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Thermal runaway is one of the most critical safety risks associated with lithium-ion batteries used in electric vehicles (EVs). Once initiated, it can quickly escalate into fires or explosions, endangering both vehicle occupants and surrounding property. Recognizing the severe hazard, the U.S. National Highway Traffic Safety Administration (NHTSA) issued final rule of the the Federal Motor Vehicle Safety Standards, effective in February 2025. The final rule newly introduced Federal Motor Vehicle Safety Standard (FMVSS) PART 571 No. 305a — Electric-Powered Vehicles: Electric Powertrain Integrity, which will become mandatory on September 1, 2027.
According to Section S13 of the PART 571 No. 305a regulation, it stressed the warning in the case of thermal event in REESS, “The vehicle shall provide a warning to the driver in the case of a thermal event in the REESS when the vehicle is in active driving possible mode. The thermal event warning system must monitor its own readiness. The warning shall activate within three minutes of the onset of the thermal event. The warning shall consist of auditory and visual signals that remain active for at least 5 minutes. For a vehicle with automated driving systems and without manually operated driving controls, the visual warning must be provided to all the front row occupants.”. The regulatory requirement underscores the growing importance of fast and timely detection of early battery failure signals to ensure occupant safety and compliance with global standards.
To support effective and fast thermal runaway detection within a few minutes, gas detection has proven to be one of the most effective methods for early thermal runaway warning among various detection strategies. During the onset of a thermal runaway event, lithium-ion batteries release a mixture of gases, including carbon dioxide (CO2), hydrogen (H2), and carbon monoxide (CO). In battery packs of different chemical types, these three gases exhibit the highest leakage concentrations. Monitoring the concentration of these gases provides direct insight into reactions occurring inside the cells, allowing for real-time recognition of abnormal behavior. Compared to temperature or voltage monitoring, gas detection can identify early-stage decomposition, offering a critical time window for the Battery Management System (BMS) to activate safety measures such as circuit isolation, cooling, or shutdown.
Among all the gases released, carbon dioxide (CO2) has emerged as the most reliable and indispensable indicator for early thermal runaway detection. CO2 is generated in substantial quantities at the very beginning of the event and exhibits stable, measurable concentration changes. Effective CO2 monitoring enables immediate recognition of thermal events, helping to mitigate escalation into severe or irreversible battery damage. Apart from CO2, hydrogen (H2) is also regarded as an effective indicator gas to provide early warnings for thermal runaway events.
With abundant R&D expertise in the gas sensing field, Cubic, a leading manufacturer of gas sensors and gas analyzers, has developed the ATRS-1012, a Li-battery thermal runaway detection integrated sensor designed to provide fast identification of early-stage CO2 and H2 gas venting of thermal runaway events, offering timely warning in response to the evolving safety demands.
Cubic ATRS-1012 sensor can effectively monitor CO2 and H2 released from lithium-ion batteries, and generate an early warning signal to Battery Management System (BMS), to formulate safety alarm strategies. Cubic innovatively combines non-dispersive infrared (NDIR) and MEMS thermal conductivity (TC) technology to integrate a sensor solution that has remarkable characteristics including fast response time, long life time and low power consumption, could be widely used for Li-battery electrical vehicles.
Features:
• Non-dispersive infrared (NDIR) technology for CO2 detection
• MEMS Thermal conductivity technology for H2 detection
• Fast response time(<1s)
• Less cross interference with other gases
• Low power consumption
• Self-made automotive grade components
As the global EV industry accelerates toward electrification, battery safety remains a top priority. Early detection of thermal runaway is not only a regulatory requirement but also a key factor in protecting lives and property. As an automotive Tier 1 supplier, Cubic has acquired the IATF 16949 certification, supported by an automotive-grade quality management system and extensive experience in automated mass production, which ensures that its automotive gas sensors are highly reliable and ready for widespread deployment, offering OEMs a dependable and adaptable thermal runaway sensing solution to enhance battery safety and promote the sustainable development of electric mobility.
For more details, please click the following link on: https://en.gassensor.com.cn/LibatteryThermalRunawaySensor/info_itemid_2739.html/ ; or contact us via sales@gassensor.com.cn
