In a development that could reshape battery safety, Nuvola Technology announced that its SafeCoat™ Direct Deposition Separator (DDS) successfully prevented thermal runaway in lithium-ion batteries under extreme abuse conditions that typically result in catastrophic fires.

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Nuvola’s SafeCoat applied lithium-ion cell with standard flammable chemistry not only prevents explosion but continues to function safely even after being punctured by a nail.

The breakthrough comes at a pivotal moment for the $100 billion lithium-ion battery industry, where safety concerns and high-profile battery fires are slowing key markets.

In testing, Nuvola's 41-layer, 5 Ah lithium-ion pouch cell with SafeCoat DDS survived the industry's toughest safety test – nail penetration – maintaining its charge without ignition or thermal runaway. In contrast, a commercial benchmark cell using thermally enhanced separators erupted into thermal runaway within ten seconds under identical conditions.

Unlike conventional film separators that shrink or melt under heat, triggering fires, SafeCoat's nanoporous layer remains structurally intact even at temperatures exceeding 220°C and direct flame. This resilience prevents the cascading failure that turns one damaged cell into an inferno.

"This isn't an incremental improvement. It’s a fundamental reimagining of battery safety," said Dr. Janet Hur, CEO and Co-Founder of Nuvola Technology. "SafeCoat represents the first separator technology that contains severe damage while keeping the battery functional."

"What's truly exciting is that this cost-effective and shovel-ready solution delivers most of the safety benefits expected from solid-state batteries – but it's available today and integrates seamlessly into lithium-ion plants operating or under construction," added Dr. Leland Smith, CTO and Co-Founder of Nuvola Technology.

SafeCoat's compatibility with existing lithium-ion production lines could accelerate adoption of technology across the industry. This also strengthens U.S. battery manufacturing capacity by reducing reliance on centralized separator facilities, mostly in Asia. In turn, SafeCoat supports national initiatives to build localized and cost-efficient supply chains, accelerating domestic battery capacity.

Global battery manufacturers serving EV, medical devices, and consumer electronics sectors are evaluating the technology. Early assessments suggest SafeCoat could lower battery pack costs by reducing insulation requirements for thermal runaway prevention. Industry analysts note that SafeCoat shatters the safety-performance trade-off, unlocking a new frontier for battery innovation even in drones and robotics.

Nuvola Technology is an advanced battery company based in Los Angeles, California, focused on revolutionizing battery production through its SafeCoat DDS platform. Backed by Y Combinator and Coeur Renewables, Nuvola was founded by two UCLA PhD materials scientists.

Learn more at https://nuvola.tech

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SafeCoat represents the first separator technology that contains severe damage while keeping the battery functional.