US-based battery company Nuvola Technology has demonstrated that its SafeCoat Direct Deposition Separator (DDS) can prevent thermal runaway in lithium-ion batteries under extreme conditions that typically result in catastrophic fires.

In testing, Nuvola’s 41-layer, 5 Ah lithium-ion pouch cell with SafeCoat DDS survived nail penetration testing, maintaining its charge without ignition or thermal runaway. That was in contrast to a commercial benchmark cell using thermally enhanced separators that erupted into thermal runaway within 10 seconds under identical conditions.

SafeCoat’s nanoporous layer remains structurally intact at temperatures exceeding 220° C, and in contact with direct flame. This prevents the cascading failure that turns one damaged cell into a fire.

SafeCoat is compatible with existing lithium-ion production lines and strengthens US battery manufacturing capacity by reducing reliance on centralized separator facilities that are mostly located in Asia.

Global battery manufacturers serving the EV, medical devices and consumer electronics sectors are evaluating the technology. Early assessments suggest that SafeCoat could lower battery pack costs by reducing insulation requirements for thermal runaway prevention, Nuvola said.

“What’s truly exciting is that this cost-effective and shovel-ready solution delivers most of the safety benefits expected from solid-state batteries—but it’s available today, and it integrates seamlessly into lithium-ion plants operating or under construction,” added Dr. Leland Smith, CTO and co-founder of Nuvola Technology.

Source: Nuvola Technology