Innovative PU battery pack solution

which was showcased at the China Composites Expo (CCE), Asia’s largest exhibition for composite materials, from September 2 to 4 in Shanghai. Under the theme “Empower Your Composite Solutions,” Covestro’s booth also featured PU composite innovations applicable in photovoltaics and energy storage, construction, and infrastructure.

Baypreg^® STM employs the Spray-Transfer-Molding process, where PU resins are sprayed onto glass fibers and molded into battery covers, enabling efficient production of composite components. Developed in collaboration with Liyang Shanhu Industrial Co., Ltd., a Tier 1 supplier of automotive parts and battery packs to Chinese and international OEMs, this solution represents a significant advancement that is also cost-effective.

Solution for lighter and high-performance battery covers

This PU solution reduces battery cover weight by more than half compared to traditional steel shell materials. As a non-metallic material, the Baypreg^® battery cover inherently offers superior anti-corrosion and insulation properties, effectively preventing electric arcing. When compared with non-metallic options, it outperforms in terms of surface smoothness and airtightness. It also demonstrates high strength meeting tough requirements from OEMs.

“As the inventor of polyurethanes, Covestro brings decades of expertise in the automotive industry, with PU solutions enhancing both driving and riding experiences in automotive interiors and exteriors. We can now extend this expertise to NEVs as well,” said Akhil Singhania, Global Head of PU Specialties at Tailored Urethanes, Covestro. “The Baypreg^® STM solution showcases Covestro’s ability to deeply understand evolving market needs and rapidly innovate cutting-edge material solutions. Our goal is to deliver lighter, more efficient, and sustainable solutions through continuous technological innovation.”

The NEV industry has witnessed rapid growth in recent years. According to the China Passenger Car Association, NEV sales accounted for 51 percent of total passenger car deliveries in China in July 2024, outnumbering those of internal combustion engine vehicles for the first time.

Diverse applications for Covestro’s PU composites

At the CCE, Covestro also showcased its PU composite solutions across various sectors. For instance, PU composites are widely utilized in photovoltaic (PV) modules to enhance efficiency and quality. Specifically, PU frames combined with coatings solutions from Covestro offer superior corrosion and weather resistance for PV modules, PU profiles excel in insulation and mechanical performance in energy storage batteries, and transparent front sheets based on composites enable high light transmittance while demonstrating exceptional strength for solar panels.

Additionally, in construction, PU windows and doors are ideal for nearly zero-energy buildings due to their excellent insulation. In infrastructure projects, PU composites are widely used in power poles, railway sleepers and cable trays for their durability, weather resistance and low maintenance costs.

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Picture: Covestro introduced the Baypreg^® STM polyurethane battery cover solution, developed with Chinese partner Liyang Shanhu, at the China Composites Expo, in Shanghai. This solution cuts battery cover weight by more than half compared to traditional steel shells. © Covestro