journal article Open Access Oct 23, 2025

Towards Fire-Safe Polymer Electrolytes for Lithium-Ion Batteries: Strategies for Electrolyte Design and Structural Design

Polymers Vol. 17 No. 21 pp. 2828 · MDPI AG
View at Publisher Save 10.3390/polym17212828
Abstract
Lithium-ion batteries, widely used in phones and electric vehicles, pose safety concerns due to the flammability of conventional liquid electrolytes, which are prone to ignition under elevated temperatures and mechanical stress, increasing the risk of fire. Polymer electrolytes have been employed as a safer solution thanks to their superior thermal stability and mechanical strength. However, despite these advantages, many polymer matrices pose a fire hazard, limiting their potential. This review assesses recent advances in enhancing the flame retardancy of polymer electrolytes through a variety of strategies, namely the incorporation of flame-retardant additives, the addition of nanoscale fillers to improve thermal resistance, and the design of layered or hybrid polymer membrane structures that function as thermal barriers. This review evaluates the effectiveness of these methods, examining their flame-retardancy as well as their influences on ionic conductivity and overall battery performance. By highlighting recent progress and enduring safety challenges in solid-state batteries, it aims to offer insights for developing lithium batteries with enhanced safety and high performance.
Topics

No keywords indexed for this article. Browse by subject →

References
145
[1]
Gao "Thermal Stability of MXene: Current Status and Future Perspectives" Small (2025) 10.1002/smll.202505881
[2]
Chen "Unraveling the Role of Metal Vacancy Sites and Doped Nitrogen in Enhancing Pseudocapacitance Performance of Defective MXene" Small (2024) 10.1002/smll.202307408
[3]
Yang "Flexible Nitrogen-Doped 2D Titanium Carbides (MXene) Films Constructed by an Ex Situ Solvothermal Method with Extraordinary Volumetric Capacitance" Adv. Energy Mater. (2018) 10.1002/aenm.201802087
[4]
Xie "Unraveling the Ionic Storage Mechanism of Flexible Nitrogen-Doped MXene Films for High-Performance Aqueous Hybrid Supercapacitors" Small (2024) 10.1002/smll.202405817
[5]
Xuan "Revealing the Ionic Storage Mechanisms of Mo2VC2Tz (MXene) in Multiple Aqueous Electrolytes for High-Performance Supercapacitors" Chem. Eng. J. (2025) 10.1016/j.cej.2025.165537
[6]
Zhou "Uncovering the Strengthening Mechanisms of Metal Vacancies in the Structure and Capacitance Performance of Defect-Controlled Mo2−□CTz MXene" Chem. Eng. J. (2025) 10.1016/j.cej.2025.165391
[7]
IEA (2025, September 15). Global EV Outlook 2025—Analysis. Available online: https://www.iea.org/reports/global-ev-outlook-2025.
[8]
The Li-Ion Rechargeable Battery: A Perspective

John B. Goodenough, Kyu-Sung Park

Journal of the American Chemical Society 2013 10.1021/ja3091438
[9]
Armand "Building Better Batteries" Nature (2008) 10.1038/451652a
[10]
Feng "Thermal Runaway Mechanism of Lithium Ion Battery for Electric Vehicles: A Review" Energy Storage Mater. (2018) 10.1016/j.ensm.2017.05.013
[11]
Larsson "Characteristics of Lithium-Ion Batteries during Fire Tests" J. Power Sources (2014) 10.1016/j.jpowsour.2014.08.027
[12]
Guo "Experimental Study on Flammability Limits of Electrolyte Solvents in Lithium-Ion Batteries Using a Wick Combustion Method" Exp. Therm. Fluid Sci. (2019) 10.1016/j.expthermflusci.2019.109858
[13]
US Department of Transportation (2025, September 17). DOT Bans All Samsung Galaxy Note7 Phones from Airplanes, Available online: https://www.transportation.gov/briefing-room/dot-bans-all-samsung-galaxy-note7-phones-airplanes.
[14]
City of New York (2025, September 17). FDNY Commissioner Announces Significant Progress in the Battle Against Lithium-Ion Battery Fires, Available online: https://www.nyc.gov/site/fdny/news/03-25/fdny-commissioner-robert-s-tucker-significant-progress-the-battle-against-lithium-ion#/0.
[15]
Finegan "The Battery Failure Databank: Insights from an Open-Access Database of Thermal Runaway Behaviors of Li-Ion Cells and a Resource for Benchmarking Risks" J. Power Sources (2024) 10.1016/j.jpowsour.2024.234106
[16]
Song "A Reflection on Polymer Electrolytes for Solid-State Lithium Metal Batteries" Nat. Commun. (2023) 10.1038/s41467-023-40609-y
[17]
Yao, P., Yu, H., Ding, Z., Liu, Y., Lu, J., Lavorgna, M., Wu, J., and Liu, X. (2019). Review on Polymer-Based Composite Electrolytes for Lithium Batteries. Front. Chem., 7. 10.3389/fchem.2019.00522
[18]
Applications of Polymer Electrolytes in Lithium-Ion Batteries: A Review

Jayeeta Chattopadhyay, Tara Sankar Pathak, Diogo M. F. Santos

Polymers 10.3390/polym15193907
[19]
Han "Incombustible Polymer Electrolyte Boosting Safety of Solid-State Lithium Batteries: A Review" Adv. Funct. Mater. (2023) 10.1002/adfm.202300892
[20]
Wu "Fire-Safe Polymer Electrolyte Strategies for Lithium Batteries" Energy Storage Mater. (2024) 10.1016/j.ensm.2024.103174
[21]
Wang "A Review of Lithium Ion Battery Failure Mechanisms and Fire Prevention Strategies" Prog. Energy Combust. Sci. (2019) 10.1016/j.pecs.2019.03.002
[22]
Liu "Materials for Lithium-Ion Battery Safety" Sci. Adv. (2018) 10.1126/sciadv.aas9820
[23]
Kumai "Gas Generation Mechanism Due to Electrolyte Decomposition in Commercial Lithium-Ion Cell" J. Power Sources (1999) 10.1016/s0378-7753(98)00234-1
[24]
Lux "The Mechanism of HF Formation in LiPF6 Based Organic Carbonate Electrolytes" Electrochem. Commun. (2012) 10.1016/j.elecom.2011.10.026
[25]
Petrocelli "Elementary Decomposition Mechanisms of Lithium Hexafluorophosphate in Battery Electrolytes and Interphases" ACS Energy Lett. (2022)
[26]
Orendorff "The Role of Separators in Lithium-Ion Cell Safety" Electrochem. Soc. Interface (2012) 10.1149/2.f07122if
[27]
Li "Polypropylene/Polyethylene Multilayer Separators with Enhanced Thermal Stability for Lithium-Ion Battery via Multilayer Coextrusion" Electrochim. Acta (2018) 10.1016/j.electacta.2018.01.114
[28]
Golubkov "Thermal-Runaway Experiments on Consumer Li-Ion Batteries with Metal-Oxide and Olivin-Type Cathodes" RSC Adv. (2013) 10.1039/c3ra45748f
[29]
Oxygen Release Degradation in Li‐Ion Battery Cathode Materials: Mechanisms and Mitigating Approaches

Soroosh Sharifi‐Asl, Teófilo Rojo, Khalil Amine et al.

Advanced Energy Materials 2019 10.1002/aenm.201900551
[30]
Hou "Unlocking the Self-Supported Thermal Runaway of High-Energy Lithium-Ion Batteries" Energy Storage Mater. (2021) 10.1016/j.ensm.2021.04.035
[31]
Bugryniec "Review of Gas Emissions from Lithium-Ion Battery Thermal Runaway Failure—Considering Toxic and Flammable Compounds" J. Energy Storage (2024) 10.1016/j.est.2024.111288
[32]
Luo "Safety Concerns in Solid-State Lithium Batteries: From Materials to Devices" Energy Environ. Sci. (2024) 10.1039/d4ee02358g
[33]
Charbonnel "Preliminary Study of All-Solid-State Batteries: Evaluation of Blast Formation during the Thermal Runaway" iScience (2023) 10.1016/j.isci.2023.108078
[34]
Yang "Benchmarking the Safety Performance of Organic Electrolytes for Rechargeable Lithium Batteries: A Thermochemical Perspective" ACS Energy Lett. (2023) 10.1021/acsenergylett.2c02683
[35]
Li "Experimental Investigation on the Thermal Runaway and Its Propagation in the Large Format Battery Module with Li(Ni1/3Co1/3Mn1/3)O2 as Cathode" J. Hazard. Mater. (2019) 10.1016/j.jhazmat.2019.03.116
[36]
Pigłowska, M., Kurc, B., Galiński, M., Fuć, P., Kamińska, M., Szymlet, N., and Daszkiewicz, P. (2021). Challenges for Safe Electrolytes Applied in Lithium-Ion Cells—A Review. Materials, 14. 10.3390/ma14226783
[37]
Hess "Flammability of Li-Ion Battery Electrolytes: Flash Point and Self-Extinguishing Time Measurements" J. Electrochem. Soc. (2015) 10.1149/2.0121502jes
[38]
(2025, September 15). Combustion (Fire) Tests for Plastics. Available online: https://www.ul.com/services/combustion-fire-tests-plastics.
[39]
Xu "An Attempt to Formulate Nonflammable Lithium Ion Electrolytes with Alkyl Phosphates and Phosphazenes" J. Electrochem. Soc. (2002) 10.1149/1.1467946
[40]
(2023). Standard Test Method for Measuring the Minimum Oxygen Concentration to Support Candle–Like Combustion of Plastics (Oxygen Index) (Standard No. ASTM D2863).
[41]
Kim, Y., Lee, S., and Yoon, H. (2021). Fire-Safe Polymer Composites: Flame-Retardant Effect of Nanofillers. Polymers, 13. 10.3390/polym13040540
[42]
Parcheta-Szwindowska, P., Habaj, J., Krzemińska, I., and Datta, J. (2024). A Comprehensive Review of Reactive Flame Retardants for Polyurethane Materials: Current Development and Future Opportunities in an Environmentally Friendly Direction. Int. J. Mol. Sci., 25. 10.3390/ijms25105512
[43]
Babu, K., Rendén, G., Mensah, R.A., Kim, N.K., Jiang, L., Xu, Q., Restás, Á., Neisiany, R.E., Hedenqvist, M.S., and Försth, M. (2020). A Review on the Flammability Properties of Carbon-Based Polymeric Composites: State-of-the-Art and Future Trends. Polymers, 12. 10.3390/polym12071518
[44]
Quan "A Review on Cone Calorimeter for Assessment of Flame-Retarded Polymer Composites" J. Therm. Anal. Calorim. (2022) 10.1007/s10973-022-11279-7
[45]
Huang, Q., Li, X., Han, P., Li, Y., Liu, C., Chen, Q., and Li, Q. (2023). Research on the Fire Behaviors of Polymeric Separator Materials PI, PPESK, and PVDF. Fire, 6. 10.3390/fire6100386
[46]
ICTAC Kinetics Committee recommendations for collecting experimental thermal analysis data for kinetic computations

Sergey Vyazovkin, Konstantinos Chrissafis, Maria Laura Di Lorenzo et al.

Thermochimica Acta 2014 10.1016/j.tca.2014.05.036
[47]
Vyazovkin "ICTAC Kinetics Committee Recommendations for Performing Kinetic Computations on Thermal Analysis Data" Thermochim. Acta (2011) 10.1016/j.tca.2011.03.034
[48]
Saadatkhah "Experimental Methods in Chemical Engineering: Thermogravimetric Analysis—TGA" Can. J. Chem. Eng. (2020) 10.1002/cjce.23673
[49]
Lalinde "On the Characterization of Lithium-Ion Batteries under Overtemperature and Overcharge Conditions: Identification of Abuse Areas and Experimental Validation" Appl. Energy (2024) 10.1016/j.apenergy.2023.122205
[50]
Spotnitz "Abuse Behavior of High-Power, Lithium-Ion Cells" J. Power Sources (2003) 10.1016/s0378-7753(02)00488-3

Showing 50 of 145 references

Metrics
3
Citations
145
References
Details
Published
Oct 23, 2025
Vol/Issue
17(21)
Pages
2828
License
View
Funding
National Research Foundation of Korea Award: NRF-2021R1A2C1008272
Cite This Article
Khang Le Truong, Joonho Bae (2025). Towards Fire-Safe Polymer Electrolytes for Lithium-Ion Batteries: Strategies for Electrolyte Design and Structural Design. Polymers, 17(21), 2828. https://doi.org/10.3390/polym17212828
Related

You May Also Like

Poly Lactic-co-Glycolic Acid (PLGA) as Biodegradable Controlled Drug Delivery Carrier

Hirenkumar K. Makadia, Steven J. Siegel · 2011

3,980 citations

Chitosan: An Overview of Its Properties and Applications

Inmaculada Aranaz, Andrés R. Alcántara · 2021

1,433 citations

Thermoresponsive Polymers for Biomedical Applications

Mark A. Ward, Theoni K. Georgiou · 2011

1,048 citations