Trinseo has developed its first recyclable1 battery top cover based on thermoplastic polycarbonate unidirectional (PC UD) tape, marking a significant advancement in lightweight, fire-resistant composite solutions for next-generation electric vehicle battery systems.
Developed at Trinseo's Global Innovation Center in Europe, the technology addresses critical design challenges facing OEMs and Tier-1 suppliers as they work to reduce vehicle weight, improve battery safety and build more circular manufacturing platforms.
A New Approach to Battery Casing Design
Built on Trinseo's flame-retardant PC UD tape technology, the battery top cover offers a compelling alternative to traditional metal- and thermoset-based designs. Available in thin-wall configurations of 1.0 mm and 1.5 mm, it supports industry efforts toward more circular vehicle platforms.
"This technology reflects Trinseo's capability to address key requirements identified by OEMs and Tier-1 suppliers, and when used in these applications, Trinseo’s solutions can contribute to lightweight design, fire-resistant performance, recyclability and cost efficiency," said Oliver Becker, Vice President, Technology & Innovation, Plastics Solutions. "It illustrates how thermoplastic composites can support evolving EV battery casing architectures while addressing sustainability considerations and scalable manufacturing requirements."
Trinseo's thermoplastic composite portfolio, encompassing UD tapes and organosheets, is designed with broad applicability across mobility sectors. In addition to EV battery systems, these materials have the potential to support a wide array of applications that use PC; for example, drones, robotics, urban air mobility and rail transportation—all areas where lightweight structures, high stiffness and strength, thin-wall design, fire resistance, corrosion resistance and high-rate production are critical performance considerations.
On Display at CIBF 2026 and Battery Show Europe
The battery top cover demonstrator made its global debut at the 18th China International Battery Fair (CIBF 2026), May 13–15 in Shenzhen, China, and will be displayed at The Battery Show Europe 2026, June 9–11 in Stuttgart, Germany. Trinseo welcomes conversations with OEMs, Tier-1 suppliers and industry partners at both events to explore collaboration opportunities in thermoplastic composite solutions for battery casing and broader mobility applications.
1 Recyclable in select facilities; availability may vary by region
