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<2026> Battery Module / Pack Materials Technology Trends and Market Outlook (~2035)

The materials used in EV batteries are a critical part of the vehicle. While a significant amount of information has been published on the current status and future evolution of battery cell materials, relatively little information has been available on the materials used in battery modules and packs. Although battery cells account for a substantial portion of both material usage and cost structure, information on module- and pack-level materials has been limited. This report has been prepared to provide an overview of the primary applications of battery module and pack materials and their future development trends. The global market for EV battery packs used in BEVs and PHEVs is projected to grow at a CAGR of 10% from 2023 to 2035. On a pack basis, the market is expected to increase from USD 113 billion in 2023 to USD 367 billion by 2035. Excluding processing costs and profit margins associated with battery cell and pack manufacturing, the market for battery pack components is projected to grow from USD 27 billion in 2023 to USD 88 billion by 2035. Components required for battery pack assembly are expected to account for approximately 24% of the total battery pack cost.

In EV battery packs, a wide range of structural materials are used in addition to battery cells. However, as battery pack designs continue to evolve toward Cell-to-Pack (CTP) and Cell-to-Chassis (CTC) architectures to improve energy density, the use of cell-to-cell structural materials is expected to gradually decline. Battery pack components can be broadly classified into housing, BMS, thermal management systems, power electronics, wiring, and cell support structures. Technologies and products designed to prevent thermal runaway, one of the most critical safety issues in battery packs, are being continuously developed, and the number of related patents is steadily increasing. Cooling technologies that maintain a stable and uniform battery pack temperature during operation, as well as components associated with battery cell thermal runaway, are receiving increasing attention. In particular, a wide variety of materials are being developed to address thermal runaway before, during, and after an event, and the usage of these components is expected to continue increasing.

The strong points of this report are as follows.

① Provides a detailed analysis of technological and product developments in EV battery modules and packs.

② Covers the components used in EV battery packs in detail.

③ Examines the current status of battery pack components, the materials currently in use, and future material trends.

④ Focuses on thermal runaway in battery modules and packs, including thermal runaway prevention materials and their development trends.

⑤ Includes an overview of companies engaged in the production and development of battery module and pack materials.

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