1
Replace plastic separators with a with a thermally stable nonwoven separator
First, the unstable plastic separator is replaced by a nanofiber nonwoven reinforced with Kevlar or Twaron for thermal stability.
2
Replace solid aluminum and copper foils with thin metallized film current conductors
Next, solid metal foils are replaced with metallized films with enough metal to run the battery, but not enough to support the intense current density that can light it on fire. The energy flow stops. The cell is also lighter and thinner.
3
The outcome is a safe cell that keeps working even after being damaged
With an internal short now isolated, the rest of the cell continues to function. In short… No more FIRE or EXPLOSION!