Innovative Battery Technology May Halt EV Fires Before and After They Ignite

Electric vehicle (EV) battery fires are once again making headlines as Hurricane Helene impacts the southeastern United States, inundating EVs and triggering thermal runaway in some batteries. Alongside a recent Tesla Semi fire that caused an interstate closure for several days, these incidents illustrate a rising concern regarding EV battery fires, which remains largely unaddressed. However, this danger could be mitigated, as LG Chem has announced the creation of a new material intended to prevent battery fires before they ignite—or extinguish them after they occur.

In an article featured in the scientific journal Nature Communications, LG Chem introduces its innovation known as the “Safety Reinforced Layer.” This one-micrometer-thick layer, compared to an electrical fuse, is made from a composite material positioned between the cathode and the “current collector.” It alters its molecular structure when temperatures exceed a normal range of 90ºC to 130ºC (194ºF to 266ºF), significantly increasing its electrical resistance by 5,000 Ohms per 1ºC, and achieving resistance levels more than 1,000 times those at standard operating temperatures. This process effectively isolates the cathode and anode, preventing the contact that can lead to fires. Notably, these chemical changes are reversible, so if the battery cools down, it returns to normal functionality.

Simply put, this thin layer chemically interrupts the battery circuit and safeguards its most sensitive components in cases of overheating. However, the effectiveness of the material remains a key question. LG Chem asserts that during impact tests, integrating this material notably reduced fire incidents, with some fires even extinguishing themselves promptly.

In tests involving conventional lithium cobalt oxide batteries, LG Chem noted that the packs ignited in 84 percent of cases when subjected to impact, whereas nickel cobalt manganese batteries ignited every time a 10-kilogram (22-pound) weight was dropped onto them. Conversely, lithium batteries equipped with LG’s “fuse” showed a fire rate of just zero percent, while the nickel variants experienced a fire rate of 30 percent—all of which extinguished shortly thereafter.

LG Chem also pointed out that previous attempts to create a material with similar protective properties compromised battery energy density or reacted too slowly to be effective. This newly developed material, however, has shown enough promise to advance to large-scale testing, which will continue with EV-sized batteries through 2025.

“This is a significant research milestone that can be rapidly transitioned to mass production,” stated LG Chem’s Chief Technology Officer, Lee Jong-gu. “We will enhance safety technologies to ensure customers can confidently use electric vehicles, which will also strengthen our competitive edge in the battery market.”

However, even with promising innovations like this, a dose of realism is necessary. Regardless of whether this material proves to be as effective as early results indicate or can be introduced to production as swiftly as promised, it will likely take considerable time before it transforms the EV landscape significantly. For starters, it appears that mass production won’t commence until at least 2026, meaning it will only begin to appear in EVs from manufacturers that partner with LG Chem. How the company manages the intellectual property surrounding this development will also play a critical role in its broader adoption throughout the battery manufacturing sector.

Even if LG Chem opts to keep this material for its own use, knowledge of its production is likely to spread, whether through industrial espionage or independent innovation by other companies. Nevertheless, this development offers an encouraging sign for advocates of electric vehicles, presenting a potential solution to the ongoing issue of EV battery fires.