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In order to understand the battery safety mechanisms including cell degradations on abuse conditions and field safety incidents, we used micro-/macroscopic tool to analyze the Li-ion battery design and manufacturing status which have strong direct relationship with the failure. The micro-/macroscopic analysis tool was applied to both gap measurements for the DPA (Destructive Physical Analysis) and the non-destructive failure/structure analysis of computerized tomography for the damaged samples after abuse testing. Through the combination analysis of the gap measurement by micro-/macroscopic tool and the non-destructive failure/structure analysis by X-Ray with the result of cell abuse verification tests, we can identify the latent root causes of field incident, study the battery safety mechanism and classify the safety risk level of each cell model. It can be suggested that a micro-/macroscopic analysis tool is a good method to study lithium ion battery safety mechanism and the root cause analysis of the failure.

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