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Smart battery packaging with the right materials

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The future of transport will be powered by batteries. To accelerate adoption, energy storage must be reliable and cost effective at both the cell and pack levels.

Better batteries with polycarbonate

Batteries play a key role in the electrification of transport, but battery packaging is what allows batteries to deliver safe, cost-efficient, versatile and dependable energy to power electric vehicles. Ideal battery packaging should be as compact as possible and contribute to the safe, long-term operation of the electric vehicle. Minimal packaging with maximum performance requires designs that integrate parts and functions with materials that are versatile and tough. Polycarbonate-based materials from Covestro can meet these challenges, providing unmatched dimensional stability and durability over a wide temperature range. This performance is required for multiple parts of the battery pack including enclosures, cell holders, cooling devices and crash absorbers.

Polycarbonates have a proven track record as the most commonly used material in packaging lithium-ion cells for electric vehicles. OEMs are looking for lower costs, high energy density, durability and safety. Polycarbonates meet these needs and offer unmatched versatility compared to other engineering plastics. Achieving high energy density requires a packaging material that is tough, easy-to-process and ultimately able to unify tasks and reduce component count.

Covestro is focused on efficient battery packaging solutions, relying on our track record and ability to collaborate with our partners. We envision a future where batteries deliver maximum value throughout their entire lifecycle with energy dense, safe and modular components.

Terry Davis

Applications Development Expert, Covestro

Versatile polycarbonate enables improved designs

The right materials allow the best designs to emerge. The versatility of polycarbonate materials allows Covestro to offer solutions for a variety of battery packing components including: cooling devices such as integrated cooling channels and hybrid plastic-metal cooling plates for long-lasting, durable cells; concealed packaging featuring innovative frames and cell holders for pouch and cylindrical cells; and pack enclosures with a ground-breaking manufacturing process for large, lightweight battery pack top covers.

We work in close collaboration with our customers to bring these designs to life and to ensure technical feasibility, cost-competitiveness and scalability.  For instance, Covestro was able to deliver the industry’s first polycarbonate-based top cover for battery packs manufactured by Haiyuan HYNM. This resulted in 20% weight savings, 50% higher productivity, lower part cost and improved performance against competitive solutions based on metal or sheet molding compound (SMC).

Exciting new packaging solutions are in various stages of development and validation. These next-gen components include modules with integrated water-glycol cooling channels, plastic-metal hybrid cooling plates, crash absorbers and thermally conductive cell holders.

Covestro is a recognized partner in the automotive and electro- industry. Our materials support our partners to mass-assemble efficiently their parts and modules. Our Bayblend® and Makrolon® materials offer unique properties like dimensional stability, high impact properties, flame retardancy and we developed special grades for thermal management.

Steven Daelemans

Business Development Manager, Covestro

  • Polycarbonates offer a proven track record of performance and unmatched versatility.
  • Long-range EVs rely on energy-dense pack designs, which can be achieved when cells are closer together and surrounded by thin-wall packaging.
  • Flame-retardant packaging materials ensure safe operation and regulatory compliance.
  • Long-lasting, durable cells depend on homogenous temperature distribution facilitated by integrated cooling.
  • Covestro materials maintain tight tolerances, which help scale production, reduce cycle times and lower costs.

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