EV safety system in China can eject batteries 20 feet away

China’s wild idea to escape EV fires

Engineers in China demonstrated a novel method to prevent an electric car fire from harming occupants inside the vehicle. The plan is to violently eject the entire battery pack when the car’s sensors detect extreme, runaway heat in the cells.

The mechanism utilizes a gas generator to generate the necessary force. This system is designed to quickly move the fire source away from the passengers. The battery is discharged from the vehicle in under one second after thermal runaway begins, which is an action as fast as an airbag deploying.

Ejection mechanics and direction

The quick reaction system operates by utilizing high-pressure gas to forcefully push the battery pack away from the car. The viral demonstration video showed the large battery being ejected sideways from the vehicle’s underside, not vertically.

The system is designed to propel the pack between 10 and 20 feet (3 and 6 meters) away from the vehicle itself. The rapid, fast-acting action is called “airbag-like” because it utilizes a similar gas-powered mechanism; however, the battery is ejected externally instead of deploying internally for protection.

Weight and risk of ejected battery

The ejection system turns an internal fire risk into a huge external hazard to the public. A single EV battery pack is very heavy, weighing on average over 500 pounds (227 kg). Large packs can weigh up to 2,000 pounds (900 kg), creating a massive, flaming projectile.

The initial test was done in a controlled demo zone with safety pads. In real-world traffic, ejecting this burning weight could hit other vehicles or pedestrians, making the safety risk completely uncontrolled.

High heat of an EV battery fire

The problem the ejection system aims to address is called thermal runaway, a severe chain reaction of rising heat within the battery cells. This occurs when the battery cannot dissipate the heat it generates, causing parts to melt. This self-heating reaction is hard to stop once it begins.

When a lithium-ion battery is on fire, it burns at extremely high temperatures, making it difficult to extinguish. The fire temperature can climb as high as 1,800°F (around 1,000°C), creating a risk that can easily melt other materials.

Test vehicle and event details

The controversial demonstration was filmed on September 19, 2025, during the Power Battery Launch Technology Demonstration and Exchange Meeting. The test was conducted using an SUV at the China Automotive Collision Repair & Technology Research Center. The vehicle resembled the iCar 03T model, a crossover made by Chery.

The iCar 03T’s production model dimensions are 4,406 mm in length, 1,910 mm in width, and 1,715 mm in height, with a 2,715 mm wheelbase. The carmaker iCar quickly released a statement that it had no official involvement in the technology’s design.

Companies deny responsibility for system

After media speculation linked Joyson Electronics to the demo, the supplier publicly denied any involvement in the system. iCar/Chery also stated that the technology is not affiliated with its products.

They are concerned about the new liability risks associated with launching a burning battery onto public streets. The companies are distancing themselves from the concept because an external fire hazard could lead to legal responsibility for any damage or injury it could potentially cause to the public.

Safety experts do not approve it

The battery ejection concept is currently only a proof-of-concept stunt and is highly unlikely to be approved for use in production cars by any government safety regulator. Regulators will not approve a system that creates a massive, flaming, external hazard.

This is considered trading the risk of occupants for a new, uncontrolled public danger. Instead of solving the fire issue, it creates an extreme risk to pedestrians and other cars outside the vehicle, making the technology unworkable for commercial electric vehicles.

Expert opinion on the concept

Expert analysis of the battery ejection system emphasizes the clear safety risks it poses to bystanders and other vehicles. This method is viewed as trading one risk for another, rather than solving the core fire issue.

The ejection concept has been described as a dangerous liability because a heavy, burning battery could hit pedestrians or other cars. The system is strictly a demonstration and not a technology intended for production vehicles, due to the extreme public hazard it would introduce if it were activated on a busy road.

EV fire rate compared to gas cars

Ideas like the battery ejection system aim to address the problem of EV fires, which are more challenging to extinguish than those in traditional vehicles. However, EV fires are rare compared to gasoline cars, which use flammable fuel.

National Transportation Safety Board shows that there are about 25 EV fires for every 100,000 EVs sold. In comparison, there are about 1,530 fires for every 100,000 gas-powered cars sold. This means the fire rate for gasoline vehicles is 61 times higher than that of fully electric cars.

The problem of fire extinguishment

The biggest challenge with EV fires is that the heat is trapped inside the battery’s protective case, making it very difficult for water to cool the cells and halt the chemical reaction. The fire can easily start again hours later, a phenomenon known as re-ignition or thermal runaway continuation.

Firefighters sometimes have to use very large amounts of water to cool the battery. A single fire can often require thousands of gallons of water and may necessitate submerging the entire car in a tank to finally extinguish the intense, lasting heat.

Global focus: better battery cooling

Engineers around the world are primarily focusing on preventing thermal runaway by improving the design and cooling of the battery. The most common efforts aim to make the battery pack safe inside the car, rather than shooting it out.

This approach prioritizes fire containment. One standard fix is to develop better thermal management systems that keep the battery at a safe temperature. These active cooling systems help prevent the initial rise in temperature that usually triggers a chain reaction fire in the high-voltage battery cells.

Renault’s fireman access innovation

The car company Renault created a helpful feature called Fireman Access, rather than developing an ejection system. This design is a simple yet crucial solution that enables rescue workers to fight fires more efficiently. It gives them a faster way to apply water to the battery’s core.

The Fireman Access system features an intentional opening that enables firefighters to spray water directly onto the heart of the battery, significantly accelerating the cooling and containment process. This system has already been deployed in some models and is being offered to other carmakers at no cost.

Geely’s insulated pack strategy

Geely Auto is developing designs that enhance the battery pack’s resilience and resistance to extreme heat. They are trying to prevent the fire from spreading from one cell to the next, a process known as propagation.

Geely is focusing on insulated casings and using special heat-resistant materials within the pack. This insulation helps contain the initial fire, preventing the rapid spread of thermal runaway between the many battery cells in the large battery pack. This containment is critical for vehicle safety.

LG Chem’s self-extinguishing cells

Battery makers themselves are also working on changes to the cell’s internal chemistry to make them safer. LG Chem, a major global battery supplier, is developing technology to create a battery that can help extinguish its own fire.

This involves adding special agents or materials that activate in extreme heat to stop the chemical reactions that cause the fire. This approach would help neutralize the fire and prevent the chain reaction from escalating into an uncontrollable event, making the battery safer from the inside out.

Focus on structural crash safety

Many car manufacturers employ a “prevention first” strategy by designing the battery pack to be extremely robust. The pack is built into the car’s structure to protect it from damage in a collision. Preventing mechanical damage is crucial, as this is a primary trigger for cell failure.

For example, a single battery defect issue in the Chevrolet Bolt EV led General Motors to spend approximately $1.9 billion on recalls and battery replacements. This high cost confirms the industry’s focus on eliminating the fire risk through strong internal design.

Discover why some U.S. cars are built in China and what it means for buyers. Check out why some U.S. brand cars are manufactured in China.

An extreme concept will not be adopted

The battery ejection idea is an extreme concept that will not be adopted by the automotive industry. The public safety concerns are considered to outweigh the benefits to the occupants of the car. Most engineering efforts are focused on improving chemical safety and better thermal management systems.

A single defect in Hyundai’s Kona EV led to a recall of approximately 76,000 vehicles, which cost the company $900 million. This shows why manufacturers are focused on eliminating the fire risk inside the vehicle through containment and prevention.

See why Mercedes is feeling the pinch from China and tariffs? Read more in China competition and US tariffs drag down Mercedes earnings.

Would you ride a car that throws its battery? Drop thoughts.

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This slideshow was made with AI assistance and human editing.