Hyundai Mobis: New battery system prevents thermal runaway

Battery Technology Hyundai Mobis: New Battery System Prevents Thermal Runaway

2025-04-28 From Stefanie Eckardt | Translated by AI 2 min Reading Time

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Thermal runaway is one of the most common causes of fires and explosions in lithium-ion batteries for electric vehicles. Hyundai Mobis has now succeeded, as the company announced, in developing a new technology with an integrated fire extinguishing function. This prevents heat from being transferred to neighboring cells if a battery cell catches fire.

Hyundai Mobis has registered three patents for its new battery system, with which thermal runaways should no longer be a problem.(Image: Hyundai Mobis) — Hyundai Mobis has registered three patents for its new battery system, with which thermal runaways should no longer be a problem.
(Image: Hyundai Mobis)

Accidents involving electric vehicles attract more public attention than a crash involving a vehicle with a combustion engine. Especially if the electric vehicle catches fire. One possible cause here may be thermal runaway of the battery. The battery cell overheats due to a self-reinforcing, heat-producing process, which can cause the cell to burst and burn. This can easily spread to neighboring battery cells. Oxygen is released internally for a short time during thermal runaway due to restructuring of the cathode and reacts immediately within the battery cell with its organic components. This is where Hyundai Mobis comes in.

The supplier has introduced a new system. This is designed to go beyond simply delaying thermal runaway with heat-resistant materials and prevent it from occurring in the first place. Countries in Europe, China and India have mandated that thermal runaway must be delayed for at least five minutes after the initial ignition of the battery cell, while some countries are tightening their regulations to prevent thermal runaway from occurring in the first place. Accordingly, Hyundai Mobis' battery system assembly (BSA) with fire extinguishing function at cell level is likely to attract interest. The Koreans have applied for a patent for this function.

Battery System Assembly in Detail

The BSA developed by Hyundai Mobis consists of a battery management system (BMS), hardware consisting of a fire extinguisher and a battery housing, and software logic that controls them. Based on the data collected by the sensors in real time, the temperature, battery voltage and pressure in the battery system are analyzed to detect any anomalies. The location where the extinguishing agent is to be sprayed is then determined.

According to the Koreans, the software is designed to make "fast and accurate decisions to respond to any physical changes in the battery system". Hyundai Mobis' decision-making logic has several safety features and a redundant algorithm structure.

The battery system is equipped with a "fire extinguishing agent that has five times the capacity of a 3.3 kilogram household fire extinguisher. This agent is a substance with excellent cooling, insulating and permeability properties that is harmless to both the environment and the human body." The supplier did not specify which agent was involved.

New Material Prevents Batteries from Overheating

In addition, Hyundai Mobis has recently developed a new material that prevents batteries from overheating. This material consists of an aluminum alloy and a coolant and can reduce the internal temperature of the battery system by placing it between the battery cells. It is expected that it can be used as a thermal management system that reliably controls heat even during fast charging. (se)

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