Development of a New Electric Vehicle Post-Crash Fire Safety Test in Korea (Proposed for the Korean New Car Assessment Program)

Recent fire incidents following electric vehicle (EV) collisions have been increasing rapidly in Korea, corresponding to the growing distribution of EVs. While the overall number of EV fires is lower compared to those involving internal combustion engine (ICE) vehicles, EV fires can lead to more severe outcomes. Current regulations for post-crash fuel system integrity evaluation do not differentiate between EVs and ICE vehicles. However, the causes of fires in these vehicles differ due to variations in the design and construction of their fuel systems. This study analyzed seventeen cases of EV post-crash fires in Korea to derive two representative risk scenarios for EV post-crash fires. The first scenario involves significant intrusion into the EV front-end structure resulting from high-speed frontal collisions, while the second scenario involves direct impacts to the battery pack mounted under the vehicle from road curbs at low speeds (30–40 km/h). Based on these scenarios, we conducted tests to assess battery damage severity under two crash test modes, simulating both high-speed frontal collisions and low-speed curb impacts. The test results led to the development of a draft crash test concept to evaluate EV post-crash fire risks. Furthermore, we assessed the reproducibility of these test modes in relation to actual EV post-crash fires. Our findings indicate that square-shaped impactors provide higher reproducibility in simulating real EV post-crash fire incidents compared to hemisphere-shaped impactors. Additionally, a fire occurred 31 days after the storage of a crash-evaluated battery test specimen, which was determined to be caused by moisture invasion during post-crash storage, accelerating a micro-short circuit. This study aims to contribute to the development of new evaluation methods for the Korean New Car Assessment Program (KNCAP) to enhance EV post-crash fire safety by utilizing these test results to refine collision severity evaluation methods.