Articles tagged with "battery-safety"
Sulfur-modified electrolyte tackles solid-state battery limits
Researchers at Kennesaw State University, led by Assistant Professor Beibei Jiang, are developing a sulfur-modified composite solid electrolyte to enhance lithium-ion transport in solid-state batteries. These batteries replace the flammable liquid electrolytes found in conventional lithium-ion cells with solid materials, improving safety and thermal stability. However, slow lithium-ion movement through solids has limited charging speed and overall performance. Jiang’s team addresses this by incorporating sulfur-based chemical groups into a ceramic-polymer composite electrolyte, which reduces interfacial resistance and facilitates faster ion movement. This modification effectively “smooths the highway” for lithium ions, potentially enabling faster charging and better battery performance. A key discovery in their research is a previously undocumented strong interaction between sulfur and zirconium in the ceramic component, which significantly contributes to the improved ion transport. This finding emerged unexpectedly during early experiments and was harnessed to optimize the electrolyte design. The project, supported by a $200,000 National Science Foundation grant, is currently focused on validating the stability
energysolid-state-batterieselectrolytelithium-ionsulfur-modificationbattery-safetymaterials-scienceRad Power Bikes reaches deal to sell itself for $13.2 million
Rad Power Bikes, an electric bike company, has agreed to sell itself to Life Electric Vehicles Holdings (Life EV) for approximately $13.2 million, shortly after filing for bankruptcy. The sale followed an auction with five bidders, where Life EV emerged as the winner with a bid totaling $14.9 million when liabilities are included. Retrospec, another e-bike company, was the backup bidder with a $13 million offer. This valuation is a significant drop from Rad Power’s peak valuation of $1.65 billion in October 2021. The acquisition requires approval from the bankruptcy judge. Life EV, based in Florida, is a developer and distributor in the light electric vehicle sector, though most of its own electric bikes were sold out at the time of reporting. Rad Power Bikes experienced rapid growth during the pandemic but later faced challenges including multiple layoffs, CEO changes, and safety issues related to older batteries that reportedly caught fire, with 31 incidents reported to the Consumer Product Safety Commission (C
energyelectric-bikesmicromobilitybattery-safetyelectric-vehiclesbankruptcytransportation-technologyAll-solid-state batteries get record-high density with new method
Researchers at the Korea Research Institute of Standards and Science (KRISS) have developed a breakthrough material technology that significantly advances the commercialization of all-solid-state batteries (ASSBs). ASSBs replace the flammable liquid electrolytes used in conventional lithium-ion batteries with non-flammable solid electrolytes, greatly enhancing battery safety by eliminating fire and explosion risks. This innovation addresses long-standing challenges in the fabrication of oxide-based ASSBs, which use garnet-type solid electrolytes known for their high ionic conductivity and chemical stability but require costly, high-temperature sintering processes. The team overcame a major production barrier by creating a novel fabrication method that involves thinly coating solid electrolyte powders with lithium–aluminum–oxide (Li–Al–O) multifunctional compounds. This coating supplies lithium during sintering, prevents lithium evaporation, and improves particle bonding, resulting in electrolyte membranes with a record-high density exceeding 98.2%. Unlike conventional methods that discard large amounts of expensive lithium-containing "mother powder," this approach eliminates the
energyall-solid-state-batteriessolid-electrolyteslithium-ion-batteriesbattery-safetymaterials-scienceenergy-storage-systemsUS team toughens ceramic electrolytes for safer solid-state batteries
Stanford University researchers have developed a method to significantly improve the mechanical durability of ceramic electrolytes used in solid-state batteries, addressing their inherent brittleness that leads to cracking and battery failure. By applying an ultra-thin, 3-nanometer silver coating onto the lithium lanthanum zirconium oxide (LLZO) electrolyte and annealing it at 300°C, silver ions diffuse into the electrolyte, replacing smaller lithium ions and creating a positively charged structural barrier. This nanoscale silver doping enhances fracture resistance by nearly five times and prevents lithium from wedging into microscopic surface cracks, which typically expand during fast charging and cause destructive fissures. The study highlights that this silver ion diffusion fundamentally changes how cracks initiate and propagate, making the electrolyte more stable under extreme electrochemical and mechanical conditions. While other ions like copper showed some effectiveness, silver remains the most efficient for this purpose. The team is now scaling up from small samples to full battery cells to test the coating’s durability over thousands of charge cycles,
energysolid-state-batteriesceramic-electrolyteslithium-ion-batteriesbattery-safetymaterials-sciencenanotechnologyWhy single-crystal EV batteries crack, fade, and sometimes fail
Researchers from Argonne National Laboratory and the University of Chicago have uncovered the underlying cause of degradation in single-crystal nickel-rich lithium-ion cathodes used in electric vehicle (EV) batteries. While single-crystal cathodes were initially expected to outperform traditional polycrystalline cathodes by avoiding grain boundary-related cracking, they still exhibited unexpected cracking and performance fade. Using advanced synchrotron X-ray and electron microscopy techniques, the team discovered that reaction heterogeneity within single-crystal particles causes internal strain, leading to nanoscale fractures from within the particles, a degradation mechanism distinct from that in polycrystalline materials. This insight challenges previous assumptions and conventional design principles that were based on polycrystalline cathodes. Notably, the study found that cobalt, which in polycrystalline cathodes tends to promote cracking but prevents structural disorder, actually improves durability in single-crystal cathodes, whereas manganese causes more mechanical damage. These findings suggest that new design strategies and material compositions are necessary to enhance battery longevity and safety.
energyelectric-vehicleslithium-ion-batteriesbattery-degradationsingle-crystal-cathodesmaterials-sciencebattery-safetyZero tolerance for EV fire or explosions: China sets mandatory rules
China has implemented a comprehensive upgrade to its national regulatory framework, introducing mandatory safety standards for electric-vehicle (EV) power batteries for the first time. Central to this initiative is the “no fire, no explosion” requirement, which sets strict technical thresholds to prevent battery fires or explosions in EVs. These new regulations are part of a broader Action Plan to Promote Equipment Renewal and Consumer Goods Trade-In Through Standards, aiming to modernize industry and enhance consumer safety. The updated EV battery safety standard, GB 38031-2025, will take effect on July 1, 2026, with all new vehicle type approvals required to comply by that date, while existing vehicles have a transition period until July 1, 2027. Beyond EVs, China’s regulatory overhaul includes 113 national standards targeting energy efficiency, emissions reduction, and the phasing out of outdated industrial capacity across sectors such as coal power, steel, and building materials. Stricter efficiency requirements have been imposed on industrial
energyelectric-vehiclesbattery-safetyregulationsChinaindustrial-standardsemissions-reductionSolid-state batteries carry fire risks similar to liquid cells: Report
The article discusses the safety risks associated with solid-state batteries, which are often promoted as a safer alternative to traditional liquid lithium-ion batteries. Despite replacing liquid electrolytes with solid ones, experts caution that solid-state batteries still carry significant fire and thermal runaway risks due to their high energy density and the reactive nature of lithium metal, especially in designs using lithium metal anodes. Experimental findings indicate that lithium metal can react with cathode materials even without oxygen, potentially causing extreme aluminothermic reactions at very high temperatures. Thus, safety challenges remain and must be addressed through careful materials engineering, cell design, and manufacturing controls rather than assuming inherent safety. In China, momentum is growing to commercialize solid-state batteries in the automotive sector, with companies like FAW Group planning to introduce these batteries in vehicles by 2027 and others initiating pilot production for testing. However, some analysts warn against viewing solid-state batteries as a guaranteed solution to fire risks, noting that liquid lithium-ion batteries continue to improve in safety through innovations
energysolid-state-batterieslithium-ion-batteriesbattery-safetymaterials-engineeringenergy-storageautomotive-energy-technologyDo EVs catch fire more than gas cars? A data-driven safety comparison
The article examines the common perception that electric vehicles (EVs) catch fire more frequently than gasoline-powered cars, concluding that this belief is not supported by data. Despite viral videos and media coverage that highlight EV fires, real-world evidence from multiple countries shows that EVs actually have a significantly lower incidence of fires compared to internal combustion engine (ICE) vehicles. In the U.S., for example, data indicates about 25 fires per 100,000 EVs sold versus roughly 1,500 fires per 100,000 gasoline vehicles. Similar trends are observed in Europe and Australia, where combustion vehicles are found to be 20 to 100 times more likely to catch fire than EVs. The persistence of the myth that EVs are more fire-prone is attributed to the visibility and nature of EV fires rather than their frequency. Gasoline vehicle fires occur regularly and often go unnoticed by the public, whereas EV fires are rare and tend to attract significant attention due to their dramatic visuals, longer burn
energyelectric-vehiclesbattery-safetyvehicle-firescombustion-enginesfire-risktransportation-safetyRad Power Bikes files for bankruptcy and is looking to sell the business
Rad Power Bikes, a prominent electric bike manufacturer, filed for Chapter 11 bankruptcy protection, aiming to sell the business within 45-60 days while continuing normal operations. The company cited the bankruptcy as a way to preserve its relationships with customers, vendors, and partners. This move follows a turbulent period marked by multiple layoffs, a CEO change, and a strategic shift from a direct-to-consumer model to a retail-focused approach under new CEO Kathi Lentzch. Rad Power entered bankruptcy with $32 million in assets against $73 million in liabilities, including over $8 million owed to U.S. Customs and Border Protection for unpaid tariffs, a debt listed as disputed. The filing comes amid broader challenges in the e-bike industry, which has seen several companies file for bankruptcy after pandemic-driven demand waned. Rad Power’s difficulties were compounded by a Consumer Product Safety Commission warning about fire risks associated with older Rad Power batteries, a claim the company disputes. Previously, Rad had hoped to secure funding through
energyelectric-bikesbattery-safetybankruptcymicromobilityelectric-vehicle-technologyconsumer-product-safetyChina's EV battery fires test the limits of layout-led safety
The article examines the challenges faced by China’s electric vehicle (EV) industry in ensuring battery safety, focusing on recent incidents involving Xiaomi Auto’s flagship Su7 sedan and Li Auto’s Mega van. Xiaomi had initially gained acclaim for its innovative battery layout, using vertically downward-facing cells developed with CATL to direct flames and toxic gases away from occupants in crashes. This design was touted as a breakthrough in mitigating fire risks, a persistent issue in EVs. However, fatal accidents in 2025, where Su7 batteries ignited upon impact causing multiple deaths, along with a spontaneous fire in a Li Auto vehicle, exposed the limitations of layout-based safety measures and reignited public concerns about EV battery risks. Despite improvements in battery cell quality, manufacturing, and management systems that have reduced fire incidents overall, the article highlights that the fundamental vulnerabilities remain tied to cell chemistry, engineering structure, thermal management, and especially battery layout decisions. Chinese automakers predominantly use prismatic lithium-ion cells arranged vertically, either upright or
energyelectric-vehiclesbattery-safetylithium-ion-batteriesbattery-management-systemsolid-state-batteriesEV-technologyChina's EV battery fires test the limits of layout-led safety
The article discusses the challenges China’s electric vehicle (EV) industry faces regarding battery safety, focusing on recent incidents involving Xiaomi Auto’s flagship Su7 sedan and other EV models. Xiaomi had initially gained acclaim for its innovative battery layout, using vertically mounted, downward-facing cells developed with CATL, designed to direct flames and toxic gases away from occupants in crashes. This "cell inversion technology" was touted as a breakthrough in mitigating fire risks, a persistent concern in the EV sector. However, two fatal accidents involving the Su7 in 2025, where batteries ignited upon impact and trapped occupants inside, severely undermined these safety claims. Additionally, a spontaneous fire in a Li Auto Mega van further heightened public fears, illustrating that battery fires can occur even without collisions. Despite overall improvements in battery safety due to better cell quality, battery management systems, and manufacturing standards, the article emphasizes that risks remain tied to cell design, thermal management, and battery layout within integrated vehicle structures. Lithium-ion cells, including
energyelectric-vehiclesbattery-safetylithium-ion-batteriessolid-state-batteriesbattery-management-systemsEV-firesRad Power Bikes’ batteries receive major fire risk warning
The U.S. Consumer Product Safety Commission (CPSC) has issued a major fire risk warning for the batteries used in Rad Power Bikes’ electric bicycles, citing a risk of ignition or explosion that could cause serious injury or death. The CPSC has received 31 reports of battery fires, including 12 incidents causing property damage, some occurring even when the batteries were not charging. The commission highlighted that the batteries can unexpectedly ignite, especially if exposed to water or debris, posing a significant fire hazard to consumers. Rad Power Bikes is facing this warning amid financial difficulties, having informed employees that it may shut down in January without new funding. The CPSC stated that Rad Power refused to agree to a recall, with the company reportedly unable to offer replacements or refunds to all customers due to its financial constraints. Rad Power Bikes strongly disputes the CPSC’s characterization of their batteries as defective or unsafe, asserting that their batteries meet the highest industry standards and that the incident rate is very low—less than one percent
energylithium-ion-batteriesbattery-safetyelectric-bikesfire-hazardconsumer-product-safetybattery-recallEVs can get 2.8x more range, 3x battery life with oxygen bodyguard gel
Researchers at the Ulsan National Institute of Science and Technology (UNIST) have developed a novel gel polymer electrolyte (GPE), named An-PVA-CN, that could significantly enhance electric vehicle (EV) battery performance by increasing driving range by 2.8 times and extending battery life nearly threefold. Traditional lithium-ion batteries face challenges at high voltages (above ~4.4 V), where nickel-rich cathodes release surface oxygen that forms reactive oxygen species (ROS). These ROS degrade the electrolyte, damage cathode structure, cause nickel dissolution, and generate gas that swells batteries, increasing failure risk and shortening lifespan. The new gel electrolyte addresses these issues with a dual protection mechanism: anthracene molecules bind to unstable surface oxygen to prevent ROS formation and also scavenge any ROS already present, neutralizing them before damage occurs. Additionally, nitrile groups in the polymer bind to nickel ions, preventing their dissolution and maintaining cathode structural integrity. This results in reduced cracking, degradation
energyelectric-vehiclesbattery-technologygel-electrolytelithium-ion-batteriesbattery-safetybattery-longevityTesla Powerwall 2 recall expands to US after reports of fires
Tesla has expanded its recall of the Powerwall 2 battery units to the United States following reports of fires. The U.S. Consumer Product Safety Commission (CPSC) announced that five Powerwalls caught fire, causing minor property damage, while another six units emitted smoke and 11 overheated. These affected units were sold between November 2020 and December 2022. The recall follows a similar action in Australia, where the issue was linked to battery cells manufactured by an unnamed third-party supplier; however, Tesla has not disclosed the manufacturer involved in the U.S. recall. The CPSC advises owners to verify their Powerwalls are online and check the Tesla app to determine if their unit is part of the recall. Tesla plans to remotely discharge affected batteries that are online and will provide replacements to customers. This recall highlights ongoing safety concerns related to the Powerwall 2 units and Tesla’s efforts to address potential fire hazards associated with the product.
energyTesla-Powerwallbattery-recallenergy-storagebattery-safetyhome-energy-systemselectric-batteriesNailed, burned, and submerged: New zinc-air battery refuses to die
Researchers at Mexico’s Center for Advanced Materials Research (CIMAV) have developed a novel zinc-air battery (ZAB) that demonstrates exceptional durability and safety, continuing to operate even after being punctured, burned, or submerged in water. Unlike conventional lithium-ion batteries, which pose fire risks due to flammable electrolytes and rely on scarce, expensive metals like lithium and cobalt, this new design uses abundant materials such as zinc and nickel. The battery features a carbon sheet embedded with individual nickel atoms as electrodes, significantly reducing metal usage while maintaining high performance. This structure, combined with a gel polymer electrolyte, eliminates many safety hazards associated with traditional batteries. The prototype was rigorously tested under extreme conditions, including nailing, burning, and submersion, and showed no loss of function or efficiency, even in very high or low temperatures. This resilience makes it a promising candidate for applications in electric vehicles, aerospace, and remote sensors, especially in challenging environments. The researchers also aim to enhance the battery
energyzinc-air-batterybattery-safetyenergy-storageadvanced-materialssustainable-energyelectric-vehiclesIs An Electric Bus A Fire Risk - CleanTechnica
The article from CleanTechnica addresses recent misinformation and fearmongering surrounding the safety of electric buses following a fatal collision in New Zealand. A petrol Subaru crashed head-on into an Auckland electric bus, which caught fire, resulting in the bus driver's death and injuries to the car occupants. Despite the bus being engulfed in flames, investigations by the bus operator and Auckland’s Fire and Emergency Department confirmed that the fire originated in the petrol car’s engine, and the electric bus’s batteries remained undamaged. Auckland city councillor Richard Hills condemned the spread of anti-EV propaganda and reassured the public that electric buses are safe, highlighting that fire safety systems are integrated into EV battery design. The article emphasizes that data from multiple countries consistently show electric vehicles are less likely to catch fire than petrol or diesel vehicles. Councillor Hills noted that fires in diesel vehicles are relatively common but do not provoke calls for bans, contrasting this with the disproportionate fear directed at electric buses. The article criticizes the spread of misinformation
energyelectric-vehicleselectric-busesbattery-safetyfire-safetyemissions-reductionpublic-transportationCATL-powered EV catches sudden fire, burns down to 'skeletal frame'
On October 23, 2025, a Li Auto Mega electric MPV powered by a CATL battery pack suddenly caught fire while driving in Shanghai’s Xuhui District. Witnesses reported no collision or external impact before flames erupted from the vehicle’s chassis, where the battery is located. The fire quickly consumed the entire minivan, leaving only a charred skeletal frame. Thanks to the vehicle’s automatic door release system, the driver and passenger escaped unharmed. Li Auto, in cooperation with local fire authorities, has launched an investigation into the cause, with early indications pointing to the battery pack as the potential ignition source. This incident is particularly concerning as it marks the third fire involving Li Auto Mega vehicles in China since June 2025, although previous cases were linked to external factors. The latest fire’s cause remains undetermined, raising new safety questions about the model. The Li Auto Mega, introduced in March 2024 as the company’s first fully electric MPV, has seen steady
energyelectric-vehiclesbattery-safetyCATLLi-Autoelectric-MPVelectric-battery-fireMetallic gel discovery could make liquid metal batteries safer
Researchers at Texas A&M University have created the world’s first metallic gel, a novel material that combines solid and liquid metal phases to form a gel-like structure capable of withstanding extreme heat. This metallic gel is produced by mixing two powdered metals and heating them until one melts while the other remains solid, creating a fine internal scaffold that traps the molten metal inside. Unlike traditional gels made from organic materials, this metallic gel is entirely metallic and can survive temperatures around 1,000°C (1,832°F). The discovery challenges previous assumptions that liquid metals could not be supported by an internal solid skeleton, with copper and tantalum mixtures demonstrating stable gel-like behavior. This breakthrough has significant implications for liquid metal batteries (LMBs), which use molten metal layers to store and release energy but face challenges due to liquid metal shifting and causing short circuits during movement. The metallic gel’s ability to hold liquid metal in place could enable LMBs to function reliably in dynamic environments such as ships or heavy industrial vehicles
metallic-gelliquid-metal-batteriesenergy-storageadvanced-materialshigh-temperature-materialsbattery-safetymetal-compositesChery unveils 600 Wh/kg solid-state battery promising 800-mile range
Chinese automaker Chery has unveiled a prototype solid-state battery module boasting an energy density of 600 Wh/kg, roughly double that of current liquid lithium-ion EV batteries, which typically range from 250 to 300 Wh/kg. This breakthrough could enable electric vehicles to achieve driving ranges of up to 800 miles (1,300 km) on a single charge, significantly surpassing the 311 to 373 miles (500 to 600 km) typical of today’s long-range EVs. The battery features an “in-situ polymerized solid electrolyte” that replaces the flammable liquid electrolyte in conventional batteries, along with a lithium-rich manganese cathode to enhance energy storage and safety. Solid-state batteries also offer advantages such as reduced fire risk, faster charging, longer lifespan, and better performance in extreme temperatures. Chery plans to begin pilot production of this battery in 2026, with mass production targeted for 2027, potentially positioning itself ahead of major Chinese battery makers like BYD and
energysolid-state-batteryelectric-vehiclesbattery-technologyenergy-densitylithium-ion-batterybattery-safetyEV batteries could keep 96% power after 1,300 cycles with silver tech
Researchers from Korea University have developed a novel silver-ion coating technology that significantly enhances the lifespan and safety of lithium-metal batteries, a promising next-generation energy storage solution. This ultrathin coating prevents the formation of dendrites—hazardous, tree-like lithium structures that cause short circuits and battery failures—by promoting uniform lithium deposition on the electrode. The method involves alternating layers of silver ions and trithioisocyanuric acid (TCA) applied via a simple, room-temperature solution process without complex synthesis or high-temperature treatments. During battery operation, silver ions convert into nanoparticles that guide even lithium growth, while TCA forms a stable matrix preventing surface damage. Laboratory tests demonstrated that batteries using this coating maintained over 96% capacity after 1,300 charge-discharge cycles and operated stably for more than 2,000 hours, marking a significant improvement in cycling stability and safety. The researchers emphasize that this technology addresses the critical challenge of dendrite formation, which has hindered the
energylithium-metal-batteriessilver-ion-coatingbattery-technologyenergy-storagebattery-safetybattery-lifespanSafer Batteries, Reliable Power: Guiding Research for Next-Generation Energy Storage - CleanTechnica
The article from CleanTechnica highlights the critical importance of safety in the development of next-generation lithium-ion batteries, which are essential for powering modern America across various sectors. As demand for advanced energy storage solutions grows, researchers are exploring innovative battery designs featuring alkali metal anodes, solid electrolytes, and Earth-abundant cathode materials. However, these new technologies present unique safety challenges that differ from conventional lithium-ion batteries, including variations in kinetics, toxicity, mechanical robustness, and fire-suppression needs. Understanding these risks is vital to designing safer, more reliable battery systems for future applications. Researchers at the National Renewable Energy Laboratory (NREL) are at the forefront of battery safety research, employing a comprehensive, multi-scale approach to evaluate battery performance and hazards at the electrode, cell, and pack levels under various conditions such as abuse scenarios and state of charge. NREL collaborates closely with industry partners to accelerate the translation of lab-scale discoveries into market-ready technologies. Their work includes advanced characterization techniques and
energybattery-technologyenergy-storagelithium-ion-batteriesbattery-safetymaterials-sciencenext-generation-batteriesGerman firm launches EV battery coatings for 2,192°F heat protection
German company Axalta Coating Systems has introduced two new coatings—Alesta e-PRO FG Black and Alesta e-PRO Dielectric Gray—aimed at enhancing safety and performance in electric vehicle (EV) batteries. Unveiled at The Battery Show North America, these coatings address the critical issue of battery safety, particularly the risk of thermal runaway, where overheating of one battery cell can trigger a chain reaction causing extreme heat and fire. Alesta e-PRO FG Black offers high thermal stability and secondary fire protection, maintaining integrity under direct flames and temperatures up to 1200°C (2,192°F), while also providing corrosion resistance and zero smoke emission. It has passed rigorous testing, including UL 2596 TaG, to help delay fire propagation in EV battery systems. The Alesta e-PRO Dielectric Gray coating focuses on electrical insulation, featuring high dielectric strength, flexibility, and consistent edge coverage suitable for complex battery pack designs. It meets UL 94 V0 and IEC
energyelectric-vehiclesbattery-safetythermal-protectioncoatingsEV-battery-technologyelectrical-insulationChina's EV system ejects batteries 20 feet away in case of extreme heat
A recent demonstration in China showcased an innovative electric vehicle (EV) safety system designed to address the rare but severe issue of battery fires. This system detects thermal runaway—a rapid, spreading ignition of battery cells—and ejects the entire battery pack from the vehicle within a second, propelling it 10 to 20 feet away. The concept aims to protect passengers by removing the burning battery from the car, simplifying firefighting efforts, which currently may require submerging the entire vehicle in water due to the intense heat and difficulty extinguishing such fires. While the system presents a novel approach to EV fire safety, it also raises significant concerns. Ejecting a heavy, burning battery pack poses risks to pedestrians, other vehicles, and nearby structures, potentially creating new hazards and liability issues. Consequently, automakers and suppliers have distanced themselves from the idea, and the technology remains at a proof-of-concept stage without regulatory approval. Despite mixed reactions from the media—ranging from cautious interest to skepticism—the
energyelectric-vehiclesbattery-safetythermal-runawayEV-battery-firefire-safety-technologyautomotive-technologyChina’s wild EV fire-safety test shows battery ejected at rocket speed
China has demonstrated a novel electric vehicle (EV) fire-safety technology that ejects the entire battery pack from the car at high speed during emergencies to prevent onboard fires or explosions. In a viral video from a controlled test, sensors detected thermal runaway in the battery, triggering a mechanism that launched the battery 3 to 6 meters away into a padded safety zone, where fire crews quickly contained the ensuing smoke and flames. The system aims to protect passengers by physically removing the fire hazard from the vehicle cabin, acting somewhat like an airbag deployment for battery fires. However, the concept has drawn significant criticism and safety concerns. Critics argue that in real-world traffic, an ejected battery—often weighing several hundred pounds—could become a dangerous projectile, potentially harming pedestrians, other vehicles, or causing additional accidents. Questions were also raised about the system’s reliability during severe crashes where vehicle deformation might prevent battery ejection, leaving occupants exposed to fire risks. The test was reportedly organized by the China Automotive Collision Repair
energyelectric-vehiclesbattery-safetyEV-fire-preventionthermal-runawaybattery-ejection-systemautomotive-safetySodium metal batteries retain 91% capacity after 1,000 cycles
Researchers at the University of Queensland’s Australian Institute for Bioengineering and Nanotechnology have developed a novel solid electrolyte for sodium metal batteries (SMBs) that significantly enhances their safety and longevity. The new fluorinated block copolymer material, P(Na3-EO7)-PFPE, is non-flammable and engineered with a body-centered cubic internal structure that facilitates efficient sodium-ion transport while inhibiting the growth of dendrites—metal spikes that cause short circuits and fires in conventional batteries. Testing demonstrated that batteries using this electrolyte retained over 91% of their capacity after 1,000 charge cycles and operated continuously for more than 5,000 hours at 80°C, marking a substantial advancement for grid-scale energy storage applications. This development addresses major safety concerns associated with traditional liquid electrolytes, which are flammable and prone to instability during repeated cycling. By replacing the liquid with a solid, plastic-like electrolyte, the researchers have created a safer, more reliable battery that could serve as a low
energysodium-metal-batteriessolid-electrolytebattery-safetydendrite-preventiongrid-scale-energy-storagematerials-scienceBattery noises decoded to reveal cracks, gas, and safety clues
Researchers at MIT have developed a novel method to decode faint acoustic signals emitted by lithium-ion batteries during charge and discharge cycles, linking specific sound patterns to internal degradation processes such as gas generation and electrode material fracturing. By combining electrochemical testing with sensitive acoustic recordings under real-world conditions, the team was able to noninvasively monitor battery health, identifying distinct acoustic signatures even amid noisy data. This approach was validated through electron microscopy, confirming the correlation between sounds and internal battery damage. Unlike previous methods that relied on simple sound thresholds, the MIT researchers employed advanced wavelet transforms to isolate meaningful signals from background noise, similar to techniques used in structural health monitoring of bridges. This acoustic monitoring provides an additional diagnostic tool beyond traditional voltage and current measurements, offering insights into battery lifespan and safety risks, including early warnings of thermal runaway. The technology has immediate applications in material research, manufacturing quality control, and electric vehicle monitoring, with ongoing collaborations such as one with Tata Motors to implement real-world diagnostic systems. The study
energylithium-ion-batteriesbattery-health-monitoringacoustic-signalselectrochemical-testingelectric-vehiclesbattery-safetyNew impact-resistant additive makes lithium-ion batteries safer for EVs
Researchers at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a novel impact-resistant additive to enhance the safety of lithium-ion batteries used in electric vehicles (EVs). Inspired by the shear-thickening behavior of oobleck—a cornstarch and water mixture that solidifies under pressure—Gabriel Veith and his team created an additive composed of uniformly sized superfine silica particles suspended in the battery electrolyte. This additive instantly hardens upon impact, preventing the battery’s electrodes from touching and short-circuiting, which can otherwise cause fires. The uniform particle size is critical to ensure even dispersion and effective solidification, and the additive can be incorporated into existing battery manufacturing processes with minimal modifications. The technology, branded as Safe Impact Resistant Electrolytes (SAFIRE), was licensed in 2022 to Safire Technology Group, a startup advancing its commercialization for automotive, defense, and electric vertical take-off and landing (eVTOL) aircraft applications. SAFIRE
energylithium-ion-batteriesbattery-safetyimpact-resistant-additivematerials-sciencesilica-particleselectrolyte-technologyASEAN Battery Conference Proposes Unified Regional Battery Ecosystem - CleanTechnica
The 3rd ASEAN Battery Technology Conference (ABTC), held in Phuket, Thailand, brought together over 340 participants from more than 20 countries to advance a unified regional battery ecosystem and promote collaboration in clean energy. Co-hosted by the Thailand Energy Storage Technology Association (TESTA) and other leading organizations, the conference featured the launch of the ASEAN Battery Safety Network (ABSN), aimed at standardizing battery safety practices across ASEAN. ABSN, led by Dr. Sing Yang Chiam of the Singapore Battery Consortium, seeks to foster cross-border cooperation, knowledge exchange, and the advancement of battery safety science, supported by a strategic partnership with UL Standards & Engagement (ULSE). Significant Memoranda of Understanding (MoUs) were signed to enhance regional collaboration and innovation, including agreements to standardize swappable battery packs, develop grid-scale Battery Energy Storage Systems (BESS), and promote solid-state battery technology commercialization. Key partnerships involved companies such as Amphenol, Singamas Container Holdings, Zhejiang
energybattery-technologyASEANenergy-storage-systemsbattery-safetyclean-energysolid-state-batteriesScientists develop easily recyclable lithium-ion battery electrolyte
Scientists at the Institute of Science Tokyo have developed a novel quasi-solid electrolyte called 3D-SLISE (3D-Slime Interface Quasi-Solid Electrolyte) that promises to enhance lithium-ion batteries by improving safety, manufacturing efficiency, and recyclability. Unlike conventional electrolytes that rely on flammable organic solvents and require energy-intensive production environments, 3D-SLISE uses a borate–water matrix combined with lithium tetraborate, lithium salt, and carboxymethyl cellulose to create a slime-like interface enabling three-dimensional lithium-ion conduction. This innovation allows batteries to charge or discharge in just 20 minutes, maintain performance over 400 cycles at room temperature, and be produced without costly environmental controls, thereby reducing both production costs and carbon footprint. A key advantage of 3D-SLISE is its water-based composition, which eliminates the need for toxic binders and solvents, enabling direct recycling by simply soaking electrodes in water. This process allows recovery of valuable materials such as
energylithium-ion-batteryelectrolyterecyclingbattery-technologysustainable-energybattery-safetyChinese EV withstands 3 successive lightning strikes; driver unscathed
A BYD Song Plus electric vehicle (EV) in Guangxi, China, was struck by lightning three times in quick succession while parked at a service area, yet the driver remained unharmed and the vehicle sustained no critical damage. Dashcam footage captured the dramatic event, where lightning repeatedly hit the roof rack area, leaving only two visible strike points on the roof. Subsequent inspections by dealership technicians confirmed that the EV’s core components—including the power battery pack, electric control unit, and motor—were unaffected. Experts attribute the safety of the occupants and the vehicle to the “Faraday cage” effect, where the metal body of a sealed car channels electrical current around the exterior and safely into the ground, protecting those inside from harm. Safety recommendations emphasize that occupants should remain inside the vehicle during and after lightning strikes, avoid touching metal surfaces, switch off electronic systems, retract antennas, and keep windows closed to maintain the protective enclosure. Waiting at least 30 minutes after the last thunderclap before exiting
energyelectric-vehiclesFaraday-cagelightning-protectionbattery-safetyautomotive-technologyelectric-powertrainBYD EV Struck By Lightning Holds Up Fine - CleanTechnica
A BYD Song Plus electric vehicle (EV) in Beihai, Guangxi, China, was struck by lightning three times while in motion, with a human driver inside. Remarkably, both the driver and the car sustained only minimal damage. A mechanic who inspected the vehicle confirmed that the power battery pack, electronic control system, and motor showed no signs of short-circuiting or damage. The lightning strikes left three small marks on the roof but did not impair the vehicle’s functionality. The incident challenges common misconceptions about lightning and cars, particularly the belief that rubber tires protect occupants from lightning strikes. In reality, the metal shell of a hard-topped vehicle provides protection to those inside by directing the lightning current around the occupants and to the ground, often through the tires. While lightning can cause damage such as melted antennas, shattered windows, destroyed tires, or even fires, this BYD EV demonstrated strong resilience. The event offers reassurance about the safety and durability of EVs in extreme weather conditions
energyelectric-vehicleslightning-strikebattery-safetyBYDelectric-car-durabilityEV-safetyNew tool predicts lithium battery failure, could help make safer EVs
Researchers at the University of California, San Diego have developed a new, straightforward method to accurately measure lithium metal battery performance using scanning electron microscopy (SEM) combined with an algorithm. This innovation addresses a critical challenge in lithium metal batteries: uneven lithium deposition on electrodes, which leads to the formation of dendrites—spiky lithium structures that can pierce battery separators, causing short circuits and battery failure. Previously, assessments of lithium deposit uniformity were subjective and inconsistent across labs, hindering progress in battery research. The team created an algorithm that analyzes SEM images by converting them into black-and-white pixels representing lithium deposits and calculates an Index of Dispersion (ID) to quantify lithium uniformity. A lower ID indicates more uniform lithium deposition, while a higher ID signals clustering and potential battery degradation. Validated on over 2,000 computer-generated images and real battery tests, the ID score correlated with battery health, with fluctuations in the score serving as early warnings of impending failure. This accessible method, leveraging standard
energylithium-batterieselectric-vehiclesbattery-safetyscanning-electron-microscopymaterials-sciencebattery-technologyLithium-metal breakthrough may double EV battery life, boost retention
A South Korean research team at the Korea Research Institute of Chemical Technology (KRICT) has developed a novel solvent-free, roll-based transfer printing technology that significantly enhances the stability of lithium-metal batteries, potentially doubling their lifespan. By applying an ultra-thin (5 μm) hybrid protective film composed of ceramic and polymer layers directly onto lithium anodes, the team effectively prevents the formation of dendrites—needle-like structures that cause short-circuits and safety hazards in high-capacity batteries. In tests, these protected lithium anodes retained 81.5% of their initial capacity after 100 charge-discharge cycles and maintained 74.1% capacity even under rapid nine-minute discharges, demonstrating more than twice the stability of unprotected cells and a Coulombic efficiency of 99.1%. This breakthrough addresses a major barrier to commercializing lithium-metal batteries, which offer up to ten times the theoretical capacity of conventional lithium-ion batteries and are critical for next-generation solid-state and lithium-sul
energylithium-metal-batteriesbattery-technologyelectric-vehiclesmaterials-scienceenergy-storagebattery-safetyUK's new built-in sensors may help prevent EV battery blasts, fires
Researchers at the University of Surrey in the UK have developed new smart sensors embedded directly within lithium-ion batteries to detect and prevent fires caused by thermal runaway. Unlike conventional external sensors, these built-in sensors monitor critical parameters such as temperature, pressure, stress, and chemical changes in real-time from inside key battery components like current collectors and separators. They not only provide faster and more accurate readings but also actively respond to overheating by using fire-resistant materials to slow down temperature rise, aiming to stop battery fires before they start. This innovation addresses a significant safety challenge as lithium-ion batteries, essential for electric vehicles (EVs) and renewable energy storage, can overheat during charging and discharging, potentially leading to explosions and fires. With the UK planning to ban new petrol and diesel car sales by 2035, improving EV battery safety is crucial. The sensors could extend battery lifespan by protecting against heat damage, thereby enhancing both safety and sustainability without compromising performance. The University of Surrey team has filed patents and seeks industrial
energylithium-ion-batteriesbattery-safetysmart-sensorsthermal-runawayfire-preventionelectric-vehiclesWood film boosts EV battery safety and extends cycle life by 60%
Researchers have developed a lignin-based film separator derived from wood that significantly enhances the safety and longevity of lithium-ion batteries (LIBs), particularly for electric vehicles (EVs) and portable electronics. This wood-based separator remains dimensionally stable at temperatures up to 300°C (572°F), outperforming conventional polyethylene and polypropylene separators that suffer from thermal shrinkage and instability. The lignin film prevents internal short circuits and thermal runaway, reducing fire risks, while also extending battery cycle life by 60%, meaning the battery can be charged and discharged many more times before degrading. The lignin separator is produced using a solvent-free dry process, which is environmentally friendly and scalable, generating no waste or emissions. Made from lignosulfonate—a natural polymer byproduct of pulping and biorefinery—the film is thin (about 25 micrometers) yet effective at maintaining battery stability. This sustainable manufacturing approach not only reduces environmental impact but also leverages abundant natural materials without additional processing. Overall
energylithium-ion-batteryelectric-vehiclesbattery-safetysustainable-materialsligninbattery-technologyGerman scientists develop safer, high-energy battery film for EVs
German researchers at Fraunhofer FEP have developed a novel metal-on-polymer current collector for lithium-ion batteries, aimed at enhancing both safety and energy density in electric vehicles (EVs). Using a roll-to-roll electron beam evaporation process, they coat polymer films with thin layers (up to 1 µm) of aluminum or copper on both sides, creating lightweight, wrinkle-free films that match the thickness and conductivity of traditional metal foils. This innovation reduces battery weight, thereby increasing energy density, and introduces an integrated safety feature: if a short circuit occurs, the polymer substrate melts, instantly interrupting the current flow and preventing thermal runaway—a major cause of EV battery fires. The new current collectors were successfully integrated into pouch cells by TU Braunschweig and demonstrated electrochemical performance and cycle stability comparable to conventional cells across various charging and discharging rates. This scalable manufacturing method offers a promising pathway for producing safer, higher-capacity lithium-ion batteries, potentially enabling longer-lasting consumer electronics and extended-range electric
energylithium-ion-batterieselectric-vehiclesbattery-safetypolymer-filmcurrent-collectorthermal-runaway-preventionExploring Silly EV Myths - CleanTechnica
The article from CleanTechnica addresses and debunks several widespread myths about electric vehicles (EVs), focusing particularly on the misconception that washing or cleaning an EV can cause an electric shock. This myth, despite being baseless, is surprisingly prevalent, with surveys showing that up to 46% of drivers aged 25 to 34 and 40% of those aged 18 to 24 believe they could get shocked while washing an EV. Regional differences are also noted, with 45% of London car owners subscribing to this false belief compared to only 7% in Wales. Experts like UK TV personality Quentin Willson and Autoglym’s technical training manager Lee Irving emphasize that EVs undergo rigorous safety testing, including water exposure tests, and that cleaning an EV is no more dangerous than cleaning a traditional petrol or diesel vehicle. The article also highlights how misinformation spreads, often fueled by misunderstandings or misinterpretations of technical details. For example, a claim about brake dust differences between EVs and
energyelectric-vehiclesEV-mythsclean-energybattery-safetyelectric-mobilityfossil-fuelsUltrasound scanner detects fire-starting battery flaws in seconds
Researchers at Drexel University have developed a novel ultrasound-based diagnostic tool that rapidly detects internal defects in lithium-ion batteries, such as gas pockets, structural flaws, dry zones, and misaligned components. These defects can lead to battery failure, overheating, or thermal runaway, which are significant safety risks for devices ranging from smartphones to electric vehicles. Unlike traditional X-ray imaging, which is slow, costly, and limited in scope, this ultrasound technique uses scanning acoustic microscopy to send low-energy sound waves through battery cells, revealing internal mechanical and structural features without disrupting battery function. The new method addresses the limitations of current quality checks, which rely on visual inspections, sample testing, and X-rays, by providing a faster, lower-cost, and more sensitive alternative. Given the rapid growth in battery-powered devices and electric vehicles, the risk of defective cells entering the market has increased, making improved detection methods crucial. The Drexel team also created open-source software to control the ultrasound instrument and facilitate quick data analysis, aiming to
energylithium-ion-batteriesultrasound-imagingbattery-safetyelectric-vehiclesbattery-defectsbattery-manufacturingIt’s Safety, Not Just Luxury, That Won Volvo a World Car Trophy - CleanTechnica
The Volvo EX90 was awarded the 2025 World Luxury Car title at the New York International Auto Show, recognized for its blend of Scandinavian design, advanced technology, and a focus on safety. This accolade underscores Volvo’s successful entry into the premium electric vehicle market, emphasizing safety innovations that align with Sweden’s “Vision Zero” goal of eliminating road fatalities and serious injuries. Sweden’s notably low traffic fatality rate—2.0 per million inhabitants—is partly attributed to Volvo’s longstanding safety policies, which have been evolving since 2010 to address the unique challenges of electric vehicles (EVs), such as battery protection, vehicle dynamics, and post-collision hazards like battery fires. Central to the EX90’s safety features is a roof-mounted lidar system that creates a precise 3D map of the surroundings, detecting pedestrians and small objects at significant distances under various conditions, enhancing collision avoidance beyond traditional camera and radar systems. Additionally, the car incorporates an AI-driven Driver Understanding System that monitors driver attent
energyelectric-vehiclesbattery-safetylithium-ion-batteriesautomotive-technologylidarVolvo-EX90New EV battery survives 54-hour saltwater submersion with no failures
Chery Automobile has successfully demonstrated the resilience of its proprietary "Guardian Battery" by subjecting it to nearly 54 hours of continuous saltwater submersion in Jakarta, Indonesia, as part of its Global Safety Challenge. The battery, installed in the Chery Super Hybrid (CSH) platform, showed no signs of leakage, short circuit, thermal runaway, or structural damage. After immersion, the battery powered the vehicle on the first attempt and maintained stable performance during a controlled road test. Key features of the Guardian Battery include IP68-rated waterproofing and dust protection, an ultra-fast 2-millisecond emergency power cut-off, a wide operating temperature range (-35°C to 60°C), and a 24/7 real-time health monitoring system, underscoring its robustness and safety. The test was witnessed and validated by numerous media representatives, industry experts, and regulatory officials, highlighting Chery’s commitment to transparency and safety. The TIGGO8 CSH vehicle, which houses the battery,
energyelectric-vehicleEV-batterybattery-safetywaterproof-batteryGuardian-Batteryenergy-storageBeyond lithium: inside the Goliath battery revolution
The article features insights from Graeme Purdy, CEO and co-founder of Ilika, on the company’s flagship solid-state battery project, Goliath, which is poised to revolutionize electric vehicle (EV) energy storage. Solid-state batteries offer significant advantages over traditional lithium-ion cells, including higher energy and power density, intrinsic safety, and faster charging. Purdy highlights that these batteries are safer, passing rigorous tests like the nail penetration test without catching fire, which reduces the need for heavy protective engineering and thus lowers vehicle weight and cost while increasing range. Contrary to common perceptions, Purdy asserts that solid-state batteries can be cost-competitive due to cheaper materials and more energy-efficient manufacturing processes, potentially saving thousands on battery pack costs and narrowing the price gap between EVs and internal combustion engine vehicles. Looking ahead, Purdy is optimistic that solid-state batteries will enter low-volume production within a few years and become dominant in the EV market within five years. He acknowledges China’s dominant role in EV
energysolid-state-batterieselectric-vehiclesbattery-technologyenergy-storagebattery-safetybattery-innovationEV fire erupts on 600-feet-long cargo ship carrying 3,000 vehicles
electric-vehiclesEV-firecargo-shipmaritime-safetyhybrid-vehiclesbattery-safetyPacific-Ocean