Electric vehicle (EV) sales surged 24% in 2024 compared to 2023, according to IDTechEx. As more EVs hit the road, EV fire protection becomes a top priority. While EVs experience fewer fires than combustion vehicles, ensuring battery safety remains essential.

Key Fire Protection Materials for Batteries

IDTechEx’s report, “Fire Protection Materials for EV Batteries 2024-2034: Markets, Trends, and Forecasts,” predicts a 15% annual growth in the fire protection materials market between 2024 and 2034. This growth highlights the increasing demand for EV fire protection solutions, according to IDTechEx.

How Cell Form Factor Affects Fire Safety

Battery cell form factor significantly influences fire safety. In 2024, prismatic cells made up 58% of the market, while cylindrical cells accounted for 22%. The remaining portion used pouch cells. Each form factor requires different fire-resistant materials:

• Prismatic and pouch cells: Often use sheet-type fire barriers.
• Cylindrical cells: Typically rely on encapsulating foams for added safety.

Since different cell types fail in unique ways, manufacturers must strategically place fire protection materials to prevent thermal runaway.

Thermal Management and Fire Protection

Effective thermal management plays a crucial role in fire protection. Many automakers use water-glycol cold plates to control cell temperature and prevent excessive heat transfer. Other methods include:

• Cooling side surfaces to reduce heat buildup.
• Heat-spreading materials that direct heat away from cells.

The chosen thermal management strategy directly affects the type of fire-resistant materials used, including foams, aerogels, and encapsulants.

Selecting the Right Fire Protection Materials

After deciding on cell form factor and thermal management, manufacturers choose from various fire protection materials, such as:

• Aerogels: Offer lightweight thermal insulation but remain costly.
• Ceramic blankets: Deliver high-temperature resistance and durability.
• Encapsulating foams: Work well in cylindrical battery systems for enhanced fire resistance.

To streamline manufacturing, suppliers now develop multi-functional materials that combine fire resistance with structural integrity.

Balancing Cost and Safety

Cost remains a major factor in fire protection. While mica provides an affordable fire-resistant solution, it often requires thicker layers to meet industry standards. In contrast, aerogels, though more expensive, offer high-performance fire protection with minimal material use.

The Future of Fire Protection

Choosing the best fire protection materials requires careful evaluation of costs, regulations, and battery design, IDTechEx said. Today, mica and encapsulating foams dominate the market, but aerogels and intumescent polymers continue gaining traction.