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Electric Car Battery Fireproofing

Prevent car battery fires and heat damage with premium fireproofing materials for electric car battery protection.

Table of Contents

Prevent Electric Vehicle Fires

Car battery fireproofing

Preventative mechanisms and fireproofing materials have become standardised within the EV industry, and for good reason. These methods decrease the likelihood of thermal events and prevent electric car battery fires whilst improving overall functionality and performance.

The EV market grows exponentially, year upon year, bringing renewed demands and expectations for electric car battery capabilities. In their Global EV Outlook 2023 analysis, The International Energy Agency (IEA) reports that global sales of Battery Electric and Plug-in Hybrid vehicles are outpacing the sales of Hybrid Electric vehicles, thus increasing car battery demand. With ever-changing designs and ever-increasing battery sizes, fire protection materials, thermal management strategies, and fireproofing tools are core to EV manufacturing and maintenance.

Gap filling

Within EVs, heat transfers between the car battery pack and a liquid-cooled plate. Thermal Interface Materials (TIMs) eradicate gaps or spaces containing air—a poor conductor of heat. These gap fillers divert heat from the battery, creating a thermal conduction path that helps to fireproof, prevent premature ageing and degradation, and aid the battery’s lifespan and speed. Gap fillers also receive praise for their lightweight nature and mechanical ageing properties.  


Encapsulation is the application of a protective resin coating to intricate equipment, such as the individual cells of car battery modules. Encapsulants harden to form a protective layer that assures resistance to extreme changes in movement and temperature, absorbing shock and vibration and providing electrical insulation, heat dissipation, and flame retardancy. Encapsulation combats instances of thermal runaway—the rapid acceleration of self-heating temperature within a cell—isolating and shielding surrounding cells and assuring that heat/fire cannot propagate.

Dielectric Coatings

A dielectric coating is a thinly applied material used on intricate electronics to provide electrical insulation. Frequently used within the EV industry on both batteries and motors, dielectric layers reduce the risk of car battery fires. Especially effective in instances of collision and impact in which prolonged electrical discharges are common, dielectric coatings prevent electrical currents from flowing across the surface of a device or jumping from connection to connection.


Adhesives are vital for reducing the risk of car battery fires. Within an electric car battery, cells are bonded onto an electrically insulated plastic carrier, helping to maintain structural integrity and prevent vibration, rotation, and movement. Adhesives are required to create a secure bond between the lightweight plastic cell carriers and the metallic cells. An adhesive bond secures the stabilisation of both the cells and their housing, vastly reducing the risk of fire caused by destabilised and damaged components.

Top Materials For Preventing Electric Vehicle Fires.

Top fireproofing materials help assure thermal management and fire protection alongside improving numerous aspects of EV battery health. Advantages include: 

  • Electrical insulation – preventing shock and limiting current flow between electrical conductors. 
  • Thermal management – maintaining the optimal temperature range of components. 
  • Fire resistance – delaying or preventing the passage of extreme heat or fire.
  • Shock absorption – preventing electronics from becoming dislodged or damaged. 
  • Battery longevity – ensuring long-term battery health and preventing faults or damages. 
  • Increased or improved battery speed – controlling the optimal battery state during charging and driving. 

Explore our range of DOWSIL™ EV fireproofing and thermal management products: 

DOWSIL™  TC-4525
DOWSIL™  TC-4525 is a Thermally Conductive Gap Filler designed to dissipate heat from electronic modules. Providing a protective and reliable cooling solution, DOWSIL™ TC-4525 is an excellent fit for automotive electronics and battery pack applications.

DOWSIL™ TC-6020 is a thermally conductive, two-part, silicone encapsulant/pottant that provides excellent thermal management for electronic modules and automotive control units. DOWSIL™ TC-6020 has excellent thermal conductivity, dielectric properties, and adhesion to aluminum.

SYLGARD™ 527 is a two-part, 1-to-1 mix ratio Dielectric Gel designed to seal and protect electronic devices with delicate components. With room temperature and heat-accelerated curing, SYLGARD™ 527 is a low-viscosity gel allowing for good flow.

For more information on EV battery packs and assemblage, we’ve created a rundown of the Essential Toolkit for EV Battery Pack Assembly. And read more on EV Battery Thermal Management & Safeguarding here.


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everything you should know about the EN 45545
everything you should know about the EN 45545 Standard

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This white paper examines the european standard EN 45545 Fire protection for passenger railway vehicles.