Researchers at SPbU Develop Polymer Gasket to Help Prevent Lithium-Ion Battery Fires
Researchers from Saint Petersburg State University have advanced a polymer-based approach aimed at dramatically reducing the risk of fires and explosions in lithium-ion batteries. The breakthrough was shared with socialbites.ca through the Russian Science Foundation, which supported the work. This collaboration highlights how targeted materials science can address safety challenges across everyday devices and high-demand technologies.
The key finding is that a very thin polymer layer placed between the battery’s foil layers and its cathode can act as a reliable safeguard against overheating. In laboratory tests, this coating demonstrated the ability to disrupt and halt hazardous current pathways when a battery edge or component begins to overheat. By conducting current under normal operation and then undergoing a chemical change when a critical threshold is exceeded, the material becomes an insulator, effectively interrupting the progression toward thermal runaway and fire. This self-regulating behavior could be a game changer for battery safety in devices ranging from smartphones to electric vehicles.
Lithium-ion batteries power a wide array of devices, from our everyday gadgets to modern transport. Inside each cell lie two conductive elements, the anode and the cathode, separated by a porous barrier that contains an electrolyte. If this separator sustains damage, the materials inside can decompose rapidly, releasing a surge of heat that pushes the battery temperature toward dangerous levels within seconds. In Russia alone, incidents of battery fires and explosions in mobile devices have been reported regularly, underscoring the importance of improving intrinsic safety features in these systems.
The protective polymer layer developed at SPbU is an organic compound that contains nickel atoms. Its behavior changes when heat is applied: the local electrical circuit is interrupted, which helps prevent a dangerous rise in temperature. This mechanism provides a passive form of safety that activates as soon as overheating is detected, reducing the likelihood of catastrophic failure without requiring external intervention.
In testing scenarios, the protection showed remarkable consistency when the battery voltage operates outside a specific window. The researchers found that when voltages dropped below 2.8 volts during discharge or rose around 5 volts during charging, the polymer layer effectively maintained safety while preserving most of the battery’s usable capacity. Importantly, the studies indicated only a modest impact on performance, with potential reductions in capacity and efficiency kept to roughly 10 percent. This balance between safety and performance is a central goal for next-generation energy storage solutions, where reliable protection is as critical as overall efficiency.
Beyond the current work, Russia has seen advances in related protective technologies, including coatings developed to convert industrial waste into protective overlays for metal and concrete. These parallel efforts show a broader trend toward functional materials designed to improve safety and longevity across a range of critical applications. The collaboration between SPbU and its funding partners continues to push the boundaries of how materials science can deliver real-world safeguards for everyday devices and future mobility solutions. The practical implications of this polymer approach extend to consumer electronics, medical devices, and aerospace or automotive systems where battery safety is a top priority. The work remains under the guidance of the organizing bodies that support Cyrillic-language and international research exchange, highlighting how safety-focused innovation travels across borders and disciplines. (RSF press service)