Power Battery Safety Risk Sources – From Cell to Pack – A B2B Guide

Battery safety must be addressed at every level: cell, module, and pack. The new GB 38031-2025 standard requires no fire or explosion after thermal runaway across all levels.

At the cell level, the primary risk is internal short circuits leading to thermal runaway, triggered by overcharging, low-temperature fast charging, or mechanical damage. Manufacturing defects also contribute.

At the module level, the key risk is thermal propagation between cells when one cell fails. Proper thermal barriers and insulation are critical to prevent spread, as required by the new standard.

At the pack level, risks include high-voltage electrical failure, structural damage, cooling system breakdown, and BMS communication loss. The pack must pass rigorous tests to ensure no fire or explosion.

B2B buyers should verify that suppliers provide test documentation at all levels and meet GB 38031-2025 compliance.