Safety Solution for EV Battery Thermal Runaway Using  Modified PPE Resin XYRON™
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Importance of “Thermal Runaway Countermeasures” Required for EV Batteries

The EV market—particularly for electric two‑wheelers—continues to grow rapidly in Asia and India. As driving range and performance continue to improve, batteries must deliver higher energy density, while meeting increasingly stringent safety requirements.

Thermal runaway, in which abnormal heat generation in one cell propagates sequentially to surrounding cells, is one of the most serious risks in EV batteries. In India’s EV battery safety standard, AIS‑156, the suppression of thermal runaway is designated as a key evaluation criterion.

The modified PPE resin “XYRON™” provides excellent heat resistance, electrical insulation, and flame‑propagation resistance, making it an ideal material for AIS‑156–compliant and next‑generation high‑energy batteries.

Thermal Runaway Demonstration Testing in Collaboration with UL Solutions

To evaluate XYRON™ ’s thermal‑runaway‑suppression and flame‑propagation‑prevention capabilities, we conducted a full‑scale thermal runaway test using 4680 NMC cylindrical cells in collaboration with UL Solutions.

<Test Condition>

• Cell type: 4680 NMC cylindrical cells
• Cell spacing: 2 mm
• Status: Fully charged
• Test method: Intentionally trigger thermal runaway in the center cell and evaluate the effect on surrounding cells

<Test Results>

• No thermal runaway occurred in surrounding cells, confirming  XYRON™ ’s flame‑propagation resistance
• Surrounding cells maintained normal voltage
• No structural damage caused by high temperature or ejected materials
• Cell holder retained its shape even under severe thermal and mechanical stress

These results confirm that XYRON™ ​can effectively suppress thermal runaway even in 4680 NMC cells.​

High‑Cell‑Wall Design: A New Potting‑less Solution

Traditionally, potting materials and gap fillers have been used to ensure thermal management, thermal runaway mitigation, and structural stability. However, these materials increase weight, extend manufacturing time, and reduce recyclability.  Because XYRON™ inherently offers excellent heat resistance, insulation, and flame‑propagation resistance, adopting a high‑cell‑wall structure enables both enhanced safety and weight reduction while reducing the need for potting materials.

This structural approach enables compliance with safety standards without adding unnecessary material weight.​

Please feel free to contact us to learn how XYRON™  can contribute to AIS‑156–compliant thermal runaway countermeasures and improved safety  in next‑generation battery designs.