New 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