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Journal of Polymer & Composites Review Article Special issue

Engineering Polymer Innovations for Improved Battery Safety and Vehicle Efficiency: A Comprehensive Review

  1. Sunil Kumar Gupta Department of Electrical and Electronics Engineering, Poornima University, Jaipur
  2. Pragyan Paramita Mohanty Department of Mechanical Engineering, Veer Surendra Sai University of Technology, Burla
  3. Babita Jain Department of Electrical and Electronics Engineering, Navkis College of Engineering, Hassan
  4. Atul Kulshrestha Department of Electrical Engineering, Arya College of Engineering, Jaipur

Abstract

Electric vehicles (EVs) are high-power systems that require high-quality materials to ensure safety, reliability, and performance under extreme operating conditions. Polymer materials have become critical engineering materials in meeting these requirements due to their lightweight nature, design flexibility, durability, and high electrical insulation capability. Consequently, polymers are widely used in key EV components, including battery enclosures, module frames, thermal interface materials, wiring insulation, and lightweight structural parts.

Recent developments in polymer science—particularly in polymer composites and multifunctional engineered materials-have led to significant improvements in thermal conductivity, flame retardancy, and mechanical strength. These enhanced properties play a vital role in mitigating thermal runaway, extending battery life, and improving overall vehicle efficiency. In addition, technologies that promote recyclability and reduce environmental impact, such as bio-based polymers, recyclable thermoplastics, and circular manufacturing models, are gaining considerable attention in support of sustainability goals.

Despite these advances, challenges remain, including achieving high filler loadings, ensuring long-term durability, and maintaining cost-effectiveness, all of which continue to be active areas of research. Future directions include the development of smart polymer systems and intelligent material design aligned with evolving EV architectures. Overall, continuous innovation in polymer materials is essential for enhancing energy efficiency, occupant safety, and sustainability, positioning engineering polymers as key enablers of the large-scale adoption of electric mobility.

Keywords

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