Freeze? Fireproof! A Revolutionary 320-Micron Bi-Layer Coating Reshapes Flame Resistance

Published on Quantum Server Networks | June 27, 2025

Bi-layer flame-retardant coating

When it comes to fire safety in electronics, transportation, energy storage, and construction, the clock is ticking. Traditional flame-retardant coatings often fail to deliver the instant response and lasting thermal insulation needed to prevent catastrophe. But that may soon change.

According to a study recently published in Nano-Micro Letters, a team of researchers has developed a bi-layered, ultrathin coating just 320 microns thick that provides a rapid and long-lasting shield against extreme heat—up to 1400 °C for over 15 minutes—making it one of the most promising flame-retardant technologies to date.

Why This Coating Stands Out

The bi-layer design includes two synergistic components: an intumescent flame-retardant (IFR) outer layer and a ceramifiable inner layer. The outer IFR layer kicks in almost immediately when exposed to high temperatures (under 300 °C), producing a dense char layer that slows down heat transfer. When the temperature rises above 550 °C, the inner layer undergoes a chemical transformation into a tough ceramic material, offering long-lasting protection.

This relay-type protection ensures that substrates such as lithium battery packs, aluminum sheets, and glass-fiber-reinforced epoxy resin can survive extended thermal exposure without structural degradation. Notably, standard coatings fail in under 200 seconds under similar conditions, while this coating performs for over 900 seconds—more than four times as long.

Composition and Fire-Tested Performance

Using alumina synergists to enhance the IFR layer and incorporating low-melting-point glass powders into the ceramifiable layer, the researchers ensured high thermal stability and mechanical integrity. The IFR layer maintained 31% mass retention at 800 °C, while the inner ceramic layer preserved over 97% of its mass, even after being subjected to intense heat.

These layers also contributed to the formation of a continuous char network that significantly blocked thermal conduction—an essential trait for effective fire retardancy in real-world applications.

Applications in Battery Safety and Beyond

One of the most promising uses for this technology is in lithium-ion battery fire protection. As battery technology scales up in EVs, drones, and portable electronics, so do fire risks. Applying this thin coating to battery packs could drastically reduce the probability of thermal runaway and explosion, all while maintaining electrochemical performance and solid-electrolyte interface (SEI) stability.

Beyond electronics, the coating has shown effectiveness on polyurethane foam, aluminum, and composite materials, making it a versatile candidate for sectors like aerospace, civil infrastructure, and consumer products.

A Scalable Innovation for Future Materials Engineering

With a thickness of just 320 microns and compatibility with various industrial substrates, the coating is highly scalable for commercial use. Its unique “relay mechanism”—combining fast-acting protection and long-term endurance—sets a new benchmark in flame-retardant material design.

As we move toward high-density batteries, sustainable construction, and more extreme operational environments, innovations like this will be crucial for both safety and performance.

Source and Further Reading

📖 Original article: AZoNano – Novel Bi-Layered Flame-Retardant Coating

📚 Journal reference: Tang, W. et al. (2025). “Bi-Layered, Ultrathin Coating Initiated Relay Response to Impart Superior Fire Resistance for Polymeric and Metallic Substrates.” Nano-Micro Letters. DOI: 10.1007/s40820-025-01739-8

Conclusion

By combining precision engineering with innovative materials chemistry, this study delivers a powerful solution to one of the most pressing challenges in energy and electronics: fire safety. Keep following Quantum Server Networks for more insights into the next generation of smart materials and nanotechnology breakthroughs.

Sponsored by PWmat (Lonxun Quantum) – a leading developer of GPU-accelerated materials simulation software for cutting-edge quantum, energy, and semiconductor research. Learn more about our solutions at: https://www.pwmat.com/en

📘 Download our latest company brochure to explore our software features, capabilities, and success stories: PWmat PDF Brochure

📞 Phone: +86 400-618-6006
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