Materials within electric vehicle batteries play a critical role in overall performance. Recent years have seen a surge in research and information about battery cell materials. While battery cells are crucial components in terms of both cost and usage, the materials used in battery modules and packs have received relatively less attention in terms of importance and available data. This report focuses on the primary purposes of materials used in battery modules and packs and their anticipated future trends. The discussion of battery cells is limited to their four core components.
The global market for electric vehicle (EV) battery packs, including both BEVs and PHEVs, is projected to grow at a compound annual growth rate (CAGR) of 19% from 2021 to 2035. The market value for EV battery packs is expected to increase from $123 billion in 2024 to $462 billion in 2035. Excluding cell and pack manufacturing costs and profits, the market for components within the battery pack is forecast to grow from $34 billion in 2025 to $113 billion in 2035, accounting for approximately 25% of the total battery pack cost.
Battery cells are the main materials in EV packs, but inter-cell structures are also important. However, with design changes like Cell-to-Pack and Cell-to-Chassis aimed at increasing energy density, the demand for these inter-cell structural materials is expected to decrease. Within battery cells, materials like nickel, cobalt, iron, and manganese for the cathode, and graphite (synthetic or natural) for the anode, constitute a significant portion of the overall material demand. Copper and aluminum, serving as current collectors, are also crucial materials. While there seems to be no significant decline in demand for specific materials through 2035, the industry is moving away from the use of expensive cobalt and focusing on enhancing safety. Additionally, this report delves into the recent surge in thermal runaway incidents in battery modules and packs, and the materials and development strategies being employed to prevent such occurrences.
This report provides updated information on companies including Sang-A Frontec, Sangsin EDP, Dongwon Systems, Yulchon Chemical, KET, Younghwa Tech, LS EV Korea, Hyunwoo Industrial, Yura Corporation, Kyungshin, Hanjoo Metal, Aluko, Inzi Controls, Shinsung Delta Tech, Hanon Systems, WACKER, Saint-Gobain PPL, Dong-A Hwa Sung, Sebang Lithium Battery, Yamada Weld Tech Korea, and Trumpf Korea.
Table of Contents
Part 1. EV and Battery, Battery Pack Market Outlook
Global EV Market Outlook
Global Battery Pack Market Outlook
Global Battery Pack Components Market Outlook
Cost Configuration of Major Battery Pack Components
Battery Pack Material Used for the EV Battery
Pack Housing Material
Thermal Management Material
Inter-cell Structure Material
Outlook for Battery Cell Material
Cathode Material
Anode Material
Separator
Electrolyte
Part 2. Trends of Major Component Material of Battery Cell, Module, Pack
Types of EV
Main Components of EV
Powertrain Specification for Each Types of EV
Battery Materials of EV
Value Chain Configuration of EV Battery Material
Difference of Cell, Module, Pack
Types of Battery Cell
Consideration of Battery Cell Type
Selection of Battery Cell Type
Selection of EV Battery Cell Type
Part 3. EV Battery Pack Specification Analysis and Summary
EV Battery Pack Specification Analysis
The Outlook for Battery Cell and Pack Prices
Average Capacity(kWh) of EV Battery Packs for Passenger Cars
Energy Density Analysis(kWh/kg) of EV Battery Packs
Usable Energy Analysis of EV Battery Packs
Weight Ratio of the Battery Pack Major Components
Major EV Battery Pack Specification Summary
Part 4. Battery Cell, Module, Pack Platform Trend
Development Trends of EV Platform and Battery Pack
VW MEB
HKMC e-GMP
GM Ultium
Tesla
Toyota e-TNGA
Features of Module-free Battery Pack : BYD CTP Pack / CATL CTP Pack
Application of Hybrid Battery Pack
AB Battery Pack System
Part 5. Main Components of the Pack
1. Cell Construction Materials and Components
Cell Components
Supply Chain of Cell Components Companies
Changes in Battery Cell Chemistry Composition (High Ni, LFP)
Changes in Energy Density at the Cell and Pack Levels
2. Thermal Interface Materials (TIM) for Battery Packs
Types of TIM
Main Materials of TIM
Application Case for EV
Comparison of TIM Shape and Material
Main Considerations of TIM
Development Trend of TIM
Outlook by TIM Type
3. Housing(Tray, Cover, Gasket) & Cooling Plate Material for Battery Pack
Housing Development and Material Trends
Polymer Composite Material
Al Alloy Material
Stainless Steel Material
Pack Sealing Gasket Material
Pack Cooling Plate Material
4. Flame Resistant Material and Solution for the Pack Protection