Reviewed by Frances BriggsJul 16 2025
Researchers at the University of Surrey have developed smart internal sensors for lithium-ion batteries to detect failures early. They could improve safety and reliability in electric vehicles and energy storage.
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The world's transition to electric vehicles and renewable energy depends heavily on lithium-ion batteries, but when they malfunction, the consequences can be disastrous.
Conventional sensors are typically mounted on the outside of batteries and often react too late to prevent damage. In contrast, Surrey’s smart sensors are built directly into key battery components, like current collectors and separators.
This enables fast, accurate readings from inside the technology. They monitor and actively respond to thermal changes, using fire-resistant materials to slow down overheating.
The sensors have been designed to be scalable, affordable, and compatible with existing manufacturing techniques. According to the team, this makes them suitable for deployment in electric vehicles, public transport, aviation, and large-scale energy storage. These are all sectors where reliability is essential.
We have all heard the stories about lithium-ion battery fires and how notoriously difficult they are to extinguish. The best approach is to stop them from starting in the first place. Our technology could be a real game-changer for many critical industries.
Dr. Kai Yang, Lecturer, Energy Materials and Nanotechnology, University of Surrey
Lithium-ion batteries are among the most expensive parts of contemporary technology, so integrated smart sensors in this way could increase battery longevity and enable safer recycling of valuable materials. This could open up new application opportunities in high-risk industries like aerospace, maritime transportation, and aviation, where dependability is crucial.
The sale of new petrol and diesel cars will be banned in the UK from 2035, but safety, especially the risk of battery fires, remains one of the biggest concerns. These battery sensors are essential to improve safety and sustainability without sacrificing performance.
This is the innovation we need to achieve net-zero targets, all the while supporting industry and delivering real benefits to end users.
Ravi Silva, Distinguished Professor and Director, Advanced Technology Institute, University of Surrey
The University of Surrey has already applied for a patent on the technology and is actively looking to collaborate with academic and industry collaborators.
With the potential to create new patents, spin-out businesses, and skilled employment opportunities, their invention also contributes to the UN's Sustainable Development Goal for sustainable energy, solidifying the UK's standing as a world leader in battery technology.