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Kevlar MicroCore for safer EV batteries

Superfine fibre material with potential to enable faster charging and higher power.

18th May 2021

Innovation in Textiles
 |  Japan


DuPont’s new Kevlar MicroCore is a highly temperature-resistant, superfine fibre material planned for use in battery separators to help address the growing demand for safer, more effective lithium-ion batteries for electric vehicles (EVs).

Unlike other materials currently used in battery separators, Kevlar MicroCore is inherently non-flammable and won’t shrink – even at temperatures up to 300°C. Throughout rigorous testing, it has demonstrated better li-ion transfer abilities in the battery separator, ultimately leading to potentially faster charging and higher power for EVs.

“This is the latest example of DuPont’s core role in electrification and providing solutions that will help advance sustainable mobility,” said Carlo Fiorella, global market manager at DuPont Automotive. “When used in battery separators, Kevlar MicroCore can help prevent the biggest safety issue for EV batteries –thermal runaway. Testing has shown that it may also enable EV batteries to charge faster and deliver higher acceleration power, addressing two key performance concerns for both consumers and EV manufacturers.” 

DuPont is working in collaboration with Nippon Kodoshi Corporation (NKK), the Japanese manufacturer of separators for energy devices, including li-on batteries, to bring the benefits of the material to the market, in its TopNove range of separators.  

Independent researchers at Yamagata University in Japan have tested the safety and performance of NKK’s TopNove made with Kevlar MicroCore and preliminary results have shown that in certain conditions it performs better than incumbent separators, such as ceramic coated microporous films.

“With its unique combination of properties, we believe Kevlar MicroCore is a real game changer that will take EV batteries to the next level of safety and performance,” said Fiorella. “What’s more, similar improvements can be achieved for advanced technology battery systems in use across other industries, such as aerospace, defence, medical, industrial, transportation, utilities or other critical commercial applications.”

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