DuPont Announces New Kevlar MicroCore for Use in Electric Vehicle Batteries

DuPont today announced the introduction of new groundbreaking development – DuPont Kevlar MicroCore, a unique, high-temperature-resistant, superfine fiber material planned for use in battery separators to help address the growing demand for safer, higher-performing 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, Kevlar MicroCore has demonstrated better lithium-ion transfer abilities in the battery separator, ultimately leading to potentially faster charging and higher power for EVs.

“New Kevlar MicroCore is the latest example of DuPont’s core role in electrification and providing innovative solutions that will help advance sustainable mobility,” said Carlo Fiorella, global market manager, 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), a Japan-based forward-thinking manufacturer of separators for energy devices including lithium-ion batteries, to bring the benefits of this innovative material to the market with NKK’s TopNove made with DuPont Kevlar MicroCore. NKK’s capability and expertise in producing thin and uniform paper made them an ideal collaboration partner for this specific project.

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

“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, defense, medical, industrial, transportation, utilities or other critical commercial applications.”



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