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Battery, Battery Materials, EV

 

 

 <2023 Edition> Battery Module Pack Material Technology Trend and Market Outlook

 

According to SNE Research, a market research firm specializing in secondary batteries and electric vehicles, the global EV market (BEV+PHEV) is expected to grow at an annual average of 21% from about 10 million units in 2022 to about 50 million units in 2030. Therefore, thanks to the growth of the battery market, the battery pack market will also grow high by 2030, and the size of the market is as follows.

 

 

 

'22

'25

'30

Pack Market

68

146

321

unit : Billion $

(2023 Battery Module Pack Material Technology Trend and Market Outlook, SNE Research)

 

Therefore, an understanding of the size and market of elements such as BMS, power unit, harness, inter-cell components, housing, and heat dissipation, which are the components that make up such a pack, is expected to provide many opportunities to the growing battery pack market. For example, materials such as Al(aluminium) / carbon fiber reinforced composite material / plastic / steel are used, and the recent development direction of the housing includes consideration of weight reduction, compliance with electromagnetic wave regulations, and thermal management.

 

EV is a vehicle in which driving power is transmitted to lithium-ion batteries, electric drive motors, reducers, and wheels. The power train does not require special maintenance during the warranty period, and periodic maintenance such as replacement of filters is required. The first part that breaks down in an electric vehicle is a battery, and the body, power electronics, and motors tend to have a long life.

Battery accounts for 40-50% of the production cost of EV, and it is urgent to secure the price competitiveness of battery packs for the growth of the EV market.

 

In the vehicle market, the use of materials occupies a large part. Some materials used in electric vehicles are almost similar to those used in internal combustion engines. This is especially true of the parts that make up the body, chassis and interior. However, the main difference between the two is the powertrain. Internal combustion engine and other powertrain components are replaced by batteries and electric motors in electric vehicles. Unlike the internal combustion engine powertrain, a very different material is considered for lithium-ion batteries and battery packs. The powertrain of an internal combustion engine vehicle is generally made of iron or aluminum alloy.

 

At the same time, these materials can be seen to be in great demand in electric vehicles. Cobalt, copper, graphite, lithium, manganese, and nickel are expected to be in high demand in the next decade. With the exception of the EV market, such big demand is not easy to see.

 

        

EV-only integrated platform (Modular Platform) is the mainstream and has the following characteristics.

     Change to a skateboard-type platform considering the ride & handling aspect of the vehicle, assemblability, and serviceability aspect

     The recently launched EV is a dedicated platform for OEMs and applies to vehicles of various sizes

     The capacity expansion of the battery pack according to the driving distance addition facilities -> Modular pack is possible

     Combining and standardizing parts and simplifying assembly lines becomes possible -> Reducing costs per vehicle

     Delivered in standardized cell or CMA form, pack assembly becomes possible in OEM

 

After analyzing the pack level information of the recently released major electric vehicles, it has a wide variety of designs and specifications by company, and the number of cells and chemical composition evolve as the generation is repeated.

     Audi and VW used NCM622 cathode materials and NG anode materials of LGES, NCM622+NCA cathode materials and NG+AG anode materials of SDI, and NCM712 of LGES for ID.4.

     BMW used SDI's NCM111 and 622 and now applies NCA, and also used CATL’s NCM523 and now applies 811

     Hyundai-Kia Motors is applying SK On's NCM811 cathode materials and NG anode materials to the e-GMP application model

     Tesla is applying cylindrical NCM811 and NCA, and recently applied CATL’s square LFP.

 

        

Energy density is improving, which is seen as a result of increased energy density of battery cells and improved battery pack material selection and pack design technology.

     The average energy density of EVs released before 2020 is 131Wh/kg, and vehicles recently launched on EV-only platforms are expected to exceed the average of 150Wh/kg to 187Wh/kg by 2025.

     Energy density is expected to increase further due to battery packs that incorporate the Module-less concept, such as Cell to Pack technology.

 

 

In this report, we describe changes in terms of materials used in accordance with the development trend of battery packs. We describe changes in battery pack materials in accordance with development directions such as light weight, improvement of EV battery density, and stability issues due to TP technology. In addition, it includes elements such as element technology (welding/soldering) necessary for the material to be bonded to the battery pack, and information on the direction of thermal runaway prevention technology.

 

Strong point of view of this report

- See the division and prospects from EV to the four major materials and battery packs market

- Know the configuration and information of the battery cell type (pouch/cylindrical/square)

- Learn about the EV platform for each vehicle OEM

- See the specifications of these battery packs, energy density, and so on

- Know about the material used for the various annexes of manufactures comprising the battery pack

- See the technique of bonding these components

- Find information about the companies participating in the above pack manufacturing technology

 

 

-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 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

Seperator Film

Electrolyte

 

Part 2. 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

     Main Components of Cell

Cylindrical / Square / Pouch Type

     Materials of Battery Packs (Major Material Companies)

Henkel / Toray / Lanxess /                      

Ascend / BASF / DuPont / Tesla

 

Part 3. Major Materials Included in Cell, Module, Pack

     Material Required for EV Battery

     Main Material to be Presented in the Report

     Changes of the Battery Cell Chemical Composition: High Ni

     Energy Density of Battery Cell and Pack Level

     Configuration of Battery Pack Main Parts

 

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 a Module-free Battery Pack

-BYD CTP Pack

-CATL CTP Pack

Application of Hybrid Battery Pack

Systems of AB Battery Pack

 

Part 5. EV Battery Pack Specification Analysis

     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 1

     Major EV Battery Pack Specification Summary 2

     Major EV Battery Pack Specification Summary 3 (Usable energy)

 

Part 6. Main Components of the Pack

     Cell Construction Materials and Components

Lithium-ion Secondary Battery

Types of Cathode Material

Types of Anode Material

Types of Separator Film

Types of Electrolyte

Main Component for Each Types of Battery Cell

     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

     Housing (Tray, Cover, Gasket) and 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

     Flame Resistant Material for the Pack Protection and Solution

Thermal Runaway

Necessity of the Battery Pack Flame Resisting

Thermal Runaway Prevention Solution

     Inter-cell Components and Materials

Component Materials Comprising Modules (cylindrical, square, pouch-type)

Insulating Material between cells (Foams)

Compression pad

Connecting Electrical Components (Busbar, FPCB)

Summary of Connecting Electrical Components Materials (Copper, Al)  

Connecting Component Junction Technique (Soldering / Welding)

 

Part 7. Major Companies Status

     Cell

Cell gasket

: Sang-A Frontec

Cell can

: Sangsin EDP

Dongwon Systems

Cell pouch

: Youlchon Chemistry

     Module and Pack

Busbar & ICB Assembly

KET / Younghwa Tech / LS EV Korea / Hyunwoo PCB / Daeduck Electronics

Harness Assembly

Yura Corporation / Kyungshin

Housing Assembly

Hanjoo Metal / Aluko / Inzi Controls / Shinsung Delta Tech

Thermal Management System

Hanon Systems

Thermal Management Materials

WACKER / Saint-Gobain PPL

Pack gasket

Dong-A Hwa Sung

Pack Module Manufacturing                           

Sebang Lithium Battery / Amada Weld Tech Korea / Trumpf Korea