The lithium-ion batteries in electric vehicles (EVs) present very different material demands at the cell- and pack-level compared with the internal-combustion engine (ICE) vehicles they replace. Whilst ICE drivetrains heavily rely on aluminium and steel alloys, Li-ion batteries utilise a great deal of materials such as nickel, cobalt, lithium, copper, insulation, thermal interface materials and much more at a cell- and pack-level. The markets for these materials will see a rapid increase in demand that would not have been present without the take-off of electric vehicle markets.
This new report from IDTechEx identifies and analyses trends in the materials used for the assembly and production of battery cells and battery packs in the EV market. The report also provides granular market forecasts from 2021-2031 for over 20 key material categories in terms of demand in tonnes, in addition to market value.
An extensive database, collated by IDTechEx, of over 300 battery-electric and plug-in hybrid passenger car variants, is further used to determine trends in the battery cell and pack energy density, energy capacity, cell geometry, cell chemistry and thermal management strategy, leading to a comprehensive set of material demands and market value forecasts.
IDTechEx forecasts over 20 materials used in the construction of electric vehicle battery cells and packs, each with shifting market shares. Several materials see a rapid increase in market share whilst others are being reduced to improve energy density or supply chain concerns. Source: IDTechEx report, Materials for Electric Vehicles Battery Cells and Packs 2021-2031.
Battery Cell Materials
OEMs are changing the way they make batteries. Improvements to energy density are one key consideration but also the sustainability of the materials used. Many materials involved have questionable mining practices or volatile supply chains. One such material is Cobalt, which in addition to being very expensive, has its supply and mining confined mostly to China and the Democratic Republic of Congo. As a result, OEMs are trending towards higher nickel cathode chemistries like NMC 622 or NMC 811 in some new models.
Up until 2018, the Chinese electric car market was predominately using LFP cathodes. This has now transitioned such that as of 2019 only 3 % of cars utilised LFP batteries. However, Tesla has now introduced the LFP Model 3 made in China which could upset this trend. Additionally, LFP is used extensively for markets like Chinese electric buses. Despite the reduction in market share of materials like cobalt, the rapidly increasing market for electric vehicles will drive demand for cobalt and many other materials drastically higher over the next 10 years.
Materials forecast for battery cells include aluminium, carbon black, casings, cobalt, copper, graphite, iron, lithium, manganese, nickel, silicon and polyvinylidene fluoride (PVDF).
Battery Pack Materials
Whilst the energy density improvements of Li-ion cells might be the most prominent battery improvements in the public eye, we are also seeing an increase in pack-level energy density at a greater rate than just cell-level improvements. Manufacturers are improving their battery designs, the mass of materials being used around the cells is steadily being reduced, allowing for a lighter battery pack or more cells to be used for the same mass. The choice of materials for several pack components also affects these improvements. More interest is being paid to composite enclosures for light-weighting, fire-retardant materials, thermal interface materials and much more. The thermal management strategy also impacts these choices, with increased energy density and consumer demand for fast charging, the thermal management must be more effective, but also present a smaller and lighter package. Several materials see a decrease in utilisation per vehicle, but this is often overshadowed by the rapidly growing market for EVs.
Battery pack materials forecasted include aluminium, copper, thermal management materials, thermal interface materials, steel, glass fibre reinforced polymers, carbon fibre reinforced polymers, inter-cell insulation, compression foams and housings and pack fire-retardant materials.
IDTechEx considered over 160 battery-electric and plug-in hybrid cars sold between 2015-2020 to show trends in energy density by thermal management strategy and by year. Full data available in IDTechEx report, Materials for Electric Vehicle Battery Cells and Packs 2021-2031.
Report Summary
Materials demand from the following EV components and parts are considered:
• Cathodes
• Anodes
• Electrolyte, separators, binders and casings
• Interconnects
• Housings
• Thermal management
• Thermal interface materials
• Inter-cell pads and insulation
• Fire-retardant papers/blankets/coatings
Market assessments:
- Trends in battery cell composition and energy density: cathodes, anodes, electrolyte, binders and casings
- Battery cell and pack design with automotive use cases and energy density breakdowns by cell type and thermal management strategy
- Thermal interface materials for electric vehicle batteries
- Battery pack enclosure and interconnect materials
Forecast lines, material demand and market value (2021-2031):
- Cathode materials
- Anode materials
- Battery cell materials
- Thermal interface materials
- Battery pack materials
- Combined cell and pack materials
Vehicle segments forecast:
- Cars
- Buses
- Vans
- Trucks
- Two-wheelers
