This study investigates the impact of state-of-charge (SOC) on thermal runaway (TR) behavior in lithium-ion (Li-ion) cells and modules. Using accelerating rate calorimetry (ARC) experiments on 3.25 Ah cylindrical Li-ion cells at different SOCs (3%, 33%, 66%, and 100%), the research demonstrates that TR characteristics such as onset temperature, maximum temperature, and self-heating rate are strongly dependent on SOC. The study develops a hierarchical TR model to simulate and analyze TR behavior at the cell level and its implications on TR propagation (TRP) in a battery module. The model incorporates thermo-kinetic parameters derived from ARC experiments to capture SOC-induced TR responses. The results show that higher SOCs lead to earlier TR onset and higher exothermic severity, which can significantly affect the thermal response of neighboring cells in a module. The study also examines TRP in a 3×3 battery module with both uniform and imbalanced SOC distributions, revealing that SOC variability plays a critical role in TRP behavior. The findings suggest that synergistic SOC control can mitigate TRP hazards in battery modules. The study highlights the importance of understanding SOC-dependent TR mechanisms for the development of advanced battery thermal management systems. The proposed framework provides insights into the influence of intrinsic factors such as SOC and cell-to-cell arrangement, as well as extrinsic factors like external heating and temperature, on TR behavior. The results demonstrate that the critical oven temperature for TR onset decreases from 250°C to 130°C as SOC increases from 0% to 100%. The study also shows that the TRP rate varies depending on SOC distribution, with higher TRP rates observed in modules with imbalanced SOC. The proposed virtual TR analytics framework can be used to design optimal cooling strategies and intelligent thermal management systems for battery modules. The study concludes that a comprehensive understanding of SOC-dependent TR behavior is essential for improving the safety and performance of Li-ion battery systems.This study investigates the impact of state-of-charge (SOC) on thermal runaway (TR) behavior in lithium-ion (Li-ion) cells and modules. Using accelerating rate calorimetry (ARC) experiments on 3.25 Ah cylindrical Li-ion cells at different SOCs (3%, 33%, 66%, and 100%), the research demonstrates that TR characteristics such as onset temperature, maximum temperature, and self-heating rate are strongly dependent on SOC. The study develops a hierarchical TR model to simulate and analyze TR behavior at the cell level and its implications on TR propagation (TRP) in a battery module. The model incorporates thermo-kinetic parameters derived from ARC experiments to capture SOC-induced TR responses. The results show that higher SOCs lead to earlier TR onset and higher exothermic severity, which can significantly affect the thermal response of neighboring cells in a module. The study also examines TRP in a 3×3 battery module with both uniform and imbalanced SOC distributions, revealing that SOC variability plays a critical role in TRP behavior. The findings suggest that synergistic SOC control can mitigate TRP hazards in battery modules. The study highlights the importance of understanding SOC-dependent TR mechanisms for the development of advanced battery thermal management systems. The proposed framework provides insights into the influence of intrinsic factors such as SOC and cell-to-cell arrangement, as well as extrinsic factors like external heating and temperature, on TR behavior. The results demonstrate that the critical oven temperature for TR onset decreases from 250°C to 130°C as SOC increases from 0% to 100%. The study also shows that the TRP rate varies depending on SOC distribution, with higher TRP rates observed in modules with imbalanced SOC. The proposed virtual TR analytics framework can be used to design optimal cooling strategies and intelligent thermal management systems for battery modules. The study concludes that a comprehensive understanding of SOC-dependent TR behavior is essential for improving the safety and performance of Li-ion battery systems.