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EV Safety Foam

Flame-Retardant Foams: The "Seatbelt" of Battery Safety

Posted 21 Okt 2024 by Jessica Sundberg, Market Product Manager – ePower, Storage & Clean Energy

A recent article by Molly Boigon, titled "Lithium-Ion Battery Fire Regulation Could Help Heal Industrywide Black Eye", highlights the growing need for stricter regulations to address the rise in battery fires in electric vehicles (EVs). The article discusses how several high-profile incidents have raised safety concerns, prompting regulators and manufacturers to take action to prevent future occurrences. With increasing pressure, new safety standards could help bolster consumer confidence and make electric vehicles a more reliable option.

Concerns about Lithium-Ion Battery Fires

As EV adoption increases worldwide, the industry faces growing concern over the safety of lithium-ion batteries. These batteries, while powerful and energy-dense, are susceptible to thermal runaway, a phenomenon that can result in fires or explosions when the battery overheats. Incidents involving EV battery fires have made headlines, affecting consumer confidence and raising concerns about the long-term viability of electric vehicles. The two main fire events causing safety concerns are:

  • Thermal propagation: the spread of heat from one cell to neighboring cells within an EV battery pack. If one battery cell experiences excessive heat or damage, it can cause nearby cells to overheat as well, leading to a chain reaction. This spread of heat can eventually ignite adjacent cells, increasing the risk of a full battery pack fire.
  • Thermal runaway: occurs when a battery cell's temperature rises uncontrollably, usually due to internal damage, overcharging, or a short circuit. As the cell heats up, it releases stored energy, generating more heat in a self-sustaining cycle. If not contained, this runaway effect can result in a fire or explosion.

How Stricter Regulations Will Shape the EV Industry

In response to these risks, regulators are implementing stricter safety standards to prevent battery fires, as Boigon’s article points out. These regulations aim to ensure that manufacturers prioritize safety throughout the entire battery lifecycle—from design and production to real-world performance. While compliance with these regulations is mandatory, H.B. Fuller believes that true leadership in the EV space requires going beyond minimum standards. For us, safety is not just a regulatory requirement; it's our highest priority. Our approach is to innovate and design products that surpass safety expectations, providing peace of mind for both manufacturers and consumers.

Innovative Solutions to Prevent Battery Fires

Our commitment to safety is embodied in the products we create alongside our customers, specifically designed to prevent battery fires in EVs. Among our vast portfolio of products for EV battery packs is H.B. Fuller Protect 5006 which significantly reduces or delays thermal propagation. This flame-retardant polyurethane encapsulant offers battery designers the ability to integrate high-level structural performance characteristics with the ability to minimize impact of thermal events. This ultra-lightweight material minimizes weight and is compatible with all cell form factors (cylindrical, prismatic, or pouch).

In an industry where even one incident can have devastating consequences, we understand that there is no room for compromise when it comes to safety. Our EV Protect line and can be considered the “seat belt” of battery packs, serving as an essential layer of protection for EV manufacturers looking to safeguard their customers and their reputations.

Why Prevention Is Key for Electric Vehicle Manufacturers

While regulations are an important step in addressing the safety challenges associated with EV batteries, we believe that prevention should be the ultimate goal. Manufacturers must not only meet current standards but also anticipate future risks. Our products are designed with this proactive approach in mind. By incorporating our technology, manufacturers can build safer batteries designed to protect consumers from potential fire hazards and prevent costly recalls or brand damage.

We’ve worked closely with leading EV manufacturers, helping them integrate our solutions into their battery designs to ensure maximum safety. The feedback we've received reinforces our belief that safety-driven innovation is critical to the future of the EV industry. Whether it's improving battery durability or enhancing structural performance, we partner with our customers to provide solutions that prioritize safety above all else.

A Safer Future

At the heart of these discussions is the commitment to developing safer technologies that not only comply with regulations but exceed them. H.B. Fuller shares this commitment, placing safety at the forefront of our culture, extending into every product we create.

As regulations tighten and safety concerns grow, we remain committed to delivering the innovative, high-performance solutions that help protect EV manufacturers, their customers, and the environment. Together, we can build a safer, more reliable future for electric vehicles. To learn more about integrating safer materials into your battery design, email [email protected].

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