HYBRID COMPOSITE MATERIALS SYSTEMS FOR BATTERY HOUSINGS HAVING IMPROVED THERMAL PERFORMANCE

A hybrid material housing for a battery is provided for reducing or minimizing thermal runaway propagation. The housing includes a composite structure that contains the battery and optionally includes a polymeric matrix selected from the group consisting of: epoxy, phenolic resin, polyester, vinyl ester, and combinations thereof and a reinforcing material selected from the group consisting of: glass fibers, carbon fibers, basalt fibers, aromatic polyamide KEVLAR® fibers, and combinations thereof. A metal layer is disposed along an exterior surface of the composite structure that comprises aluminum, steel, stainless steel, alloys, and combinations thereof. In a first mode, the metal layer contacts the composite structure and in a second mode after exposure to a thermal load of greater than or equal to about 500° C., the metal layer at least partially delaminates from the exterior surface and forms insulating air gaps to define a thermal barrier. Methods of forming the hybrid material housings are also provided.