The American Journal of Interdisciplinary Innovations and Research
85
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Type
Original Research
PAGE NO.
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10.37547/tajiir/Volume07Issue08-10
OPEN ACCESS
SUBMITTED
28 July 2025
ACCEPTED
08 August 2025
PUBLISHED
27 August 2025
VOLUME
Vol.07 Issue 08 2025
CITATION
Saloni Agrawal. (2025). High-Performance Polymers for Faster Cars:
Advancing Electric Vehicle Battery Systems- A Comprehensive Review. The
American Journal of Interdisciplinary Innovations and Research, 7(8), 85
–
96.
https://doi.org/10.37547/tajiir/Volume07Issue08-10
COPYRIGHT
© 2025 Original content from this work is licensed under the terms of
the Creative Commons Attribution 4.0 License.
High-Performance
Polymers for Faster Cars:
Advancing Electric Vehicle
Battery Systems- A
Comprehensive Review
Saloni Jitendra Agrawal
Staff Supplier Industrialization Engineer, Lucid Motors, California;
MBA Candidate, California Institute of Advanced Management
Abstract
-
The electric
vehicle
(EV) revolution
demands new materials
that address performance,
safety,
and
sustainability imperatives.
High-
performance
polymers
are
emerging
as essential replacements for heavy metals and brittle
glass in electric vehicle battery systems, where they
offer weight
reduction,
insulation,
thermal
management,
and
fire hazard
solutions.
This paper explores how high-performance
polymers can help enhance EV performance by offering
lightweight, high-durability,
thermally
and
electrically feasible alternatives to traditional metals
and glass. By the analysis of some of the most
significant polymer families, such as polyurethanes,
epoxies, and glass-filled nylons. A comprehensive
analysis of over 40 peer-reviewed papers, industry
reports, and technical standards was conducted to
analyze and detail their specific applications in thermal
management, electrical insulation, and mechanical
protection in high-voltage battery systems. The findings
emphasize the key role of
polymers in
the development of faster, safer, and more efficient
electric vehicles.
Keywords:
Electric
vehicles,
high-performance
polymers, high voltage battery systems, thermal
management, lightweight materials, sustainability,
electrical insulation, sealing and bonding, AIOps,
Industry 4.0, lightweight composites, e-mobility
innovation, advanced battery safety systems.
1. Introduction
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Electric vehicles (EVs) have made a remarkable
transformation from niche prototypes in the early 20th
century to mass produced automotive technology in the
21st century. Initially dominating the U.S. market in the
early 1900s due to their low noise while running and
ease of use, EVs lost prominence with the extensive
mass production of internal combustion engine (ICE)
vehicles.
However,
growing awareness of climate
change,
air pollution,
and dependence
on fossil fuels has stimulated renewed interest in zero-
emission transport (Hannan
et
al.,
2014).
The commercial success of the lithium-ion battery by
SONY in 1991 spurred the growth of EVs by enabling
lightweight, high-capacity, and efficient energy
storage. Battery
electric
vehicles
(BEVs)
are currently leading the decarbonization of the world.
Although they quickly obtained
very
considerable
traction
in
the market,
EVs
face very severe engineering problems. Large battery
packs carry considerable weight, reducing driving range
and efficiency as well as presenting risks of thermal
runaway and electrical hazards in high-voltage
environments.
Traditional application of metals to battery enclosures,
cooling,
and
protective
components provides little design freedom and
increases weight.
These
constraints require substitute materials capable of prov
iding mechanical strength, thermal stability, and
electrical insulation without compromising safety or
performance.
While
high-performance
polymers are current promises
—
with low
density,
chemical
resistance,
and
complex
formability,
their use in
high-voltage
EV
battery
applications is currently yet
to
be
thoroughly
explored in the fields of
optimal choice of
materials, processes,
and
long-
term response to thermal and mechanical stress (Saeed
et al., 2019; Zhang & Zhou, 2020). This gap is
particularly intense in multifunctional
polymer system integration capable
of substituting metals for thermal
management,
insulation,
mechanical shielding,
and
adhesion
applications.
This study endeavors to evaluate the potential of high-
performance polymers in EV battery systems by:
1. Identifying the most significant polymer families
and their functional performance compared to metal.
2.
Discussing their use in thermal management,
electric insulation, mechanical reinforcement, and
bonding applications.
3.
Measuring their impact toward weight
reduction, safety enhancement, and design flexibility in
high-voltage applications.
This research has potential to significantly impact the
material selection process for clean energy vehicles and
other high voltage products. Replacing the existing high
weight materials like metals, Original Equipment
Manufacturers (OEMs) can improve driving range,
robustness and vehicle efficiency. Moreover, this
research contributes to academic knowledge in the field
of automotive, polymer and material sciences. The
findings further contribute to industrial practice,
offering a summarized materials knowledge to leverage
for right material selection for the correct application
that balances performance, manufacturability and
safety in the next gen Battery Electric Vehicles (BEVs).
2. Best Polymers for High-Voltage Battery Applications
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Figure 1.
Estimated distribution of polymer types used in electric vehicle powertrain and electronics applications.
The majority is composed of polypropylene (33%), polyurethane (23%), polyamide (13%), and PVC (8%), with
smaller contributions from high-performance polymers and other engineering plastics.
Sources: ACT Group
(2024); Kuraray Elastomer (2023); ResearchGate (2020).
High-voltage (HV) battery systems in electric vehicles
demand materials that can withstand extreme thermal,
electrical, and mechanical stress while offering cost-
effectiveness, weight savings, and environmental
durability. Over the past decade, polymers have gained
importance in this application space, often replacing
heavier metals in structural and functional roles. Several
key classes of polymers have emerged as top contenders
in HV battery environments, including thermoplastics,
thermosets, and elastomers, each offering unique
strengths and limitations. The popular polymer families
used is shown in
Figure 1
.
2.1 Epoxy Resins
Among thermosets, epoxy resins are widely used due to
their excellent dielectric strength, chemical resistance,
and thermal stability. Their low shrinkage and
dimensional stability during curing make them ideal for
potting and encapsulation of battery cells (Chen et al.,
2021; Zhang & Zhou, 2020). Epoxies can be modified
with fillers like aluminum oxide or boron nitride to
improve thermal conductivity while maintaining
insulation properties (Zhou et al., 2023).
2.2. Polyurethanes (PU)
Polyurethanes (PU) are known for their flexibility,
adhesion, and ability to absorb vibrations, making them
useful for bonding and cushioning within battery
modules. While standard PUs have limited thermal
resistance, high-performance formulations can achieve
operating temperatures up to 120°C. Some hybrid PU
systems are tailored with fire retardant properties to
meet UL 94 V-0 standards (Singh & George, 2021).
2.3 Polypropylene (PP) & Polyamide (PA)
In the thermoplastic family, glass fiber-reinforced
polypropylene (PP-GF) and polyamide (PA) variants are
widely adopted in structural components like battery
enclosures, coolant channels, and module frames. PP-GF
offers high stiffness, low cost, and excellent chemical
resistance, though its performance at sub-zero
temperatures can be a drawback (Saeed et al., 2019).
Polyamides such as PA6, PA66, and PA12 exhibit
superior strength, wear resistance, and thermal
stability, making them suitable for parts exposed to
mechanical and thermal cycling. However, polyamides
are hygroscopic, which requires controlled processing
and conditioning (Kulkarni & Maiti, 2019).
2.4 Polyether ether ketone (PEEK)
Polyether ether ketone (PEEK) and other high-
temperature engineering polymers like polyphenylene
sulfide (PPS) and polyimides (PI) are gaining ground in
premium EV applications where thermal endurance
beyond 200°C is necessary. PEEK, for example, offers
exceptional creep resistance, flame retardancy without
additives,
and
compatibility
with
high-voltage
environments. These polymers are ideal for high-
reliability connectors, cable insulation, and contactor
housings (Zhou et al., 2023).
2.5 Elastomers
Elastomers such as EPDM and fluoroelastomers (FKM)
are commonly employed for sealing and gasketing.
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EPDM exhibits excellent ozone, UV, and weather
resistance, making it suitable for pack perimeter seals.
FKM provides outstanding chemical resistance to
aggressive battery electrolytes and high service
temperatures, albeit at a higher cost (Singh & George,
2021; Wang et al., 2023).
2.6 High-density polyethylene (HDPE)
, although less
common in functional battery internals, is used for non-
critical protective casings and routing channels due to its
impact resistance and lightweight nature. However, its
limited thermal and flame resistance restricts its use in
more demanding applications (Chen et al., 2021).
Emerging materials such as liquid crystal polymers
(LCPs) and polyaryletherketones (PAEKs) are also being
explored for ultra-high performance in niche
applications due to their unique molecular structures
that enable high dielectric strength and low water
absorption (Zhang & Zhou, 2020).
Overall, no single polymer meets all performance
criteria. The choice of material is highly application-
specific and often involves trade-offs between cost,
weight, processing, and safety compliance as listed in
Table 1
. With increasing regulatory pressure for
recyclability and sustainability, bio-based flame-
retardant polymers and thermoplastic composites are
poised to play a larger role in future battery system
design (Sustainable Polymers EV, 2024).
Table 1.
Common polymers in EV battery systems and their key traits
Polymer
Key Properties & Advantages
Limitations
PU
Good Flexibility, adhesion, sealing,
vibration dampening
Limited thermal resistance (Zhou et al.,
2023)
Epoxy
Excellent electrical insulation, structural
strength
Brittle, limited flexibility (Chen et al., 2021)
PP (Glass
Filled)
Lightweight, cost-effective, chemical
resistance
Poor impact resistance at low temps (Saeed
et al., 2020)
PA12, PA6,
PA66
High strength, chemical resistance,
thermal stability
Hygroscopic, needs drying (Zhang et al.,
2020)
PPS, PEEK, PI
High temperature, stability, flame
retardancy
Expensive, complex processing (Zhou et al.,
2023)
EPDM
Weather and chemical resistance, sealing
Poor mechanical strength (Singh & George,
2021)
FKM
Exceptional chemical and temperature
resistance
Expensive, less flexible (Wang et al., 2023)
HDPE
Lightweight, impact resistant
Lower temperature resistance (Kulkarni &
Maiti, 2019)
LCP, PAEK
High dielectric strength, low moisture
absorption
High cost, niche applications (Zhang & Zhou,
2020)
To understand the environmental impacts of each listed
material, quantitative lifecycle analysis comparison is
shown in Figure 2. When the different polymer families
to the widely used metals
–
aluminum and steel are
compared, we analyzed the two key indicators of
sustainable materials, i.e. the carbon footprint in
CO₂e/kg and energy consumption
in manufacturing in
MJ/kg. Aluminum takes the highest carbon footprint of
approximately 12 kg CO₂e/kg and ~200 MJ/kg energy to
manufacture due to its smelting process: steel, although
heavier and less fuel efficient has a much lower carbon
footprint of 2.
5 kg CO₂e/kg and ~35 MJ/kg energy
requirements. To overcome this challenge of choosing
between greener material or lighter material, advanced
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polymers can provide the right balance between weight
and their environmental impact. Common engineering
polymers
like Polypropylene (1.65 kg CO₂e/kg) and
polyethylene (1.48 kg CO₂e/kg) gives us larger carbon
savings. Nylons, especially PA66 and glass filled as seen
in the analysis have higher energy consumption in the
range of 150 to 180 MJ/kg due to its energy intensive
and chemically complex processing. The bio-composites
have significantly lower footprints and showcase a
strong sustainability case, their adoption in automotive
is limited currently due to the performance challenges
like mechanical strength and thermal limitations
(Koronis et al., 2013; Pil et al., 2016).
Figure 2.
Lifecycle analysis comparison of carbon footprint and manufacturing energy consumption for metals and
polymers used in EV battery applications.
Note.
Carbon footprint and energy consumption values compiled from
Arkema (2024), CarbonCloud (n.d.), PlasticsEurope (2014), U.S. Department of Energy (2022), and Wu et al.
(2021).
3.
Polymer Capabilities in EV Battery Packs
As shown in Figure 3, polymer composites are integrated
into multiple systems within an electric vehicle
powertrain. In current EV battery pack designs, these
materials serve critical roles across four main application
areas: thermal management, electrical insulation and
protection, mechanical and environmental sealing, and
adhesion/bonding. The following subsections examine
each of these categories in detail, highlighting the
specific functions, material choices, and design
considerations that enable optimal battery performance
and safety.
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Figure 3.
Electric vehicle powertrain layout showing major components. This image illustrates areas where
plastics are typically applied, such as motor housing, battery packs, and electronic controllers,
Reproduced from
EVReporter (2023).
3.1 Thermal Management
Plastics, as generally considered poor conductors of
heat, support a wide variety of thermally resistant
components in the car. Especially when heat can be
sensitive in the powertrain, as it directly impacts the
lifespan, safety, and performance of the battery pack.
This is one of the most critical applications polymers are
considered. Electric Vehicles, when first gaining
popularity in the 2010s, had several accidents involving
fires due to the battery pack experiencing thermal
runaway. This caused the consumer to slow down EV
adoption. Integrating AIOps into battery management
systems enables automated anomaly detection, real-
time
performance
monitoring,
and
predictive
maintenance, helping prevent thermal runaway before
it occurs.
3.1.1 Potting & Encapsulation
A wide variety of polymers are working to make the cars
thermally stable in powertrains. One of the major costs
per car is the potting and cell encapsulation. Two-part
polymer systems that cure in place when poured over
battery cells have been adopted to stop the thermal
runaway. Though the weight and cost of these systems
are something the top EV companies are currently
working on improving, the effectiveness for thermal
management and stability is unmatched.
Figure 4
explains how encapsulation can limit the thermal
runaway to only one cell and protect the fire from
propagating. Common polymers used are epoxy, PU,
and silicone systems are used for encapsulating battery
cells to improve shock resistance and thermal insulation
(Zhang & Zhou, 2020).
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Figure 4.
The use of protective materials around cells can prevent or delay thermal runaway propagation.
Source:
IDTechEx (2023)
3.1.2 Thermal Manifolds
Another key requirement for achieving battery
performance for longer range is maintaining the Li-ion
battery cells temperature typically between 15°C and
35°C (59°F to 95°F). Coolant Circulation systems are
designed to circulate the coolant in and out of the
battery cell. Nylon and PP composites are used in
coolant channel housings due to their thermal
resistance (Chen et al., 2021). The hoses can be of a
greater complexity in design to route the most optimum
way to reach most cells in the shortest time possible,
depending on the infrastructure. This required injection
molded connectors, usually with glass-filled polymers to
provide the mechanical strength to hold the extruded
pipelines together. The connections are critical sealing
joints that are made with barb heights, O-rings, and
wedding bands.
3.1.3 Insulation Covers
High-voltage components such as battery packs,
inverters, and electric motors generate significant heat
during operation, which, if unmanaged, can lead to
reduced efficiency, shortened component life, or safety
hazards like thermal runaway. To address these
challenges,
advanced
polymer-based
insulation
materials
—
including silicone foams, mica composites,
and aerogels
—
are widely adopted for their lightweight
structure, high dielectric strength, and excellent thermal
resistance (IDTechEx, 2023; Kuraray, 2023). These
materials are typically integrated into cell-to-cell
barriers, module housings, and encapsulants to limit
thermal propagation and improve thermal management
in confined spaces (Thermtest, 2024). In particular, the
use of flame-retardant polymers with low thermal
conductivity helps to isolate high-energy cells and
prevent cascading failure events in battery systems
(MDPI, 2023). High-performance polymers are integral
to advanced battery safety systems, serving as thermal
barriers, impact absorbers, and flame-retardant
enclosures to mitigate the effects of cell failure.
3.2 Electrical Applications
Not just limited to powertrain systems, most electronics
in an electric vehicle use polymers for protective
enclosures, brackets, and covers.
Several electrical components need a safe covering to
either hold or protect the contact with other
components. These covers can range from a simple
injection molded or thermoformed part to as
complicated as an insert molding with tens of sub-
components and intricate features. These can enhance
operator safety while installing or working close to any
conductors carrying electricity or heat. Multi-layer
PP/PA structures provide flame retardant and thermal
shielding capabilities (Wang et al., 2023). These covers
offer not just insulation but also help the shelf life of the
part, offering corrosion resistance. There have been
advancements in the coating processes, like powder
coating the long and complex profiles like low or
medium-voltage busbars. This powder-coated covering,
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usually referred to as sleeves, enhances the operator’s
safety, durability, and electrical insulation. The polymers
mainly used for such applications are epoxy resins.
As also listed in Table 2, Housing for PCBAs and
Connectors mainly use nylons. Glass-filled PA66 and
epoxy composites offer dimensional stability and
electrical insulation (Kulkarni & Maiti, 2019). Whereas,
in USB Modules, miniaturized components benefit from
polymers like PC/ABS blends with flame-retardant
additives (RadiciGroup, 2024).
Table 2.
Plastics Used in Electrical Components of EV Electronics
Component
Plastic / Polymer
Function in EV Electronics
PCB Substrate (PCBA)
FR-4 epoxy glass fiber
(or polyimide)
Provides structural board support, thermal
stability
PCBA Enclosure /
Housing
PA6 GF, PC/ABS
Mechanical protection, flame retardancy,
insulation
Connector / Wire
Overmold
PVC, PBT, TPE
Electrical insulation, environmental and
vibration sealing
Conformal Coating /
Potting
Epoxy, Acrylic,
Silicone/Urethane
Moisture and vibration protection, anti-EMI
USB/Infotainment/Sens
or Housing
PC/ABS, Silicone,
Acrylic
EMI shielding, vibration resistance, user safety
enclosure
3.3
Environmental and Mechanical Protection
Battery packs, being a highly safety critical system, need
isolation from debris and moisture for its optimum
performance. Polymers are extensively employed in the
form of foam gaskets, overmolded seals, and liquid-
applied sealants to safeguard the battery pack from
moisture, dust, thermal stress, and mechanical shock as
shown in
Figure 5
. The environmental sealing is designed
from materials like silicone foam, butyl-coated PVC, or
PU. Foam structures made from PU or EPDM also absorb
environmental stress (Singh & George, 2021). EPDM and
FKM-based gaskets prevent ingress of moisture and dust
in pack assemblies (Sustainable Polymers EV, 2024).
Over molded seals, typically manufactured using
elastomeric materials, provide enhanced protection
against environmental ingress and offer dimensional
stability, even in complex housing geometries (Envalior,
2024). Room temperature vulcanizing (RTV) silicones
and liquid gaskets are applied for gap filling and offer
excellent adhesion, flexibility, and thermal resistance,
making them ideal for use between modules or around
cable penetrations (Arkema, 2023). These sealing
materials must meet stringent automotive standards for
ingress protection (IP67/IP69K) and chemical resistance
to battery electrolytes and coolants, emphasizing the
importance of polymer formulation and material
selection in high-voltage applications (Wang et al.,
2023).
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Figure 5.
Sealing and thermal management components in EV electronics. The illustration shows common
materials and designs used for battery pack gaskets (e.g., silicone foam, EPDM), high-voltage connector seals (PBT
O-rings, FKM), BMS and ECU enclosures (PC/ABS, rubber gaskets), thermal interface materials (gap pads,
thermally conductive silicone), and cooling system seals (EPDM, fluorosilicone).
3.4
Adhesion and Bonding
Adhesives are extensively used to mate components
with or without a secondary sealing like mechanical
fasteners, welding, or crimping, depending on design
and service requirements (Loh et al., 2020).
In high-
voltage battery systems, adhesives not only bond parts
together but also contribute to structural integrity,
vibration damping, gap filling, and thermal management
(Zhang et al., 2022).
One of the main applications is Room Temperature
Vulcanizing (RTV) Sealants which are Silicone-based
RTVs widely used for flexible sealing (Arkema, 2023).
This is a good option for enclosing the top and bottom
halves of the battery enclosures and provide safety
against environmental contaminants. Integration of
adhesives with elastomeric seals is an increasingly
common design approach, where liquid gaskets, over-
molded seals, or form-in-place gaskets (FIPG) are used in
conjunction with mechanical fastening to ensure
redundancy and improved sealing performance (BASF,
2022).
4. Challenges and Future Trends
The most critical and emerging issue is the circularity of
polymers. End of life recycling needs to be further
increased as the current global percentage of plastic
waste recycled is projected to reach only 17% by 2060
without major policy intervention (OECD, 2022).
Research is going on to study recycled thermoset
matrices, as thermosets don’t have the ability to melt or
reshape. To improve sustainability and regulation
compliance, bio-based flame retardants are researched
further (Patil et al., 2023).
Lightweighting has great benefits to the overall range for
powertrain, giving more miles in full charge by reducing
energy consumption per mile. (Alonso et al., 2021). This
ever-emerging demand to light weight has opened more
possibilities for composites and polymers to replace
metals and glasses in the car. Fiber-reinforced
composites and engineering polymers can deliver 20
–
50% weight reduction compared to traditional
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aluminum or steel components with similar mechanical
performance (Das et al., 2020). Hybrid polymer-metal
designs have an upward trend in lightweighting
solutions, making polymer-based solutions even more
competitive in structural and semi-structural battery
components (Kakroodi et al., 2022).
Another technical challenge for the implementation of
polymers in battery packs is balancing between thermal
conductivity and electrical insulation. Most neat
polymers have thermal conductivity in the range of 0.1
–
0.5 W/m·K, which is insufficient for efficient heat
dissipation in densely packed modules (Wang et al.,
2021). Incorporating filler such as boron nitride,
alumina, or graphene, can increase thermal conductivity
while maintaining insulation, but often at the expense of
processability or mechanical toughness (Goli et al.,
2013; Hu et al., 2020).
Some challenges from a manufacturing standpoint have
long been the flashing of molten polymers between
parting lines, smooth de-gating, warpage, shrinkage and
maintaining profiles. Advanced CAE simulations are
employed to predict the mold design accuracy in
development stages. (RadiciGroup, 2024; Lan et al.,
2023) The adoption of Industry 4.0 technologies, such as
IoT-enabled molding equipment and data-driven quality
control, is optimizing the production of high-
performance polymers for EV battery enclosures.
5. Integration of Polymers in EV Battery Pack Design
With the options of manufacturable polymer and
composites growing every day, it is important to choose
the most cost-effective material that can serve all the
requirements of the part in the battery lifespan. For
example, glass fiber
–
reinforced polyamides and
polypropylene composites are widely used for module
frames and coolant distribution components, delivering
high stiffness, lightweighting, and chemical resistance
(RadiciGroup, 2024). Elastomers such as EPDM and
fluorosilicone provide environmental sealing, enabling
high ingress protection ratings and accommodating
thermal expansion mismatches (BASF, 2022; Lan, Wang,
& Hu, 2023).
Overmolding, insert molding, sandwich compression
molding are some of the newer approaches to building
parts with several different plastic, rubber and metals
combined, significantly increasing the functionality of a
single part. This improves the seal integrity in the long
term as well (BASF, 2022). In addition, co-extrusion and
multi-material molding enable the integration of
electrical insulation layers directly into structural
housings, further improving assembly efficiency (Lu et
al., 2021). Proper interface adhesion between dissimilar
polymers is critical to avoid delamination during
vibration or thermal cycling, a challenge addressed
through surface treatments and primer chemistries
(Zhang, Sun, & Luo, 2022).
6. Conclusion
Today, we are maximizing the purpose every single
component serves in the powertrain, fighting to save
every millimeter of space and gram of weight possible.
Polymers and composites have enabled some of the
most powerful and efficient electric vehicles ever built,
offering multifunctionality that goes far beyond simple
structural support (Alonso et al., 2021; Kakroodi et al.,
2022). The continued advancement of material science,
manufacturing technology, and design innovation can
push the boundaries of what engineering can achieve in
e-mobility innovation. With each passing day, we collect
more data on polymer performance under real-world EV
conditions, deepening our understanding of their true
capabilities (Lan et al., 2023). This growing knowledge
base fuels a cycle of innovation
—
where insights from
field performance inform the next generation of
polymer formulations, designs, and applications
—
ultimately leading to lighter, safer, and more sustainable
electric vehicles.
Emerging priorities include the development of
thermally conductive yet electrically insulating polymer
composites, bio-based flame-retardant materials, and
design-for-recyclability approaches that meet global
regulatory targets (Patil et al., 2023; Hu et al., 2020).
With the transition toward solid-state batteries,
polymer roles will continue to evolve
—
shifting toward
dielectric optimization, multifunctional integration, and
compatibility with next-generation manufacturing
technologies (Lu et al., 2021).
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