Polyurethane materials & adhesives boost crash safety and power in EV batteries

Innovative materials are the key to overcoming electric vehicle pain points

Pultrusion technology for cost-efficient composite battery housing 

Covestro solutions outperform benchmark materials in multiple crash test simulations

We tested a range of battery housing designs that used pultruded polyurethane in the bottom plate, struts, and frame. Our Baydur® PUL solution outperformed a benchmark pack of current materials in two key simulations - a crash test based on a Chinese standard, and a side-pole crash test based on NCAP requirements. The simulation measured energy absorption and deformation, and results showed very low likelihood of damage to the battery cells with the Covestro design. Also, in three UNECE R100 tests evaluating mechanical integrity, mechanical shock and vibration, the Covestro battery design produced excellent results.

Thermal interface materials for higher battery speed and lower recharge time

Within the battery housing, the purpose of gap fillers and adhesive materials is to improve the heat transfer from the battery cells to the cooling devices. Better heat transfer means a higher performing battery cell. TIMs integrating our Desmodur® and Desmophen® polyurethane products are much lighter and more heat conductive than conventional aluminum oxide-based metals, giving the electric vehicle more power and faster charging. They also isolate overheated cells from each other, lowering the risk of fire.