Built-in smart sensors can prevent lithium-ion battery fire before starting

Researchers at the University of Surrey say the new smart sensors will help detect dangerous internal failures in lithium-ion batteries before escalating to a fire or explosion. Lithium-ion batteries are at the heart of the global shift towards electric vehicles and renewable energy, but if they fail, the results are devastating.

Unlike current sensors that sit outside the battery that respond too slowly, Sally’s advanced sensors are embedded directly to monitor temperature, pressure, stress and chemical changes in real time, providing early warnings and triggering built-in fire suppression features.

Designed to be scalable, low cost and compatible with existing battery manufacturing processes, the technology paves the way for safer and more reliable electric vehicles, transportation, aviation and energy storage systems.

“I’ve heard about lithium-ion battery fires and how difficult it can be to extinguish,” said Dr. Kai Yang, lecturer in Energy Materials and Nanotechnology at the University of Surrey Advanced Technology Institute.

“The smart sensors are built directly on key battery components such as current collectors and separators, providing quick and accurate readings from within. Not only do they monitor heat, they also use fire-resistant materials to slow overheating and respond aggressively.”

With lithium-ion batteries among the most expensive components in the latest technology, built-in smart sensors are more likely to extend battery life and allow for safer recycling of valuable materials. When new possibilities and relevances in high-risk sectors such as aviation, maritime transport, and aerospace are important.

Professor Ravi Silva, director of the University of Surrey’s Advanced Technology Research Institute, said, “While new petrol and diesel vehicles will be banned in the UK from 2035, the risks of safety in particular are one of the biggest concerns. It offers a real benefit to the end users.”

The University of Surrey has already applied for a technology patent and is actively seeking collaborations with academic and industry partners. This innovation could support the United Nations Sustainable Development Goals on Clean Energy, create new patents, spin-out companies, skilled jobs, and strengthen the UK’s position as a global leader in battery technology.