Case study · E-mobility
Lightweight EV Battery Pack Insulation for Next-Generation Electric Vehicles
Supporting lightweight, flame-retardant battery pack designs with high-performance polycarbonate films.
A LEXAN™ reference application, shared to show what the material can do. Laxmi Plastopack supplies genuine LEXAN™ grades across India.
Overview
As electric vehicle manufacturers continue to reduce battery pack weight while improving safety and reliability, insulation materials play a critical role in battery module design. Thin-gauge insulation films must combine excellent electrical performance with consistent thermoformability, enabling manufacturers to produce complex three-dimensional insulation components at high production volumes.
For this project, a high-performance flame-retardant polycarbonate film was selected to support the mass production of thermoformed battery insulation components for EV battery modules.
The challenge
The battery insulation material needed to satisfy several demanding requirements simultaneously:
- Support high-volume thermoforming of complex 3D insulation components
- Meet stringent electrical insulation and flame-retardancy standards
- Comply with global environmental regulations, including RoHS and REACH
- Deliver high dielectric strength and Comparative Tracking Index (CTI) performance
- Reduce overall battery pack weight without compromising durability or reliability
Balancing these performance requirements while maintaining manufacturing efficiency was essential for large-scale EV production.
The solution
LEXAN™ EFR95 Polycarbonate Film was selected for its combination of flame-retardant performance, electrical insulation properties, and excellent thermoformability. The material integrates seamlessly into automated forming processes, enabling consistent production of lightweight, precision-formed battery insulation components.
Its dimensional stability and mechanical strength also help maintain component integrity throughout the battery pack assembly process.
Why LEXAN™ EFR95
- UL94 V-0 flame-retardant performance for enhanced electrical safety
- Halogen-free formulation supporting RoHS and REACH compliance
- High dielectric strength for reliable electrical insulation
- Good Comparative Tracking Index (CTI) performance for demanding electrical environments
- Excellent thermoformability for complex three-dimensional components
- Thin-gauge construction that contributes to lighter battery pack assemblies
Results
Using LEXAN™ EFR95 Film enabled the production of lightweight, thermoformed battery insulation components that met demanding electrical, mechanical, and environmental performance requirements. The solution helped support efficient, high-volume manufacturing while giving battery designers greater flexibility to optimise battery pack architecture and reduce overall system weight.
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