Powering the energy transition: A new polypropylene concept for battery pouch cell laminates

Borealis has introduced a new three-layer cast polypropylene (cPP) concept for polymer-aluminum laminate for lithium-ion battery (LIB) pouch cells.

September 12, 2025 – Borealis has introduced a new three-layer cast polypropylene (cPP) concept for polymer-aluminum laminate for lithium-ion battery (LIB) pouch cells.

With a strong heritage in the energy and mobility sectors, and deep expertise in flexible packaging, Borealis is uniquely positioned to meet the complex requirements of LIB pouch films—ensuring safety, durability, and efficient processing.

The three-layer cPP polymer-laminate structure delivers:

·Efficiency through excellent deep-drawing behavior in cell manufacturing

·Safety via hermetic pouch seals and high seal strength

·Durability enabled by robust laminate bonding and adhesion

As battery production scales in regions, the ability to source materials locally is becoming a strategic advantage. Portable energy storage is not only a key enabler of decarbonization—it also supports strategic autonomy and a wide range of applications beyond electric vehicles. This aligns with initiatives like the EU Battery Booster package, as well as major public investments and regulatory frameworks across Europe—such as the EU’s Horizon Europe and Innovation Fund. These are designed to accelerate battery manufacturing, secure critical raw materials, and strengthen energy resilience as well as industrial competitiveness.

This project is a testament to the power of collaboration. From the Borealis innovation lab to film producers, laminators, adhesive experts, battery technology advisors, and cell manufacturers—our partners in all areas bring valuable expertise. 

Following successful internal testing and promising trials with customers, the solution is now entering the next phase of validation with an independent testing institute specialized in battery technology.