Revolutionizing EV battery safety: advanced coatings and composite solutions

Thermal runaway in electric vehicle (EV) batteries is rare, but it can happen, producing smoke, fire, and explosions. This uncontrollable, self-heating state can transfer intense heat to adjacent cells and cause pressure buildups that exceed the mechanical limits of cell casings. Since the gases that can form inside a battery cell are flammable, a spark or other ignition source could propagate fire or lead to an explosion and cause the violent venting of shrapnel or particulates, putting vehicle occupants and emergency responders at risk.

To support EV safety, silicone thermal management materials are placed between battery cells and between battery modules. For battery pack enclosures, however, mica sheets traditionally have been used as protective barriers. Mica provides thermal and electrical insulation, but sheets made of this mineral are limited in terms of thermal performance, mechanical durability, processability, and sustainable sourcing. To address these challenges, advanced silicone-based coatings and fiber-reinforced composite systems offer a transformative approach to the safety and manufacturing efficiency of battery enclosures and other EV battery components.