Greenville, South Carolina-based Soteria Battery Innovation Group filed a patent application on a battery safety technology designed to reduce the probability and ferocity of e-bike battery fires.
Company officials said the technology offers a simple yet effective solution: a thermally insulating, fire-retardant blanket that can be easily wrapped around each individual cell within an e-bike battery pack.
By slowing or preventing fire propagation from cell to cell, the technology addresses a critical safety concern in the e-bike market, the officials said.
E-bike batteries often are composed of more than 50 individual cells, closely packed within a tight, sealed container.
The officials said when one cell catches fire, the resulting heat can quickly ignite neighboring cells, causing 50 miniature explosions, each one shooting jets of flame and molten material outside the battery pack.
Company officials said the technology borrows the geometry of spacer material used in aerospace composites called honeycomb.
When formed from a flame-retardant, insulating material, and in the size and shape to cover each battery, this honeycomb barrier forms the perfect insulator that can keep each cell from heating the other cells, slowing or stopping the propagation of the fire, the officials said.
As part of a years-long study on e-bike battery safety in collaboration with industry partners including NASA, Polaris, the Fire Department of New York and many others, Soteria's technology team dismantled over 30 different e-bike batteries to gain a thorough understanding of potential safety gaps.
Though insulating cells from one another is a common battery safety strategy, not one of these batteries had any insulation between the cells, Soteria officials said.
"When I saw these results, I realized that for something to be widely adopted, it had to be easy to install, light weight and inexpensive," said Brian Morin, CEO and co-founder of Soteria and one of the inventors of the technology.
The honeycomb structure, made from inexpensive fibers commonly used in firefighter uniforms, will add only about three ounces to the weight of the pack and cost less than $3 per e-bike battery pack once fully licensed and installed, Soteria officials said.
With e-bike battery pack prices running $700 – 900 or more, this technology represents a small add-on to significantly improve safety, the officials said.
They said installation is straightforward: once the cells are placed in their frame, the honeycomb slips neatly over the array of cells, allowing a top frame, busbars and other electrical components to be installed in their normal fashion afterwards.