Why did Stellantis, one of the world’s largest automotive groups, just patent an exhaust system for its electric models?
Electric cars are supposed to be silent and emission-free. And above all, the very idea of an exhaust system on an EV that doesn’t have an engine is pretty amusing! But the answer to this question might just be surprising.
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An exhaust on an electric car?
When we think of electric cars, we picture quiet, clean vehicles with no exhaust pipes. Yet, manufacturers have already found ways to artificially add sound to simulate the noise of combustion engines. Some brands even hire composers like the famous Hans Zimmer to give their cars a “sonic soul.” But what Stellantis is working on has nothing to do with artificial noise. The group recently filed a patent in the U.S. for a real exhaust system on its electric vehicles, intended for Dodge, Jeep, and RAM models. This system has a very specific function: improving safety in the event of a battery fire. Because yes, even though EVs are statistically less prone to fires than their gasoline or diesel counterparts, these incidents—while rare—can be spectacular and extremely difficult to control. You probably remember those smartphones that caught fire uncontrollably? Now imagine that with a battery pack a thousand times larger…
A real issue: thermal runaway
One of the biggest concerns for engineers is what’s known as “thermal runaway.” This occurs when a battery cell overheats, triggering an uncontrollable chain reaction. In addition to extreme heat, this process generates flammable gases like hydrogen, methane, and butane, significantly increasing the risk of explosion. When this happens, firefighters often have to use specialized techniques like immersion containers to cool the battery. But Stellantis wants to take it a step further by developing an exhaust system that can vent these toxic gases before they become a major hazard. The idea is to reduce pressure and minimize explosion risks while chemically treating the gases to make them less harmful.
A solution inspired by combustion engines
The principle behind this system is similar to the catalytic converters used in gasoline and diesel cars. In its patent, Stellantis describes a series of “treatment zones” designed to neutralize these gases before they escape into the atmosphere. This project is part of a broader effort to enhance EV safety. Back in 2019, Bosch had already proposed a system using small explosives to instantly cut off a battery’s power supply in case of a malfunction. Today, pyrofuses are already present in some cars to limit damage in case of a short circuit. But Stellantis wants to go even further with a system that doesn’t just prevent fire from spreading—it actively deals with the gases released.
Will this system actually be implemented?
Will this solution even remain relevant in the long run? The automotive industry is actively working on solid-state batteries, which are far safer than today’s lithium-ion packs. Less flammable and more stable, they could significantly reduce fire risks, making this “electric exhaust” obsolete before it ever sees widespread use. For now, this initiative shows that manufacturers are leaving nothing to chance when it comes to safety—and that’s pretty reassuring!
This article explores Stellantis’ surprising move to equip its electric cars with an exhaust system to vent dangerous gases in the event of a fire. A technology that could improve safety, but whose future depends on upcoming battery advancements.
