Battery technology has come a long way, but safety concerns remain a hot topic—especially when it comes to fire risks. Lithium-ion batteries are widely used in everything from smartphones to electric cars, yet they come with risks. Solid-state batteries, a newer technology, promise better safety, but how do they truly compare?
1. Lithium-ion battery failure rate: Approximately 1 in 10 million cells
Lithium-ion batteries are generally safe, but when they fail, the results can be catastrophic. A failure rate of 1 in 10 million means that out of 10 million cells produced, at least one might experience an issue. However, as battery production scales up, even a tiny failure rate can translate to thousands of potential failures globally.
To reduce the chances of failure, manufacturers implement strict quality control, and users should always follow manufacturer guidelines for charging and usage.
2. Solid-state battery failure rate: Estimated to be 10x lower than lithium-ion
Solid-state batteries are designed with fewer failure points than lithium-ion, making them significantly safer. Their non-liquid electrolyte is far less prone to overheating and short circuits. As a result, their failure rate is estimated to be at least ten times lower than lithium-ion batteries.
This makes solid-state technology particularly promising for electric vehicles and high-performance devices, where battery safety is critical.
3. Thermal runaway temperature (Li-ion): ~60°C to 100°C
Thermal runaway occurs when a battery overheats uncontrollably, leading to potential fire or explosion. Lithium-ion batteries can reach thermal runaway at temperatures as low as 60°C (140°F), which is not difficult to reach in a malfunctioning device or under extreme environmental conditions.
To prevent overheating, avoid exposing devices to direct sunlight, never leave batteries charging unattended, and use only manufacturer-approved chargers.
4. Thermal runaway temperature (Solid-state): Over 200°C
Solid-state batteries have a much higher thermal runaway threshold—over 200°C (392°F). This makes them significantly safer in extreme conditions. Since they lack flammable liquid electrolytes, they are far less likely to ignite, even under stress.
This higher safety margin makes solid-state batteries a strong candidate for future electric vehicles, where overheating has been a concern with lithium-ion technology.
5. Energy density (Li-ion): 150-250 Wh/kg
Energy density determines how much power a battery can store for its size. Lithium-ion batteries typically hold 150 to 250 watt-hours per kilogram (Wh/kg), making them powerful enough for high-energy applications like electric cars and power tools.
However, this energy density also contributes to fire risks. When a battery with a high energy density fails, the release of stored energy can be explosive. Manufacturers counteract this by incorporating fire-resistant casings and advanced cooling systems.
6. Energy density (Solid-state): 300-500 Wh/kg (theoretical)
Solid-state batteries have the potential to double the energy density of lithium-ion cells. This means longer-lasting battery life and more power packed into smaller spaces. While they are still in development, the higher energy density of solid-state batteries could revolutionize electric vehicles by increasing range while reducing weight.
With great energy density comes responsibility. Proper design and safety testing will be essential to ensure that these batteries remain safe even with increased energy storage.
7. Li-ion battery fires per year (U.S.): ~2000 reported cases
Every year, about 2,000 lithium-ion battery fires are reported in the United States alone. This number includes everything from small smartphone fires to large-scale electric vehicle incidents.
Most of these fires result from improper charging, overheating, or damage. Users can reduce their risks by using quality chargers, avoiding overcharging, and replacing damaged batteries immediately.
8. Probability of Li-ion battery fire in consumer electronics: 1 in 1 million
The risk of a lithium-ion battery fire in consumer electronics is relatively low—about 1 in 1 million. However, given the billions of batteries in circulation, this still means thousands of incidents worldwide.
To stay safe, never charge your device on flammable surfaces, such as beds or couches, and keep an eye out for battery swelling or excessive heat.
9. EV battery fire rate (Li-ion): ~0.03% per vehicle per year
Electric vehicles (EVs) powered by lithium-ion batteries have a fire rate of about 0.03% per year, meaning that out of 10,000 EVs, about three may experience a battery-related fire annually.
While rare, EV fires tend to be more challenging to extinguish due to battery chemistry. This is why many manufacturers are investing in better cooling systems and solid-state alternatives.
10. EV fire rate compared to gasoline cars: 60-80% lower
Contrary to popular belief, EVs are significantly less likely to catch fire than gasoline cars. Gas-powered vehicles have a much higher fire rate due to fuel leaks and engine malfunctions.
That said, when EVs do catch fire, they burn hotter and longer. Firefighters use specialized techniques, such as water immersion, to control lithium-ion battery fires.
11. Li-ion explosion risk (if punctured): High due to electrolyte flammability
If a lithium-ion battery is punctured, the flammable electrolyte inside can leak and ignite upon contact with air. This is why damaged batteries should be handled with extreme caution.
To prevent punctures, avoid dropping or crushing devices with lithium-ion batteries, and never attempt to open battery casings.
12. Solid-state explosion risk: Very low due to non-flammable electrolyte
Solid-state batteries replace the flammable liquid electrolyte with a solid material, dramatically reducing the risk of explosion. Even if punctured, they are far less likely to ignite.
This makes them a promising solution for industries requiring high safety standards, such as aerospace and medical devices.
13. Li-ion self-discharge rate: ~2-8% per month
Lithium-ion batteries naturally lose charge over time, even when not in use. This self-discharge rate ranges from 2% to 8% per month, depending on temperature and battery age.
To extend battery life, store devices in a cool, dry place and avoid letting the battery drain completely before recharging.
14. Solid-state self-discharge rate: <1% per month
Solid-state batteries have an even lower self-discharge rate, often below 1% per month. This makes them ideal for applications where long-term energy storage is needed, such as emergency power backups.
With such low self-discharge, these batteries could revolutionize how we store energy for renewable sources like solar and wind power.
15. Li-ion internal short circuit probability: 1 in 40 million
Internal short circuits are a leading cause of lithium-ion battery failures, but they are relatively rare, occurring in about 1 in 40 million cells.
However, when they do happen, they can lead to sudden overheating and potential fires. This is why thermal management systems are critical in high-power applications.
16. Solid-state internal short circuit probability: Nearly zero
Since solid-state batteries do not contain liquid electrolytes, the chances of an internal short circuit are close to zero. This dramatically increases their safety and makes them ideal for mission-critical applications.
17. Cycle life (Li-ion, typical): 500-3000 cycles
The cycle life of a battery refers to how many times it can be charged and discharged before its capacity significantly degrades. Lithium-ion batteries typically last anywhere from 500 to 3,000 cycles, depending on their quality, chemistry, and how they are used.
Frequent deep discharges, overheating, and fast charging can shorten battery lifespan. To maximize the cycle life of your lithium-ion battery, avoid fully depleting it before recharging, keep it between 20-80% charge whenever possible, and store it at moderate temperatures.
18. Cycle life (Solid-state, estimated): 5000+ cycles
Solid-state batteries are expected to last much longer than lithium-ion, with estimates suggesting they could exceed 5,000 charge cycles. This is because they suffer less from degradation, as they don’t have the same liquid electrolyte that can break down over time.
With such an extended lifespan, solid-state batteries could revolutionize industries that require long-lasting energy storage, such as electric vehicles and renewable energy systems. This means fewer battery replacements, lower long-term costs, and less environmental waste.
19. Charge rate (Li-ion max safe charge): ~1C to 2C
The charge rate of a battery is expressed in terms of “C,” where 1C means the battery can be fully charged in one hour. Most lithium-ion batteries can safely charge at rates of 1C to 2C, meaning they take 30 minutes to an hour for a full charge.
Charging too quickly generates excess heat, increasing the risk of degradation or failure. To keep your battery healthy, avoid using fast chargers unless necessary and opt for slower, more controlled charging when possible.
20. Charge rate (Solid-state potential): Up to 10C
Solid-state batteries are expected to support much faster charging speeds—potentially up to 10C, meaning a full charge could take as little as 6 minutes. This is possible due to their improved thermal stability and lower risk of overheating.
With such rapid charging capabilities, electric vehicles and consumer electronics could see significant convenience improvements, eliminating long wait times for recharging.
21. Fire risk when overcharged (Li-ion): High if no BMS protection
Overcharging a lithium-ion battery can lead to excessive heat buildup, causing thermal runaway and potential fire. Most modern lithium-ion batteries include a Battery Management System (BMS) to prevent overcharging, but faulty or cheap chargers can sometimes bypass these safeguards.
To avoid overcharging risks, always use chargers that meet the manufacturer’s specifications and unplug devices once they are fully charged.
22. Fire risk when overcharged (Solid-state): Low due to stability
Unlike lithium-ion batteries, solid-state batteries are much more resistant to overcharging. Their solid electrolyte prevents dangerous reactions that lead to thermal runaway, making them far safer.
This inherent safety advantage makes solid-state batteries ideal for applications where reliability is crucial, such as medical implants, aerospace, and electric cars.
23. Weight reduction in solid-state vs Li-ion: ~30-50%
One of the key benefits of solid-state batteries is their potential to be 30-50% lighter than lithium-ion batteries while maintaining the same or higher energy capacity.
This weight reduction is particularly significant for electric vehicles, where lighter batteries mean improved efficiency, longer range, and better overall performance. It could also benefit consumer electronics by making devices slimmer and lighter without sacrificing battery life.
24. Cost per kWh (Li-ion): ~$100-150 (as of 2024)
Lithium-ion battery prices have steadily declined over the years, now averaging around $100-150 per kilowatt-hour (kWh). This cost reduction has helped accelerate the adoption of electric vehicles and renewable energy storage.
However, lithium-ion batteries still require expensive materials like cobalt and nickel, and as demand rises, costs may fluctuate. Researchers are actively seeking alternatives to make batteries even more affordable.
25. Cost per kWh (Solid-state, projected): ~$50-100 by 2030
Solid-state batteries are currently expensive due to manufacturing challenges, but their costs are expected to drop to $50-100 per kWh by 2030 as production scales up.
If these cost reductions materialize, solid-state batteries could become the new standard for EVs, consumer electronics, and industrial energy storage, offering better performance at a lower long-term cost.
26. Solid-state vs Li-ion production waste reduction: ~50% less waste
Solid-state battery production is expected to generate about 50% less waste compared to lithium-ion manufacturing. Since they don’t require liquid electrolytes and use fewer hazardous materials, they have a smaller environmental impact.
This makes solid-state technology an attractive option for companies looking to meet sustainability goals while still advancing battery performance.
27. Li-ion decomposition gases in failure: CO, CO2, H2, HF
When a lithium-ion battery fails or overheats, it can release dangerous gases like carbon monoxide (CO), carbon dioxide (CO2), hydrogen (H2), and hydrogen fluoride (HF). These gases are highly toxic and can create explosive conditions if they accumulate in confined spaces.
To minimize risks, avoid exposing lithium-ion batteries to extreme heat or physical damage, and ensure proper ventilation when using large battery systems.
28. Solid-state decomposition gases in failure: Minimal (no liquid electrolyte)
Unlike lithium-ion batteries, solid-state batteries do not contain volatile liquid electrolytes, meaning they produce minimal gas emissions when they fail.
This safety advantage makes them highly desirable for applications in enclosed spaces, such as airplanes, submarines, and wearable devices, where gas buildup can be a serious hazard.
29. Solid-state ignition probability in accident: ~1% vs ~10% for Li-ion
Lithium-ion batteries have an ignition probability of about 10% when involved in high-impact accidents, such as vehicle crashes. This risk is largely due to the flammable liquid electrolyte inside.
Solid-state batteries, on the other hand, have an ignition probability closer to 1%, making them far less likely to catch fire even in severe collisions. This is a major advantage for automotive and aerospace applications, where safety is a top priority.
30. Projected solid-state EV adoption by 2035: ~50% of market
With their superior safety, higher energy density, and lower weight, solid-state batteries are expected to capture about 50% of the EV battery market by 2035. Major automakers, including Toyota, BMW, and Volkswagen, are already investing heavily in solid-state technology to bring these batteries to mass production.
As production costs decrease and manufacturing processes improve, solid-state batteries could replace lithium-ion in everything from smartphones to energy grids, ushering in a new era of safer and more efficient energy storage.
wrapping it up
Battery technology is at a turning point. Lithium-ion batteries have served us well for decades, powering everything from smartphones to electric vehicles, but their risks are undeniable.
Fires, explosions, and degradation over time remain significant concerns, especially as energy demands increase. Solid-state batteries promise to solve many of these issues with greater safety, faster charging, longer lifespan, and higher energy density.
