In the rapidly evolving world of electric vehicles (EVs), safety remains a paramount concern, especially when it comes to post-crash fires. A groundbreaking study led by Jeongmin In of the Korea Transportation Safety Authority has shed new light on the unique challenges posed by EV fires, paving the way for enhanced safety standards. The research, published in the World Electric Vehicle Journal, delves into the intricacies of EV post-crash fires, offering insights that could reshape the industry’s approach to safety testing.
The study, which analyzed 17 cases of EV post-crash fires in Korea, identified two primary risk scenarios. The first involves high-speed frontal collisions that cause significant intrusion into the EV’s front-end structure. The second scenario involves direct impacts to the battery pack, often from road curbs at low speeds (30–40 km/h). These findings highlight the distinct vulnerabilities of EVs compared to internal combustion engine (ICE) vehicles, where the causes of fires differ due to variations in fuel system design and construction.
Jeongmin In emphasized the urgency of addressing these issues, stating, “The mechanisms causing direct impact to the battery differ in high-speed frontal collisions between EVs and ICE vehicles. In the case of EVs, the battery pack can be damaged due to intrusion from external structures resulting from excessive deformation of the front structure.”
The research conducted tests to assess battery damage severity under two crash test modes, simulating both high-speed frontal collisions and low-speed curb impacts. The results led to the development of a draft crash test concept to evaluate EV post-crash fire risks. Notably, the study found that square-shaped impactors provide higher reproducibility in simulating real EV post-crash fire incidents compared to hemisphere-shaped impactors.
One of the most alarming findings was the delayed onset of fires in some test scenarios. In one instance, a fire occurred 31 days after the storage of a crash-evaluated battery test specimen, attributed to moisture invasion during post-crash storage, which accelerated a micro-short circuit. This discovery underscores the need for comprehensive post-crash evaluations, including waterproof performance assessments.
The implications of this research are far-reaching for the energy sector. As the global supply of EVs continues to grow, driven by government policies aimed at expanding the adoption of eco-friendly vehicles, ensuring the safety of these vehicles becomes increasingly critical. The study’s findings could influence the development of new evaluation methods for the Korean New Car Assessment Program (KNCAP), enhancing EV post-crash fire safety.
Jeongmin In highlighted the importance of these developments, saying, “It is reasonable to develop separate evaluation methods for high-speed frontal collisions and low-speed bottom impacts, as the mechanisms causing damage to the battery differ between these two crash types.”
The study’s recommendations include the development of new test protocols aimed at minimizing post-crash fires in electric vehicles. Although further modifications and improvements will be made before KNCAP is implemented in 2026, this research marks a significant step forward in enhancing EV safety. The findings, published in the World Electric Vehicle Journal, offer a roadmap for future developments in the field, ensuring that as the EV market expands, so too does our understanding of how to keep these vehicles safe on the road.