Connecticut Company Launches Product Responding to Safety Hazards of Lithium Batteries

As the number of battery-driven technologies continue to increase to keep the multitude of electronic devices charged, so too has the threat of lethal battery fires, raising concerns in Connecticut and beyond.   

The town of Wilton earlier this year published on its town website a series of safety tips provided by the National Fire Protection Association, noting that “if not used correctly, or if damaged, these batteries can catch on fire or explode.” The Town of Fairfield’s Fire Department also provides tips on its official website.  A Connecticut Fire Academy warns fire fighters to “watch for a rapid & highly pressurized release of flammable gases/smoke followed by jet like flames.”

An NBC News report earlier this year highlighted the increasing danger as incidents are rapidly becoming more frequent, and according to a recent report by CNN, the Fire Department of New York (FDNY) attributed 216 fires to faulty batteries in 2022, resulting in pleas for better regulation and safety standards.  CT Insider reported last summer that federal officials from the National Transportation Safety Board are investigating a fire in a Connecticut Transit bus in Hamden.

A Connecticut business, Packaging and Crating Technologies (PACT®), has responded by developing a patented, fire-suppressant packaging wrap called PACT® Thermo ShieldTM, designed to control lithium battery thermal runaway, which causes dangerous and oftentimes deadly fires.  It has passed the proposed testing standards of the SAE International for safety in shipping lithium-ion batteries via land, sea and air, according to company officials. 

“Lithium-ion batteries are in most every electronic device you own whether it be for work or play and can become hazardous if they’ve been damaged or have some kind of defect, ultimately causing devastating, explosive fires ,” said Rodger Mort, President of PACT®, LLC, based in Watertown.  “Our proprietary PACT® Thermo ShieldTM product line is a protective and affordable solution that is quickly becoming an industry must when travelling, shipping, storing or disposing of products containing lithium-ion batteries.”

The PACT® Thermo ShieldTM is described as a lightweight, pleated, paper material with a non-toxic, moisture vapor application that prevents thermal runaway, a phenomenon in which the lithium-ion cell enters an uncontrollable, self-heating state caused by extremely high temperatures, shaking or puncturing during transit. 

Thermal runaway can result in the ejection of toxic gas, shrapnel and/or particulates, as well as smoke and fire, officials explain.  If this occurs, the protective PACT® Thermo ShieldTM wrap immediately cools the internal environment of the package, while limiting oxygen around the payload.  This process prevents the thermal runaway from spreading to other areas of the package, thus, suppressing a potential fire and shielding the surrounding environment from damage.

National Fire Data Week is observed May 15‑18, according to the U.S. Fire Administration,  an entity of the U.S. Department of Homeland Security’s Federal Emergency Management Agency (FEMA).  The mission of the U.S. Fire Administration is to support and strengthen fire and emergency medical services (EMS) and stakeholders to prepare for, prevent, mitigate and respond to all hazards.

Every year during the third week of June, Firefighter Safety Stand Down highlights critical safety, health and survival issues for fire and emergency services personnel. This year the focus is on lithium-ion batteries, a potential risk for first responders during fire incidents. Safety Stand Down is a joint initiative of the International Association of Fire Chiefs’ Safety, Health and Survival Section; the National Volunteer Fire Council; the National Fire Protection Association; and the Fire Department Safety Officers Association.

In the event of a fire, Mort notes that PACT® Thermo Shield TM is capable of containing temperatures up to 800 degrees Celsius or nearly 1,500 degrees Fahrenheit, while restricting the temperature outside of the wrap to 60 degrees Celsius/140 degrees Fahrenheit. 

“Lithium-ion battery fires are very difficult to extinguish and usually have to smolder out on their own after many hours, emitting lethal fumes and gases,” he adds. “This makes our product’s ability to contain both the fire and residual smoke within the protective wrap even more crucial.”

The Fire Department of New York (FDNY) has published a four-page informational booklet, titled “Dangers of Lithium-Ion Batteries,” which indicates that “fires caused by lithium-ion batteries have increased dramatically in New York City with deadly consequences.”

The booklet explains that “lithium-ion battery fires are very dangerous. Water may not prevent a battery from burning and spreading. Battery cells are known to explode and quickly spread to another battery. It can spread to other devices. These batteries may continue to generate heat even when there is no visible sign of fire. Once heat reaches a certain level fire may reignite on the battery and surrounding area. Fire Extinguishers do not work on lithium-ion batteries fires.”

Mort elaborates that besides hand-held devices, like cell phones, Bluetooth headsets and headphones, computer accessories, digital cameras, e-readers, game controllers, laptops, tablets, smartwatches and smoke/fire/carbon monoxide detectors, the most recent and prevalent items containing lithium-ion batteries that have become fire hazards are electric bikes, scooters, hoverboards, unicycles and electric cars.

A 2018 Health and Safety Information Bulletin from the federal Occupational Safety and Health Administration (OSHA) pointed out that the U.S. Consumer Product Safety Commission’s Status Report on High Energy Density Batteries Project reported over 25,000 overheating or fire incidents involving more than 400 types of lithium battery[1]powered consumer products that occurred over a five-year period.”

The OSHA Bulletin also noted that “workers who wear or frequently handle lithium-powered devices or batteries are particularly at risk if a lithium battery catches fire or  explodes since the device or battery is close to the body.”

To address this escalating issue, PACT® has recently designed a special product for E-mobility batteries – the PACT® Thermo Shield TR SleeveTM, in which its specially-coated, fire-suppressant paper is wrapped around each battery cell to mitigate thermal runaway between them, thus serving as a heat and flame barrier.  Two independent 3rd party organizations tested TR Sleeve multiple times and concluded that TR sleeve prevented thermal runaway propagation amongst cells.

Besides transporting and storing items that contain lithium-ion batteries, Mort notes that PACT® Thermo Shield TM also provides an eco-friendly way to ship or transport products safely to a battery recycler.  In fact, the company recently unveiled a smaller product- the TR Envelope to safely transport and store recyclable smaller devices such as cell phones, pagers, smartwatches and A-D batteries. 

“Consumers need to do their part to prevent lithium-ion battery fires by properly recycling their unused electronics and mobility devices,” concludes Mort. “They cannot be tossed in the trash or a regular recycling bin but must be separated from combustible materials like cardboard, paper, and wood scraps.”  Public safety officials echo those comments. 

He encourages people to check the recycling rules and facility policies within their communities to learn how one should appropriately recycle lithium-ion batteries.  Likewise, businesses, property managers, and anyone interested in recycling large quantities of batteries can acquire secure battery recycling containers and recycling information from PACT®.

For more information about the innovative PACT® Thermo Shield TM product line go to www.pactthermoshield.com/.