Electric Vehicles
Expertise in refinement of dielectric powder coating and surface bonding required by the electric vehicle industry
The need for reduced carbon emissions has challenged the industry to look at different, lighter materials for vehicle design. Whereas previously the automotive industry relied on steel for chassis structure, aluminium and composites are now used alongside, or entirely replacing, conventional materials.
Not only do we offer a range of services ideally suited to this rapidly emerging sector but we are also at the forefront of designing and evaluating new surface treatments for lightweight metals.
We have been fortunate to hone our expertise in dielectric coating through working with major OEMs and Tier 1 companies in the EV sector. This has provided the opportunity to discover many challenges arising in the application of dielectric coatings and to find the best solutions.
Proficiency in applying dielectric coatings for electrical insulation in EV battery assemblies
Electrical insulation, isolation and temperature regulation is required within battery cells. Fluctuating temperatures can cause the battery cell temperature to rise incredibly fast, known as a thermal runaway, and this brings the risk of battery failure, as does electrical arcing.
Dielectric coatings are designed to prevent arcing within the battery enclosure and must be applied in precise areas to electrically isolate certain parts of the metal.
Our years of experience in CAD design and application of masking schemes is essential for the efficacy of the dielectric coating application.
These coatings also need to be applied at the exact thickness required for electrical isolation and free from even the smallest pin hole. Any failure in the integrity of the coating would result in unsafe leakage of current.
Quick checklist of what is required – and expertly delivered by our team at Powdertech Surface Science.
The coating:-
High dielectric strength >30kV/mm
Flammability test UL-94 V-0
Suitable for use in-cell, in-pack and to protect the cooling system
The application:-
Applied at the required high coating thickness to meet the Hi-Pot
requirementsExpertise in masking to apply the insulating coating only where required
Automated application process to deliver a consistent performance level
We use systems similar to Resicoat, a range of coatings specifically designed to help protect battery systems, motors and electrical storage units. These coatings provide exceptional resistance to thermal shocks and have high dielectric strength.
Cleaning metal and testing its cleanliness
Maintaining structural integrity is critical. The lightweight aluminium alloys used must be thoroughly cleaned and treated to offer enhanced bonding for powder coatings and structural adhesives, together with resistance from corrosion.
We have the ability to quantify cleanliness levels and we do this for every piece of aluminium prior to any coating.
How clean is clean? Watch the video to find out…………………
TiZr pre-treatment for welding and bonding
Your metal will undergo our optimised Titanium Zirconium (TiZr) conversion process whereby the unstable layer of natural oxide on the metal is replaced with a stable, chemically modified ‘shield’ layer of titanium zirconium. This surface will allow bonding and welding processes to deliver repeatable, strong, durable adhesive bonds and also provides a stable base for powder coating, with additional protection against corrosion.
We were the first powder coater in the UK to install TiZr as a chrome-free passivation process, in 2001, and have unrivalled experience in the process. We use the latest Gardobond® systems for TiZr passivation and apply it to aluminium components (cast, extruded or formed) to enhance adhesive durability for metal-to-metal bonding and welding.
Tests across a range of aluminium alloys have shown that our optimised TiZr layer matches the performance of anodising for durability of adhesive joints.
Adhesive-free structural bonding for aluminium to polypropylene composite
Our innovative adhesive-free structural bonding system, PowderBond, is already being used in bonding between aluminium and glass fibre composite materials for battery box enclosures.
More details and case studies can be found on our separate PowderBond website.
Typical projects
EV battery assemblies needing dielectric coating
TiZr enhanced bonding for lightweight aluminium chassis
Powder coating lightweight aluminium interior components
Ongoing research
Staying at the cutting-edge of this revolution in vehicle design sees us regularly partnering with research outfits and OEMs on private, EU & UK funded projects, often taking the lead role. See our Research Case Studies.
Electric vehicle case studies
In this emerging highly innovative sector most of our clients are carrying out work with NDAs attached, including prototype development. Here are a few we can mention.
“Having worked closely with Powdertech over many years I have always been impressed by the team’s technical expertise, up-to-date knowledge and level of service”
Can we help with your electric vehicle surface treatment project?
or find out more about our dielectric coating, TiZr and PowderBond services
Other Sectors
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Automotive
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Electric Vehicles
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Medical
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Aerospace Interiors
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Robotics, Space & Satellite
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Lighting
