following regulations set by UL (Underwriters Laboratories) or IEC (International Electrotechnical Commission).
Battery Testing: Conduct thorough testing of the battery and charging system under various conditions (normal use, overload, extreme temperatures) to identify and address potential safety issues.

By considering these aspects throughout the design process, designers can create products with rechargeable batteries that are safe, reliable, and user-friendly.

Exploding Batteries: A Lesson We Can't Afford to Ignore

To ensure your product’s battery is designed safely (to avoid an accident like the mentioned cargo vessel’s), consider the points outlined above. Additionally, adhering to the requirements of the IEC 60079 standard family for explosive atmospheres is crucial. This standard encompasses both electrical (IEC 60079-11) and mechanical safety (IEC 60079-1, IEC 60079-7, IEC 60079-18, etc.) requirements.

At ADOTT Solutions, our team of engineers are experts in Ex battery design. We specialize in creating safe, reliable products that meet rigorous safety standards (Like Functional safety requirements, Explosive atmosphere requirements, and Underground mines requirements). By partnering with ADOTT Solutions, you can trust that your product will not only comply with all necessary regulations but also provide exceptional safety and performance for your users. Our extensive experience in Ex battery design ensures that your product is in capable hands.

Last but not least:

Staying Informed: Designers must stay updated on relevant safety standards and regulations applicable to their products, whether they are building codes for physical products or data privacy regulations for digital products.
Meeting Requirements: Ensure that your design complies with all applicable safety regulations to guarantee that the product is both legal and safe for consumers.