Global EV Battery Separator Market Size, Share, Opportunities, And Trends By Material Type (Polyethylene (PE), Polypropylene (PP), Ceramic-Coated Separator, Composite Separator, Others), By End-Use Application (Electric Vehicles (EVs), Hybrid Electric Vehicles (HEVs), Plug-in Hybrid Electric Vehicles (PHEVs)), And By Geography - Forecasts From 2024 To 2029

The global EV battery separator market is expected to account for a compound annual growth rate of  11.97% and increase from US$2.869 billion in 2025 to account for US$ 5.049 billion in 2030.

Battery separators are materials that act as a barrier between anode and cathode and help in enabling lithium-ion exchanges. They play a critical role in the electric battery market, ensuring the safety of the battery, as they isolate anodes and cathodes. In electric vehicles (EVs), the battery separators also help in improving the performance and efficiency of the battery, and in reducing waste. A multi-cell battery consists of an anode and a cathode that are separated from each other by an insulator known as the battery separator. Additionally, the separator is soaked in an electrolyte that assists in the flow of ions from the cathode into the anode when the battery is being charged while opposing the same process when the battery is being discharged. This type of separator is a non-conductive electrical insulator. Separators are key components within the battery components and even have to be present since they keep the anodes and cathodes apart without preventing the movement of lithium ions (Li-ion) between them. In the. contemporary Li-ion battery models, the cell volume occupied by the separator containing electrolyte is nearly three percent of the cell volume.

The increasing global production of electric vehicles will boost the global demand for EV battery separators. The production of electric vehicles worldwide has witnessed major growth due to the increasing governmental initiatives towards the sector. The International Energy Agency, in its report, stated that in 2023, the total EV stock of battery electric vehicles (BEVs) in China was recorded at 16.1 million. In Europe and the USA, the total EV stock was recorded at 6.7 million and 3.5 million, respectively. The EV stock witnessed significant growth from 2022, with a total stock of BEVs in China recorded at 10.7 million, with 4.4 million of stock in Europe and 2.1 million in the USA

What are the EV battery separator market drivers?

• The growing global demand for electric vehicles is projected to propel the EV battery separator market expansion. 

A major factor propelling the growth of the EV battery separator market is the increasing global demand for electric vehicles. The EV battery separator plays a critical role in offering an optimum and efficient battery performance. The global demand for EVs has increased significantly over the past few years, primarily due to the increasing consumer preferences toward sustainable automotive solutions. 

The International Energy Agency, in its global EV sales report, stated that the total sales of electric vehicles witnessed a major growth. The agency stated that in 2021, the total global sales of battery electric vehicles were recorded at 4.7 million, which increased to 7.3 million in 2022. In 2023, the total sales of battery electric vehicles were recorded at 9.5 million. 

The rising demand for EVs provides the opportunity for the availability of battery separators and more requirements of performance-oriented batteries for EVs. While these battery separators merely separate the anode from the cathode but permit ion passage, the global growth for demand in battery separator production in the EV category rises from the need around this sustainable channel of mobility-from making efficient and reliable battery separators.

In 2023, about 14 million electric cars were sold, of which ninety-five percent found owners in Europe, China, and the United States. Compared to 2022, this figure represents a 35% increase, with 3.5 million more registered EVs. The total number of electric cars that ended up on roads worldwide rose to 40 million, according to the Global EV Outlook of the International Energy Agency (IEA). The IEA data further showed that the sale of electric cars increased from 13.7 million in 2023 to 16.6 million units by 2024.

Moreover, manufacturers are increasing battery capability so that the driving range is longer. While separators that can withstand very high energy densities and temperatures need to be developed, such research and development have been conducted with safety as the primary focus for the EV industry, clearly recognizing that short circuits and thermal runaways can be avoided with separators of very high quality. This will provide an opportunity for market expansion in the coming years.

• Rising cost of diesel and petrol, is anticipated to fuel the EV battery separator market expansion. 

Rising interest in electronic drive vehicles (EDVs) is predicted to propel because people are demanding more fuel-efficient, high-performing, and less emission-based vehicles. The other factor of the industry is powered by lithium batteries, allowing for hybrids, plug-ins, full battery electrics, and vehicles like buses, taxis, and fleets, among others. Within this range of EDV battery cell configurations, Celgard lithium-ion battery separators have advantages in safety and energy, power performance optimal combinations. The company provides various separator solutions to address the several performance needs of EDV systems, including safety, chemical and dimensional stability, and cycle life.

Furthermore, Tekra’s Mylar and Melinex polyester films are provided in various thicknesses for use in lithium-ion battery insulation and separators, Kaladex films from DuPont Teijin Films are PEN films offered in considerable varieties of thicknesses alongside Teonex films from Toyobo Film Solutions Limited. 

Another illustration of this is SETELA, which Toray Industries provided. This is a battery separator film of high performance and great reliability. It is often used as a separator material in secondary lithium-ion batteries in consumer electrical accessories and electric automobiles. Similarly, in November 2022,  General Motors and Microvast made a joint venture to build a separator factory in the US. The new plant and separator project received support from a $200 million grant awarded to the US Department of Energy from its Battery Materials Processing and Manufacturing Initiative.

Currently, EVBs employ lithium-ion batteries only, and this trend is believed to continue in the coming years. Moreover, when designing and operating Li-ion batteries and related systems for the market, producers make sure that environmental, sustainable development issues such as appropriate life cycle management (repair and reuse, recycling or disposal) are addressed. Rising demand for batteries is also expected to fuel the EV battery separator industry's growth. In 2022, the demand for automotive Li-ion batteries increased by approximately 65%, reaching 550 GWh, compared to around 330 GWh in 2021. This growth was primarily driven by a 55% rise in new registrations of electric passenger vehicles during the same period.

Additionally, there was an increase of more than 70% in battery demand for cars in China, coupled with an 80% growth in sales of EVs in 2022 as compared to 2021. However, this rise in battery demand was further mitigated by a higher percentage of plug-in hybrid electric vehicles (PHEVs). The battery consumption for vehicles in the United States went up by close to 80% in 2022, while the sales of EVs went up by about 55%. The sales volume of BEV and PHEV worldwide has started surpassing that of HEV, and as the battery capacity of BEV and PHEV is on the rise, so is their battery demand.

What are the key geographical trends shaping the EV battery separator market?

Based on geography, the embedded finance market is segmented into North America, South America, Europe, the Middle East and Africa, and the Asia Pacific. Asia Pacific is anticipated to hold a substantial market share. The separation of EV batteries is forecast to be one of the lucrative markets in the Asia Pacific region owing to the growing usage of EVs within the region and the subsequent increase in the number of EVs manufacturing companies. In particular, China, Japan, and South Korea will lead the nations as they provide some government policy and funding for battery development while encouraging green energy techniques. Additionally, as this region leads in EV manufacturing, high-performance battery separators that are important for boosting battery performance and safety are in high demand.

According to statistics on EV sales published by the Japan Automobile Dealers Association (JADA) and the Japan Mini Vehicle Association (Zenkeijikyo), a total of 58,813 Battery Electric Vehicles (BEV) were sold in Japan as of the end of 2022, such rise representing 2.7 times growth from 2021. The ratio of BEVs to total passenger car sales also termed the BEV ratio, grew to 1.7 in 2022, an increase from 0.6 percent in 2021 before crossing the 1 percent figure for the first time. Further, BEV Sales in Japan would also cause sales of BEV motor vehicles to increase due to the strict target of 100% clean vehicles in the country set for 2035 while also considering the benefits of EVs outdoors.

Further, as stated by the IEA, it is estimated that 95% of the electric LDV lithium ion phosphate batteries used in the region were sourced from China, with BYD holding the largest market share at 50%. Tesla provided 15%, with its share of LFP batteries growing from 20% in 2021 to 30% in 2022. LFP batteries are used in around 85% of the cars manufactured by Tesla, most of which are produced in China.

Nonetheless, battery prices depend on the region, with the lowest being in China and the highest in the remainder of the Asia Pacific region. The differences in pricing are because approximately 65 percent of battery cells are manufactured in China, while more than 80 percent of cathodes come from there. This fast-changing scenario reinforces the importance of Asia Pacific in shaping the market for EV battery separators, which is aggressively competitive in establishing and enhancing technology to meet increasing demands.

Key developments in the EV battery separator market: 

• In April 2024, Asahi Kasei announced the plan to construct a fully furnished production facility in Ontario, Canada, to produce and coat Hipore’s wet-process lithium-ion battery (LIB) separators. Asahi Kasei reached a basic understanding of this plant with Honda Motor Company Limited, and the two have held negotiations on the subject of joint investment.
• In January 2024, 24M featured a new battery separator known as 24M ImpervioTM, which is set to revolutionize the battery industry. It targets battery safety, mostly in electric automobiles, energy storage systems (ESS), and even consumer goods. With this technology, lithium-ion and lithium-metal batteries will achieve better safety than before. Thus, explosions and product recalls associated with materials such as metallic dendrites, faulty alignment of electrodes, and lithium dendrites will be prevented.

The Global EV Battery Separator Market is segmented and analyzed as below:

• By Material Type
  • Polyethylene (PE)
  • Polypropylene (PP)
  • Ceramic-Coated Separator
  • Composite Separator
  • Others
• By End-Use Application
  • Electric Vehicles (EVs)
  • Hybrid Electric Vehicles (HEVs)
  • Plug-in Hybrid Electric Vehicles (PHEVs)
• By Geography
  • North America
    • United States
    • Canada
    • Mexico
  • South America
    • Brazil
    • Argentina
    • Others
  • Europe
    • United Kingdom
    • Germany
    • France
    • Spain
    • Others
  • Middle East and Africa
    • Saudi Arabia
    • UAE
    • Isreal
    • Others
  • Asia Pacific
    • Japan
    • China
    • India
    • South Korea
    • Indonesia
    • Thailand
    • Others

1. INTRODUCTION

1.1. Market Overview

1.2. Market Definition

1.3. Scope of the Study

1.4. Market Segmentation

1.5. Currency

1.6. Assumptions

1.7. Base and Forecast Years Timeline

1.8. Key benefits for the stakeholders

2. RESEARCH METHODOLOGY  

2.1. Research Design

2.2. Research Process

3. EXECUTIVE SUMMARY

3.1. Key Findings

4. MARKET DYNAMICS

4.1. Market Drivers

4.2. Market Restraints

4.3. Porter’s Five Forces Analysis

4.3.1. Bargaining Power of Suppliers

4.3.2. Bargaining Power of Buyers

4.3.3. The Threat of New Entrants

4.3.4. Threat of Substitutes

4.3.5. Competitive Rivalry in the Industry

4.4. Industry Value Chain Analysis

4.5. Analyst View

5. GLOBAL EV BATTERY SEPARATOR MARKET BY MATERIAL TYPE

5.1. Introduction

5.2. Polyethylene (PE)

5.3. Polypropylene (PP)

5.4. Ceramic-Coated Separator

5.5. Composite Separator

5.6. Others

6. GLOBAL EV BATTERY SEPARATOR MARKET BY END-USE APPLICATION

6.1. Introduction

6.2. Electric Vehicles (EVs)

6.3. Hybrid Electric Vehicles (HEVs)

6.4. Plug-in Hybrid Electric Vehicles (PHEVs)

7. GLOBAL EV BATTERY SEPARATOR MARKET BY GEOGRAPHY

7.1. Introduction

7.1. North America

7.1.1. By Material Type

7.1.2. By End-Use Application

7.1.3. By Country

7.1.3.1. United States

7.1.3.2. Canada

7.1.3.3. Mexico

7.2. South America

7.2.1. By Material Type

7.2.2. By End-Use Application

7.2.3. By Country

7.2.3.1. Brazil

7.2.3.2. Argentina

7.2.3.3. Others

7.3. Europe

7.3.1. By Material Type

7.3.2. By End-Use Application

7.3.3. By Country

7.3.3.1. United Kingdom

7.3.3.2. Germany

7.3.3.3. France

7.3.3.4. Spain

7.3.3.5. Others

7.4. Middle East and Africa

7.4.1. By Material Type

7.4.2. By End-Use Application

7.4.3. By Country

7.4.3.1. Saudi Arabia

7.4.3.2. UAE

7.4.3.3. Israel

7.4.3.4. Others

7.5. Asia Pacific

7.5.1. By Material Type

7.5.2. By End-Use Application

7.5.3. By Country

7.5.3.1. Japan

7.5.3.2. China

7.5.3.3. India

7.5.3.4. South Korea

7.5.3.5. Indonesia

7.5.3.6. Thailand

7.5.3.7. Others

8. COMPETITIVE ENVIRONMENT AND ANALYSIS

8.1. Major Players and Strategy Analysis

8.2. Market Share Analysis

8.3. Mergers, Acquisitions, Agreements, and Collaborations

8.4. Competitive Dashboard

9. COMPANY PROFILES

9.1. SK Innovation Co., Ltd.

9.2. Celgard

9.3. Evonik Industries AG

9.4. Asahi Kasei Corporation

9.5. Teijin Limited

9.6. Toray Group

9.7. ENTEK

9.8. Mitsubishi Plastics

9.9. Tekra LLC

9.10. 24M Technologies

9.11. Microtex Energy Private Limited

9.12. Daramic 

9.13. GVS S.p.A. 

SK Innovation Co., Ltd.

Celgard

Evonik Industries AG

Asahi Kasei Corporation

Teijin Limited

Toray Group

ENTEK

Mitsubishi Plastics

Tekra LLC

24M Technologies

Microtex Energy Private Limited

Daramic 

GVS S.p.A.