Stellantis has a surprising solution for EV battery fires — an exhaust system.
The parent company of Dodge, Ram, and Jeep filed a patent application in 2023 for an electric vehicle exhaust system that could help prevent or limit battery fires. The United States Patent and Trademark Office (USPTO) published the filing on January 16.
Battery thermal runaway — when cells overheat uncontrollably — can release dangerous flammable gases including hydrogen and various hydrocarbons like methane, ethane, and propane. These gases often ignite due to the extreme heat, making battery fires particularly challenging for first responders.
Stellantis’ proposed system would treat these gases chemically through multiple stages, similar to how catalytic converters clean exhaust in gas-powered vehicles. The setup aims to both remove hazardous gases and relieve pressure from the battery pack.
This isn’t the company’s first venture into EV exhaust systems.
The upcoming Dodge Charger Daytona EV already incorporates an exhaust-like system — though that one’s purely for recreating the signature V-8 rumble of its gas-powered predecessors. The automaker’s new STLA vehicle platforms are designed to accommodate both traditional exhaust systems and electric powertrains, making the safety-focused system technically feasible.
Modern EVs already employ sophisticated battery management systems with liquid cooling and cell-level monitoring to prevent thermal events. These systems can isolate problematic cells before they cause larger issues. However, automotive suppliers continue exploring novel safety approaches — like Bosch’s 2019 proposal to use controlled explosives to disconnect battery packs during emergencies.
While battery fires have triggered several major recalls, the Insurance Institute for Highway Safety noted in 2023 that EV weight and its impact on other vehicles remains a more pressing safety concern than fire risk.
The patent shows automakers are still grappling with battery safety challenges as EVs become mainstream. However, like many patented technologies, there’s no guarantee this system will make it into production vehicles anytime soon.
