---
title: No Overheating of Lithium-Ion Batteries Thanks to Pressure Measurement
description: Prevent overheating of lithium-ion batteries through precise pressure measurement and optimized cooling concepts for increased safety and efficiency.
---

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# [No Overheating of Lithium-Ion Batteries Thanks to Pressure Measurement](https://stssensors.com/knowledge/no-overheating-of-lithium-ion-batteries-thanks-to-pressure-measurement)

 Written by [STS](https://stssensors.com/knowledge/author/sts) | Jun 23, 2025 1:17:59 PM

Lithium-ion batteries are powerful – but thermally sensitive. Precise pressure measurement is key to preventing overheating and optimizing cooling systems.

Whether it's exploding laptops or burning electric vehicles – thermal runaway of lithium-ion batteries can have dramatic consequences. This instability often results from overloading or high ambient temperatures and occurs in several dangerous stages:

- **from 80 °C:** Dissolution of the SEI layer, initial exothermic reactions
- **from 110 °C:** Decomposition of organic solvents, gas formation, pressure increase
- **from 135 °C:** Melting of separator foil → short circuit
- **from 200 °C:** Decomposition of cathode, oxygen release, ignition

## Thermal management through liquid cooling

To control these risks, modern EV batteries use liquid-cooled systems. Coolers and BMS (Battery Management System) regulate temperature and heat dissipation.

Designing these systems requires sound data: temperature and pressure measurements during charge and discharge cycles form the basis. Only then can cooling channels be dimensioned and simulations set up – for example with software like PTC CreoParametric 3D.

## Why pressure measurement is crucial

Optimal heat transfer depends on the interplay of coolant flow, temperature, and pressure. A pressure difference of just **0.008 bar** between inlet and outlet can be decisive – demanding **highest precision in pressure measurement**.

Sensors like the **ATM.1ST from STS** meet these requirements. They offer:

- Very high measurement accuracy at low differential pressures
- Long-term stability over broad temperature ranges
- Compact, media-resistant design for contact with liquids

Engineers use this data to compare pressure losses along various channel designs – visually represented in curves for minimal and maximum flow rates. The Bernoulli equation shows: *Higher flow rate = quadratically increasing pressure loss.*

## Design optimization through measurement data

For this reason, developers adopt wider cooling channels with multiple passages to improve heat dissipation via forced convection. The result: more stable cell temperatures, reduced risk of thermal runaway, and higher cycle life.

## Conclusion

Accurate pressure measurement makes an essential contribution to the safety and efficiency of lithium-ion batteries – especially during development. Sensors like the **ATM.1ST** from STS enable optimization of cooling concepts, reduction of risks, and long-term system performance security.

[View full post](https://stssensors.com/knowledge/no-overheating-of-lithium-ion-batteries-thanks-to-pressure-measurement)

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