SABIC, a global leader in the chemical industry, is reporting here at NPE2024 test results that underline the high potential of thermoplastic-based thermal runaway barrier solutions to help prevent fire spread in electric vehicle (EV) batteries. The SABIC sub-system level test series showed that a battery module box made from the company’s STAMAX 30YH570 long glass fiber polypropylene (PP) resin with intercellular thickness as low as 1mm has a potential to act as an effective thermal barrier solution by preventing thermal runaway propagation in 18650 cylindrical cells. It provides the necessary thermal insulation and flame resistance to reduce the chances of cell-to-cell propagation in a thermal runaway scenario and thus mitigate the risks of a catastrophic safety incident. This material in combination with compressible foams also has shown promising results to contain thermal runaway propagation in prismatic and pouch cells.

The new results build upon previous independent evaluations of SABIC’s STAMAX 30YH570 resin. In 2023, the product earned the UL Verified Mark from Underwriters Laboratories for effective flame delay performance. The assessment was based on UL 2596, the Test Method for Thermal and Mechanical Performance of Battery Enclosure Materials, using the thermal runaway box test.

“We are pleased to share this additional validation of our thermoplastic solutions’ strong potential for use in EV battery components and systems,” Fahad Al-Harthi, Global Director, Automotive, SABIC Polymers, said “Our portfolio of flame-retardant materials, combined with our expertise in application design and fire-polymer interaction, can help enable new thermal runaway barrier approaches. We look forward to continued collaboration across the automotive value chain to help improve the safety, efficiency and performance of EV battery systems.”