Fire protection in the automotive industry and in modern vehicle construction
According to the German Insurance Association, 15,000 vehicle fires occur every year in the 50 million or so vehicles in Germany alone (as of 2021). Regardless of the type, motor vehicles have a high fire load, i.e. they release a considerable amount of heat when they catch fire. With the steadily increasing number of electrically powered vehicles (hybrid or electric vehicles), fire brigades, towing or waste disposal companies, building operators, as well as insurance companies, are faced with the question of behaviour in the event of a fire and ask for suitable protective measures.
However, due to the trend towards SUVs and larger cars in general, and in particular the increasing use of plastics in vehicles to reduce weight and energy consumption, newer vehicles tend to have a significantly greater fire load than a few decades ago. This does not only apply to electric cars (see documentation WD 8 – 3000 – 002/22 of the Scientific Services of the German Bundestag on the behaviour of electric cars in the event of fire). However, when lithium-ion batteries in hybrid or electric vehicles catch fire, more toxic gases can be produced, in particular hydrofluoric acid and hydrogen phosphide, depending on the composition of the lithium-ion battery.
Fire protection is therefore becoming increasingly important in the modern automotive industry and vehicle manufacturers must take various precautions to prevent fires. International standards and national regulations must be observed, e.g.
- ISO 6469-1: International safety specifications for electric vehicles, including fire safety requirements
- UN ECE R100: Regulations regarding the safety of electric vehicles, including specific requirements for high-voltage batteries.
- DIN EN 50604-1: European and German standard for safety requirements for lithium-ion batteries in vehicles.
- FMVSS 305: US safety standards for electric vehicles, which include specific requirements for protection against battery consequences.
By using different technologies and materials, vehicle manufacturers can significantly reduce the risk of vehicle fires and improve safety for occupants and emergency services.
With the HENSOTHERM® and HENSOMASTIK® product series, we offer solutions for fire protection requirements for components made of various plastics, sheet metal and aluminium, especially for electromobility and its increased fire protection requirements for modern battery systems. These passive fire protection measures are crucial for increasing safety in vehicle construction and minimising the effects of fires.
Possible applications for intumescent materials
Intumescent materials based on expandable graphite, also known as “intumescent formers”, expand when exposed to heat and increase greatly in volume, forming a protective insulation layer that delays the passage of heat and can also seal cavities.
1. Fire protection coatings: The intumescent HENSOTHERM® 7 KS fire protection coatings can be used, for example, for battery compartments of electric vehicles, tanks or other critical components or enclosures and offer the highest level of fire safety. These coatings are able to swell or foam in the event of a fire, creating a thick, insulating layer. The insulating layer slows the transfer of heat to the underlying structures and protects them from the effects of heat.
The coatings can be applied to various materials and vehicle components and offer a high level of protection with a low weight per unit area, even at extreme temperatures. The starting temperature of the chemical reaction, foam factor/height and inflation pressure can be customised.
The solvent-free HENSOTHERM® 2C fire protection systems for steel can be used indoors and outdoors due to their high mechanical strength and resistance to climatic influences and achieve corrosivity category C5 on steel elements when used as a system (primer + fire protection coating + top coat) with excellent processing properties and thin layer thicknesses. The top coat is available in all RAL colours or according to an individual colour sample. The 2-component coating system is AgBB-tested, free from halogens, alkylphenol and benzyl alcohol and categorised in VOC emission class A+.
The solvent-free HENSOTHERM® 2C fire protection systems for steel can be used indoors and outdoors due to their high mechanical strength and resistance to climatic influences and achieve corrosivity category C5 on steel elements when used as a system (primer + fire protection coating + top coat) with excellent processing properties and thin layer thicknesses. The top coat is available in all RAL colours or according to an individual colour sample. The 2-component coating system is AgBB-tested, free from halogens, alkylphenol and benzyl alcohol and categorised in VOC emission class A+.
2. Intumescent fabric strips: Highly flexible HENSOTHERM® 7 KS Gewebe strips made of A2 glass filament fabric coated with the HENSOTHERM® 7 KS fire protection coating provide an alternative to full surface applied intumescent coatings. The HENSOTHERM® 7 KS fabric SKL is even available ex works as a self-adhesive version, which enables quick installation. Both fabric variants can be easily cut with a knife or scissors, or punched out into complex shapes to selectively improve the fire-resistant properties of vehicle components. By forming an insulating layer, the integrity and function of mechanical and electrical components can be maintained for longer.
Possible applications of ablative materials
Ablative coatings are also fire protection coatings, but they have a different mode of action. Instead of foaming as with intumescent materials, ablative materials delay the passage of heat to the materials to be protected by releasing chemically bound water. In addition to this “cooling effect”, the fire gases are diluted, i.e. the toxicity of the gases is reduced. Vehicle occupants and emergency services are protected.
1. Fire protection coatings: Ablative fire protection coatings slow heat penetration and can preserve the structural integrity of electrical wiring and controls. The water-impermeable, oil and petrol-resistant fire protection coating HENSOMASTIK® 5 KS paint is also weatherproof, UV-resistant, ageing-resistant and mechanically resilient.
2. Special adhesive: Organic, temperature-resistant and permanently elastic fire protection adhesive for bonding and sealing vehicle components.
Our core competence – your competitive edge
Fire protection is a decisive factor in the automotive industry, especially in the era of electric vehicles. As a manufacturer, we endeavour to develop innovative solutions that meet the growing requirements and increase safety on the roads. Our fire protection coatings and components provide reliable protection and contribute to the safety and longevity of vehicles.
We offer the development, testing and production of intumescent and ablative materials, components and coatings specifically for your product as a service – also as a partner for research projects. Let our team advise you on your individual requirements.
Please contact us for further information on our products and solutions. Together we are making the mobility of the future safer.