The proliferation of lithium-ion power banks poses significant fire hazards, yet research on their fire risks remains scarce. Therefore, this pioneering study systematically investigates the combustion behavior of power banks and their components under different states of charge (SOC) through cone calorimeter tests and localized overheating experiments. A comprehensive risk assessment framework is established based on fire characteristic parameters, principal component analysis (PCA), and risk matrices. Results illustrate that both power bank units (PBUs) and cells (PBCs) undergo four combustion stages: localized ignition, full ignition, thermal runaway (TR) and extinction. And the heat release rate (HRR) curves exhibit a bimodal characteristic. Key combustion parameters, including the peak value of heat release rate (HRRpeak) and total heat release (THR), are positively correlated with SOC. Furthermore, PBUs exhibit lower HRRpeak and combustion intensity than PBCs at identical SOC levels. Component contribution analysis indicates a nonlinear coupling effect where the whole is not equal to the sum of its parts for THR parameters. The power bank enclosure serves as the primary source of heat and smoke (contributing over 55%), while PBC contributes secondarily (ranging from 4% to 39%). Localized overheating experiments further confirm that the severity of TR in PBUs positively correlates with SOC. PCA extracts two primary dimensions representing “total yield” and “maximum combustion intensity”. Combined with the risk matrix, these confirm that PBUs exhibit highest fire hazard level across four SOC conditions. This study provides experimental evidence and theoretical support for fire risk prevention and safety design in power banks.
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