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1. Overcharge explosion

The loss of control of the protection circuit or detection cabinet results in a charging voltage greater than 5V, causing electrolyte decomposition and violent reactions inside the battery. The internal pressure of the battery rapidly rises, and the lithium battery of the forklift explodes.

2. Overcurrent explosion

The loss of control of the protection circuit or detection cabinet can cause excessive charging current, resulting in insufficient time for lithium to be embedded in the forklift. As a result, lithium metal forms on the surface of the electrode, penetrates the diaphragm, and the positive and negative poles are directly short circuited, causing an explosion.

Explosion during ultrasonic welding of plastic casing

When ultrasonic welding plastic shells, due to equipment reasons, the ultrasonic energy is transferred to the battery cell. The ultrasonic energy causes the internal diaphragm of the battery to melt, causing a direct short circuit between the positive and negative electrodes and resulting in an explosion.

4. Explosion during spot welding

Excessive current during spot welding causes severe internal short circuit and explosion. In addition, during spot welding, the positive electrode connector is directly connected to the negative electrode, causing the positive and negative electrodes to short-circuit and explode.

5. Overdischarge explosion

Overdischarge or overcurrent discharge (above 3C) of forklift lithium batteries can easily cause the negative copper foil to dissolve and deposit on the separator, leading to direct short circuit between the positive and negative electrodes and explosion (rarely occurring).

6. Explosion during vibration and falling

The internal pole displacement caused by severe vibration or falling of the battery cell can lead to a serious short circuit and explosion.

Reasons for lithium battery explosion and fire in forklifts

1、 Insufficient negative capacity of lithium forklift battery

When the capacity of the negative electrode in the positive electrode of a lithium forklift battery is insufficient, the lithium atoms that appear during charging cannot be inserted into the interlayer structure of the negative graphite, and will precipitate on the surface of the negative electrode, forming crystals. Long term crystallization in forklift lithium batteries can lead to short circuits, causing the battery cells to rapidly discharge, resulting in a large amount of heat and burning the separator. High temperature can cause the electrolyte to decompose into gas, and when the pressure is too high, the battery cell will explode.

2、 Excessive moisture content

When charging, water can react with lithium to generate lithium oxide, causing a loss of capacity in the battery cell and making it easy for the cell to overcharge and generate gas. The decomposition voltage of water is low, making it easy to decompose and generate gas during charging. When this series of generated gases increases the internal pressure of the cell, the cell will explode when the outer shell of the cell cannot withstand it.

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