China has introduced a groundbreaking electric vehicle (EV) battery safety standard, GB38031-2025, set to take effect on July 1, 2026. This regulation mandates that EV batteries must not catch fire or explode, even during thermal runaway events, marking a significant advancement in battery safety protocols.
What’s Changing: From Delay to Prevention
1. The previous standard required a 5min warning i.e. a delay-to-evacuation methodology. However, the new regulation shifts focus to actively preventing fires and explosions during thermal runaway (TR) incidents. The TR propagation test requires battery to demonstrate no fire or explosion during internal TR events for up to 2 hours. The aim is to fully isolate and contain thermal events within the module or pack, to try and eliminate the risk of fire propagation to the rest of the vehicle or surroundings. This approach emphasises containment and safety, even under extreme conditions.
2. Batteries in vehicles and energy storage systems are subject to a variety of physical impacts during their lifespans, including vibrations, shock and accidents. As a precautionary measure, to address the growing complexity and increase in energy of modern battery systems, the risk of mechanical failure due to impact must be thoroughly tested to ensure battery safety. Consequently, the impact energy applied in the bottom impact test has been increased to better simulates real-world threats like hitting road obstacles at speed or debris impact in off-road.
3. As EVs become more mainstream, consumers are increasingly expecting faster charging times. Rapid adoption of EVs requires robust charging infrastructure, but this also places significant stress on the battery’s ability to handle high-current charging without degrading performance or safety. The fast-charging cycle safety test requires batteries withstand 300 fast-charging cycles without fire or explosion during subsequent short-circuit tests.
Additionally, any smoke emitted during such events must be non-toxic and non-harmful to vehicle occupants.
Industry Implications
This standard sets a new global benchmark for battery safety, potentially influencing international regulations. While leading manufacturers like CATL claim readiness with technologies such as their “No TR” modules, other companies may face challenges in meeting these rigorous requirements.
Looking Ahead
China’s proactive approach to EV battery safety reflects its commitment to consumer protection and technological leadership in the EV sector. As the implementation date approaches, manufacturers worldwide will need to assess and adapt their battery technologies to align with these stringent safety standards.
At ESS, we focus on preventing thermal runaway at its source and ensuring that cell-to-cell propagation is avoided in every design we create. Contact us to learn how we can support your project and enhance battery safety!
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