Lithium-ion battery fires might soon not take place anymore
22 Dec 2025

Lithium-ion batteries, the powerhouses behind everything from smartphones to electric cars, have been known to catch fire under certain conditions.

The problem is especially worrying in commercial aviation, where a single battery fire can lead to catastrophic consequences.

Now, a team of researchers from The Chinese University of Hong Kong has proposed a simple but effective solution: altering the chemical composition of the electrolyte in lithium-ion batteries.

Understanding the fire risk in lithium-ion batteries
Fire hazards

Lithium-ion batteries are prone to catching fire due to their flammable electrolytes, which are liquid solutions of lithium salts in organic solvents.

These batteries can become unstable under certain conditions such as physical damage, any overcharging, extreme temperatures or manufacturing defects.

When things go wrong, a battery can heat up and catch fire very rapidly, undergoing a dangerous chain reaction called thermal runaway.

The impact of battery fires on aviation
Aviation risks

The risk of battery fires is particularly high in commercial aviation, where the presence of battery-powered devices makes them a potential fire hazard.

The US Federal Aviation Administration (FAA) has banned spare lithium-ion batteries in checked baggage and requires all batteries taken into the cabin to be accessible.

In 2024 alone, it recorded around 89 incidents involving smoke, fire or extreme heat from batteries on passenger and cargo aircraft.

Battery fires pose risks beyond aviation
Widespread danger

The threat of thermal runaway isn't limited to aviation. It extends to homes and businesses as well, with a 2024 survey by insurance provider Aviva finding that over half of UK businesses experienced incidents related to lithium-ion batteries. These incidents included sparking, fires, and explosions.

Researchers propose a simple solution to enhance battery safety
Innovative approach

The research team from The Chinese University of Hong Kong has proposed a change in lithium-ion battery design that could be easily integrated into existing manufacturing processes.

This involves simply swapping chemicals in the current electrolyte solution.

The new design uses an electrolyte with two solvents to stop the chain reaction that usually leads to battery fires.

New electrolyte design shows promise in lab tests
Lab results

In lab tests, the new electrolyte design showed promising results.

A battery with this new design that was pierced with a nail saw its temperature rise by only 3.5 degree Celsius instead of the usual spike of over 500 degree Celsius.

The researchers say there is no negative impact on the battery's performance/durability, and it retained over 80% of its capacity after 1,000 charging cycles.

Researchers seek commercial viability
Market potential

The researchers are looking to make their design commercially viable and are in talks with battery manufacturers to do so. This could take around three to five years.

The new chemical composition would also slightly increase the manufacturing costs, but at scale, the price would be comparable to current batteries.