IDTechEx Covers Fire Protection Materials
IDTechEx showcases a broad coverage of the latest EV research in their electric vehicles research reports portfolio. The extensive list of reports covers the entire electric vehicle sector and includes "Fire Protection Materials for EV Batteries 2025-2035: Markets, Trends, and Forecasts", which explores the different materials and chemistries needed to make electric vehicles safer as they become more widespread.
The multitude of battery chemistries available for different EV types means that a variety of safety materials to accommodate their requirements are also necessary. IDTechEx's VP of Research, Dr James Edmondson, presented at the Plastics in Electric & Autonomous Vehicles Conference 2025 - SPE Automotive Division on topics including evolving vehicle technology and materials, while Technology Analyst, Mika Takahashi, covered the wider EV sector.
Thermal runaway and fire hazards
Recalls of certain EVs have occurred after faults were discovered in specific battery cells that posed a potential fire risk, while others were found to have wiring harness faults that could eventually have resulted in a fire. The subsequent evolution of safety standards, alongside the large costs incurred by companies due to these recalls, are two large drivers for the development of fire protection materials.
With Li-ion batteries, IDTechEx reports that there is always a slight chance of thermal runaway, despite the risks of fires being lower than in an internal combustion (ICE) vehicle. The "Fire Protection Materials for EV Batteries 2025-2035: Markets, Trends, and Forecasts" report states that fires are not only limited to occurring while a vehicle is driving, but thermal runaway is possible during charging, crashes, and even simply when parked.
Aerogels, solid-state, and sodium-ion
IDTechEx covers multiple material options for preventing thermal runaway within batteries. Aerogels are an option with growing adoption for preventing heat transfer between cells, as they have very low thermal conductivity and density, with foams and ceramics having similar performance advantages. Mica, however, can be easier to implement than aerogels and ceramics, and while having much higher density, it can be used in thin, very low-cost sheets to maximize its benefits. It is also chosen for its strong electrical properties.
Changing the battery makeup and chemistries can also have a huge impact on improving the safety of a vehicle. The implementation of solid-state batteries has the potential to revolutionize safety, largely due to improving thermal stability with the replacement of flammable liquid electrolyte. Solid-state batteries can also allow for a wider operation temperature range and can result in less heat being generated from an external heating failure then liquid electrolyte. Hot spots are less likely to occur due to the higher thermal conductivity of solid-state electrolytes and the improved thermal dissipation. IDTechEx's report, "Solid-State and Polymer Batteries 2025-2035: Technology, Forecasts, Players", has further details.
Na-ion batteries as an alternative to lithium-ion can offer improved safety benefits, covered extensively in IDTechEx's report, "Sodium-ion Batteries 2025-2035: Technology, Players, Markets, and Forecasts". They can be transported at 0V without impacting the battery's performance, and their heat release rates are lower than in Li-ion batteries. Na-ion has also been successful in producing no flames or ignition during nail penetration tests. However, IDTechEx states that the use of solid-state electrolytes in Li-ion batteries could make them just as safe as Na-ion.
EV battery designs for safer vehicles
Longer escape times are being implemented by manufacturers to give passengers more than a five-minute warning before encountering a hazardous situation with thermal runaway. With regulations in place at pack level to ensure no fire or smoke can be seen outside of the pack, there are currently no mandates globally, except in China. China requires a 5-minute warning for vehicle occupants from thermal runaway. This will soon (July 2026) rise to a 2-hour period of no fire or explosion. IDTechEx predicts that the rest of the world will take longer to mandate standards and sees them as being less stringent. However, other sectors, such as aerospace, are much stricter.
As battery technologies and chemistries rapidly develop and evolve, it is hard for regulators to stay on top of implementing battery-specific regulations. However, in the future, more thorough regulations should be expected across all battery types to prevent scenarios such as harmful gases coming from the battery, even in the event of a contained fire.
For more information, visit IDTechEx's reports, "Fire Protection Materials for EV Batteries 2025-2035: Markets, Trends, and Forecasts" and "Electric Vehicles: Land, Sea, and Air 2025-2045". Downloadable sample pages are also available for these reports.
For the full portfolio of electric vehicle market research available from IDTechEx, please visit www.IDTechEx.com/Research/EV.
About IDTechEx
IDTechEx provides trusted independent research on emerging technologies and their markets. Since 1999, we have been helping our clients to understand new technologies, their supply chains, market requirements, opportunities and forecasts. For more information, contact [email protected] or visit www.IDTechEx.com.
