Coleitec Launches Coleitec SafePack?: Collaboratively Shaping the Composite Value Chain to Establish a New Benchmark for Power Battery Safety

By 2025, the electrification transition will accelerate as performance boundaries continue to be pushed, bringing battery safety back into the industry spotlight. Balancing energy density improvements with robust safety defenses has become the critical challenge in power battery system design.

On May 16th, at the new product release area of Hall 13 in the 17th Shenzhen International Convention and Exhibition Center, Coleitec officially launched its brand-new battery box product - Coleitec SafePack?. This is a systematic solution centered on composite materials and meeting the new national safety standards.

As a new generation of battery box products, Coleitec SafePack?, through the combination of multiple materials and integrated structural design, focuses on three dimensions: structural safety, thermal safety and electrical protection, to reconstruct the protection logic of the battery system. While achieving high integration, it also takes into account high safety, high adaptability and high cost performance, creating a new paradigm for safety performance in the industry.

New National Standard Released: Power Battery Safety Upgrade Imperative

According to data released by the Ministry of Public Security on January 17, 2024, by the end of 2024, China's new energy vehicle (NEV) ownership reached 31.4 million, accounting for 8.9% of total vehicles. Annual new registrations exceeded 11.25 million, representing over 40% of total registrations, as market penetration continues to rise and the electrification transition enters a critical phase.

However, safety risks associated with NEVs have become increasingly prominent. The 2024 NEV Insurance Development Report revealed that during January-November 2022, 38.67% of NEV fire incidents occurred while stationary, 22.67% during charging, 16% during operation, and 9.33% were collision-induced. Safety concerns now pose a tangible challenge to industry growth.

To establish robust safety lines and drive high-quality development, the Ministry of Industry and Information Technology (MIIT) recently released the mandatory national standard Safety Requirements for Traction Batteries in Electric Vehicles (GB 38031-2025), set to officially take effect in July 2026. Compared to the 2020 version, the updated standard significantly elevates safety thresholds with new testing requirements, earning the of "the strictest battery safety regulation." Key provisions include:

Structural Safety: The bottom structure must withstand three consecutive impacts from a 30mm-diameter hemispherical indenter at 150J energy, with no electrolyte leakage, casing rupture, fire, or explosion.

Thermal Runaway Safety: The entire battery pack must prevent fire or explosion after a single-cell thermal runaway event, ensuring smoke emissions pose no hazard to occupants.

High-Voltage Electrical Safety: After 300 fast-charge cycles, the battery must pass external short-circuit tests without fire or explosion.

The latest safety standard upgrades impose higher requirements and unprecedented challenges in material selection, structural design, and engineering processes for battery enclosures.

Technological Breakthrough: Coleitec SafePack? Composite Material Solution

As a National-level specialized and sophisticated "Little Giant" enterprise dedicated to the R&D and application of high-performance fiber-reinforced composites, Coleitec has launched the Coleitec SafePack? system solution in response to evolving power battery safety standards. By integrating systematic technological innovation, proven engineering solutions, and sustainable commercial value, this solution not only comprehensively enhances the safety protection capabilities of battery systems but also accelerates the industrial adoption and expansion of composite materials in electrification applications.

The Coleitec SafePack? system is composed of three key components: a high-performance composite upper cover, pultruded composite beams, and a multi-material hybrid lower enclosure, forming a complete"sandwich-structure" technical architecture. Through multi-material synergy, this system establishes holistic protection capabilities against thermal, mechanical, and electrical operating conditions, significantly enhancing the safety performance of the entire battery pack.

Upper Cover: A V0 flame-retardant high-performance composite upper cover, offering high design flexibility, robust structural performance, and superior functionality in insulation, flame resistance, weather resistance, and airtightness.

Pultruded Beams: V0 flame-retardant high-performance pultruded composite profiles, delivering a self-insulating structural solution with high modulus and ultra-high strength.

Lower Enclosure: A multi-material integrated lower enclosure designed for enhanced structural safety, thermal management, and electrical protection.

This highly integrated protective architecture is not an isolated technological breakthrough but is rooted in Coleitec’s proprietary molding processes and manufacturing systems.

In terms of materials and processes, the Coleitec SafePack? fully leverages the core advantages of composites—lightweight design, high flame retardancy, and electrical insulation—while enabling rapid single-step molding of complex geometries through high-efficiency liquid molding processes (e.g., RTM). This approach balances design adaptability with production efficiency.

Structural Design Advantages: The modular design and cold mechanical joining assembly method significantly reduce component count (50% fewer components compared to traditional l-d assemblies), lowering overall production line costs while improving assembly efficiency and energy efficiency. Additionally, the system’s exceptional airtightness, corrosion resistance, and electrical insulation ensure long-term operational reliability with enhanced environmental adaptability and quality consistency across the battery pack system.

In terms of adaptability，Coleitec SafePack? supports diverse technical pathways including plug-in hybrid (PHEV), range-extended electric vehicles, and battery electric vehicles (BEV), meeting the requirements of mainstream automotive platforms. Its structural protection capabilities adapt to safety tiers spanning impact energy resistance from 150J to 1500J (via spherical indenter testing), aligning with varied vehicle safety design strategies. The system accommodates flexible cell configurations such as prismatic, cylindrical, and pouch formats, delivering a unified solution applicable across multiple vehicle models.

d on the design of industrialization path, Coleitec SafePack ? The effective transition from material innovation to engineering mass production has been achieved, demonstrating good commercial potential while meeting safety performance requirements.

With the lightweight characteristics of composite materials, this solution can achieve a weight reduction of 20-30% compared to traditional steel or aluminum alloy enclosures, effectively optimizing the overall energy consumption performance of the vehicle; In the manufacturing process, the overall cost is reduced by more than 20% compared to the aluminum alloy box solution, further improving the cost-effectiveness of the entire package.

Under the increasingly stringent carbon emission and environmental protection policies, the advantages of Coleitec SafePack?'s green materials will empower OEMs to meet higher energy efficiency and environmental standards, seize dual benefits from policy incentives and market opportunities, and expand the value boundaries of their products.

Building an Industry Benchmark: Ushering in the "Composite Era" for Power Batteries

Coleitec SafePack? represents an ongoing commitment to advancing new energy safety systems. Looking ahead, its applications are expected to expand beyond passenger vehicle battery packs to high-risk thermal platforms such as electric buses, heavy-duty trucks, marine vessels, and aerospace power systems, driving electrification safety upgrades across industries.

The launch of Coleitec SafePack? marks another milestone in Coleitec’s innovation in composite materials. Key partners—including Sinochem Advanced Fiber, China Jushi, Huipu New Materials, Asahi Kasei, Ginewell, and FE Corporation—provided critical supply chain support during product development.

As power battery safety standards evolve, Coleitec will continue to leverage Coleitec SafePack? as a cornerstone, transforming composite solutions from isolated innovations into industry benchmarks. By collaborating with partners, the company aims to pioneer the "Composite Era" for power batteries, injecting safer, greener, and more efficient momentum into the new energy vehicle industry.