The Evolution of Lithium Battery Safety: Insights from the SAE G27 Lithium Battery Packaging Performance Committee

Article Summary

1. Lithium batteries present significant safety risks in air transport due to thermal runaway potential.
2. Aviation incidents exposed gaps in existing lithium battery transport regulations.
3. ICAO initiated the formation of the SAE G27 Committee to strengthen packaging safety standards.
4. The committee’s goal is to create standardized testing for lithium battery packaging performance.
5. A key objective is improving containment of thermal runaway during air shipment.
6. The committee includes battery manufacturers, regulators, testing labs, engineers, and industry stakeholders.
7. Battery manufacturers contribute expertise on chemistry and failure mechanisms.
8. Aviation regulators ensure alignment with global air safety requirements.
9. Testing laboratories validate thermal runaway and flame resistance performance.
10. Packaging engineers develop solutions to contain battery failures.
11. Industry stakeholders help ensure practical and scalable implementation.
12. Developing a universal standard required balancing diverse and sometimes conflicting priorities.
13. Variations in battery chemistry added complexity to standardized testing development.
14. Multi-lab validation was necessary to ensure consistent and repeatable results.
15. The first G27 standard was released in July 2024, focusing on cylindrical lithium-ion cells.
16. The standard introduced consistent testing protocols and additional hazard “slash sheets.”
17. Future updates will expand coverage to prismatic and pouch battery formats.
18. Ongoing work will address additional risks, including external heat exposure.

Lithium batteries have become an essential part of modern life, powering everything from smartphones to electric vehicles. However, their widespread use has also raised significant safety concerns, particularly in air transport. The risk of thermal runaway, where batteries overheat and potentially catch fire, has led to stringent regulations and the need for robust packaging solutions.

To address these concerns, the SAE G27 Lithium Battery Packaging Performance Committee was formed in response to a request from the International Civil Aviation Organization (ICAO). This group has worked for years to develop a standardized testing framework for lithium battery packaging performance.

In this blog, we explore how the SAE G27 Lithium Battery Packaging Performance Committee was formed, the challenges it has faced, and what the future holds for lithium battery safety in air transport.

Why Was the SAE G27 Lithium Battery Packaging Performance Committee Formed?

The ICAO recognized that existing regulations did not adequately address the hazards associated with lithium battery transport by air. Several aviation incidents highlighted the potential dangers of unchecked thermal runaway events, prompting a call for better safety testing and packaging standards, with the committee tasked with:

• • Developing standardized tests to evaluate the safety and effectiveness of lithium battery packaging.
• • Establishing best practices for containment of thermal runaway.
• • Ensuring global regulatory compliance in transporting lithium batteries by air.

Key Players in the SAE G27 Lithium Battery Packaging Performance Committee

The committee consists of:

• • Battery Manufacturers – Providing insight into lithium battery chemistry and failure mechanisms.
• • Aviation Regulators – Ensuring compliance with air safety regulations.
• • Testing Laboratories – Conducting rigorous thermal runaway and flame resistance tests.
• • Packaging Engineers – Developing solutions to contain potential battery failures.
• • Industry Stakeholders – Offering perspectives on practical implementation.

Challenges Faced in Developing the Standard

Creating a universal safety standard is no easy task. The SAE G27 Lithium Battery Packaging Performance committee encountered several challenges, including:

• • Diverse Industry Perspectives – Different stakeholders had conflicting priorities, requiring years of negotiation.
• • Complex Battery Chemistry – Not all lithium batteries behave the same, adding layers of complexity to the testing.
• • Lengthy Validation Process – Multiple test labs were needed to ensure that consistent results could be replicated across different environments.

Key Achievements and Future Outlook

The first version of the SAE G27 lithium battery packaging standard was released in July 2024, focusing on:

• • Thermal runaway containment for cylindrical lithium-ion cells.
• • Testing consistency across multiple labs.
• • Introduction of slash sheets for additional hazard mitigation.

The next steps involve expanding the standard to include other battery formats, such as prismatic and pouch cells, as well as addressing additional hazards like external heat exposure.

Do you have questions about your company’s compliance? Schedule a quick call with our expert today.