At the Battery Show 2026 in Stuttgart, Germany on June 9-11, Envalior will showcase material innovations that improve the performance, safety, and lifespan of high-voltage batteries for electric vehicles (EVs) while also contributing to lightweight design.

Envalior will showcase material innovations for EV batteries at the Battery Show 2026. (Source: Envalior)

The focus will be on both existing technologies, such as lithium-ion batteries, and upcoming systems, such as sodium-ion and solid-state batteries.

Less stress cracking in busbars

Designed as a solution to rising temperatures in high-voltage battery and powertrain systems of EVs, XytronTM M5080ET is a new polyphenylene sulfide (PPS) for overmolding and functionalizing busbars.

The compound withstands temperatures above 150°C while also being particularly resistant to stress cracking during thermal shock. Thermal shock tests within a temperature range of -50°C and 180°C have confirmed that its stress cracking resistance is more than 70% higher than that of similar PPS compounds.

The new material is also flame-resistant and achieves V-0 classification in flammability tests according to UL 94. Due to these strengths, the material ensures the electrical safety and mechanical functionality of busbars over their entire service life.

XytronTM M5080ET is part of Envalior's broad portfolio of thermoplastics for busbars, which includes Durethan PA6, Akulon PA66, Pocan PBT, and ForTii PPA. It meets a wide range of requirements, including high tracking resistance, excellent electrical and insulative properties, and toughness.

Improving thermal shock resistance of battery junction boxes

Tailor-made for EV battery junction boxes are PBT compounds Pocan XHR and Pocan BFN Z. Such housings must meet strict thermal shock resistance requirements, as they are typically large, contain numerous metal inserts and often include integrated metal busbars.

Pocan XHR grades, such as Pocan B3233XHR, feature enhanced elongation at break, superior hydrolysis resistance, and excellent heat ageing performance. This balanced property profile improves significantly the thermal shock stability of the housings.

In addition, if high flame retardancy is required, the impact-modified Pocan BFN Z grades are the material of choice. Unlike conventional flame-retardant PBT grades they exhibit high elongation at break thus ensuring excellent thermal-shock behavior.

A highlight material in this context is Pocan BFN4221Z achieving an elongation at break of 2.9%. This grade meets stringent safety requirements. It attains UL 94 V-0 classification in all colors (0.4 mm) and exhibits a maximum Comparative Tracking Index of 600 (CTI A, IEC 60112), ensuring superior electrical reliability under high-voltage conditions.

Preventing thermal runaways in batteries

Envalior has developed a technology tool box based on Stanyl and Tepex for preventing thermal runaways in batteries. It inhibits the onset of such an event at the cell level, delays or stops its cell-to-cell propagation, and prevents it from spreading further through the battery system.

Stanyl SN-PURE forms a thin protective layer on the cell cathode surface, reducing heat generation during thermal abuse about one-third and interrupting self-accelerating reactions. Overall, the SN-PURE additive lowers the severity of single-cell events.

The continuous fiber reinforced thermoplastic Tepex acts as thermal barrier between cells and delays the propagation of critical temperatures to neighbor cells.

Positioned on top of the battery cells or modules at battery pack level, Tepex also helps to contain a thermal runaway already in progress featuring outstanding resistance to heat and particle bombardment.

As Envalior’s technology tool box acts at several levels, it can help to meet new "zero propagation" standards like China’s GB 38031-2025 mandate "no thermal propagation".