What do industries like robotics, aerospace, electric vehicles, and energy storage have in common?
The answer is: many things, especially when you consider the commonalities in terms of engineering, technology, increased impact on the world around us—and yes, the use of lithium-ion batteries.
As the need for li-ion batteries increases, so does the need for fire-resistant battery technology. Li-ion batteries have long lifespans, charge quickly, are lightweight, and have many other properties that make them essential to modern technology.
However, there is growing concern over lithium-ion battery safety due to overheating and fire risks due to a process called thermal runaway.
That’s why flame retardant battery solutions are a critical safety measure in these emergent industries and the technology on which they rely.
Because lithium ion batteries have become so essential, battery fire prevention has taken a front seat over the past few years. This has taken many different forms, depending on the industry.
Here are a few examples:
Each of these industries is focusing on preventing thermal runaway, which is the rapid and uncontrollable increase in temperature, leading to the release of stored energy almost instantaneously. This iThe most common overcharging, physical damage, short circuits, and manufacturing defects.
This release manifests as intense heat, accompanied by the violent expulsion of flammable gases, such as hydrogen fluoride, and particulates, which can ignite, causing fires or even explosions. We covered this in more detail on our page, What is Thermal Runaway?
In January 2025, the world’s largest battery storage plant, located in Northern California, caught fire. Nobody was hurt, but 1,500 people were evacuated and the fire sent “plumes of toxic smoke” into the atmosphere.
“This is more than a fire, this is a wake-up call for the industry. If we’re going to be moving ahead with sustainable energy, we need to have a safe battery system in place,” said Monterey County Supervisor Glenn Church. Source
Why?
There have been 7 known reports of these scooters overheating, smoking, melting, or igniting, and in one case causing a fire that caused burn injuries and substantial property damage to a residential apartment building. Source
HALO 1000 Portable Power Stations were recalled in August 2024 after several reports of battery fires, including one that resulted in the death of a 79-year-old man who died from smoke inhalation caused by his power station catching on fire. Source
In 2013, a parked Boeing 787 caught fired after a battery experienced a short circuit that led to thermal runaway of the cell. The battery ejected flammable materials and caught fire.
According to the article, the National Transportation Safety Board faulted Boeing for ruling out the possibility of thermal runaway in its safety assessment of the battery, and it criticized the FAA for certifying the battery without thoroughly scrutinizing the potential danger. Source
So, how exactly do flame retardant battery solutions work?
The most effective solutions focus on prevention—that is, balancing temperature and heat transfer within li-ion batteries to prevent thermal runaway and other dangerous side effects.
Here are LHS Solutions, we use technology like phase change materials (PCMs), thermal barriers, and specialized coatings, depending on the application. Solutions like these offer high heat absorption properties with tailorable temperature ranges with a minimal impact on the overall weight of the battery system.
The benefits of these technologies include:
If you want to see these solutions in action, check out our Battery Safety Use Case, in which our patented XTSⓇ technology dramatically improved battery life and safety. Read the use case to learn more about the application of barrier materials at key risk areas for rupture or ejection and material capable of withstanding extreme temperatures for a short period of time.
One of the positive impacts of these battery fires and recalls is that they are drawing more attention from regulatory bodies. There is an increased effort toward global regulations for safer energy storage solutions, and manufacturers are quickly adapting to new safety guidelines.
That’s why it’s important to prioritize flame-retardant battery solutions and work with an expert partner to ensure longer battery life and battery safety.
At LHS, our focus is to prevent thermal propagation should a cell or cells go into thermal runaway rather than trying to stop the cell(s) from achieving thermal runaway. The key criteria is how this immense amount of heat can be removed or shuttled away to prevent further damage.
Our XTSⓇ provides consumers and businesses with all the required features, including reducing temperatures at both the cell and pack level, by:
Contact Us to learn more about battery fire prevention and how you can increase both battery life and battery safety with our technology.