Coating increases durability of EV management system

With the rise in demand for electric and hybrid vehicles, protecting battery systems from harsh environments has never been more critical. The secret to enhancing battery performance, safety and reliability lies in implementing the most effective electrochemical protection materials, particularly given the increasing trend towards high-capacity, fast-charging battery packs. Electrolube’s extensive portfolio of resins, coatings and thermal management solutions supports the entire protection of EV batteries.

An EV customer in India recently approached Electrolube to help provide a solution for an issue with an existing coating they had used from a different supplier for their battery management system (BMS). The BMS continuously monitors parameters such as temperature, voltage and current in and out of the battery pack to ensure it is operating in safe conditions at all times. BMS is a critical system that’s responsible for the thermal management of the battery and not only adjusts cooling, but can also trigger other safety mechanisms to stop operations and minimise risk. For instance, if overheating of the battery pack is detected by the BMS, the vehicle’s power output is automatically limited and the vehicle is put into failsafe mode.

The EV battery customer required a robust, high-performance coating that was scratch-resistant and solvent-free, and provided a high level of protection against harsh environments. Electrolube’s next-generation coating, UVCL — part of a wider range of UV cure coatings — was selected to protect the BMS with excellent results. And since the customer didn’t have a UV curing facility in-house, Electrolube’s customer service team in India sourced a reputable supplier to assist them.

The low-viscosity, single-component UVCL provides a high level of protection for electronic circuitry at high production throughputs. The coating also cures within seconds upon exposure to the correct dose of UV light and has a highly effective, moisture-initiated secondary cure mechanism to ensure curing in shadowed areas. UVCL eliminates the use of solvents, being both VOC-free and non-flammable, and is applied via selective spray equipment. It has been widely tested and demonstrates ease and speed of application in an automated process, achieving high-speed surface cure.

The UVCL coating allows the application of relatively thin films and requires no dilution, so it is ready to use instantly. It also provides good storage stability and a long shelf life. With a high level of flexibility, the coating provides protection in harsh environments, including high-humidity, thermal shock, moisture, corrosive and chemical atmospheres at minimal cost. The coating also fluoresces under UV light for ease of inspection and offers good electrical properties with a wide operating temperature range of -65 to +135°C.

“We are very pleased to have provided such a successful solution for this EV application, especially given the critical nature of BMS,” said Ron Jakeman, Managing Director of Electrolube. “Electrolube is experiencing increasing demand from EV battery designers and manufacturers, and we have been providing effective solutions that have been tested and proven to address heat, performance and protection issues. We have always relished challenges — it’s what drives us to innovate constantly — and the EV battery industry is increasingly reaching out to us for solutions that safeguard every conceivable aspect of an EV battery to ensure they have every box ticked when it comes to safety, reliability and performance.”

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