Trinseo has developed its first battery top cover based on thermoplastic polycarbonate unidirectional (PC UD) tape, marking a significant advancement in lightweight, fire-resistant composite solutions for next-generation electric vehicle battery systems.

Trinseo’s PC UD tape-based battery top cover.

Developed at Trinseo's Global Innovation Center in Europe, the technology addresses critical design challenges facing OEMs and Tier-1 suppliers as they work to reduce vehicle weight, improve battery safety and build more circular manufacturing platforms.

The battery top cover demonstrator made its global debut at the 18th China International Battery Fair (CIBF 2026), on May 13–15 in Shenzhen, China, and was also displayed at The Battery Show Europe 2026, on June 9–11 in Stuttgart, Germany.

A new approach to battery casing design

Built on Trinseo's flame-retardant PC UD tape technology, the battery top cover offers a compelling alternative to traditional metal- and thermoset-based designs. Available in thin-wall configurations of 1.0 mm and 1.5 mm, it supports industry efforts toward more circular vehicle platforms. 

“It illustrates how thermoplastic composites can support evolving EV battery casing architectures while addressing sustainability considerations and scalable manufacturing requirements,” said Oliver Becker, Vice President, Technology & Innovation, Plastics Solutions.

Trinseo's thermoplastic composite portfolio, encompassing UD tapes and organosheets, is designed with broad applicability across mobility sectors.

In addition to EV battery systems, these materials support a wide array of applications that use PC, including drones, robotics, urban air mobility and rail transportation, where lightweight structures, high stiffness and strength, thin-wall design, fire resistance, corrosion resistance and high-rate production are critical performance considerations.