Zircotec, the thermal technologist that has owned the science of heat management for more than 30 years, has applied its expertise to the Electric Vehicle sector by designing a range of new plasma-sprayed ceramic and polymer coatings that ensure the safe and efficient operation of EV battery enclosures and cooling plates.

The ElectroHold® range – unveiled in Hall 4 on stand C4-211 during Cenex Expo 2024 – has been developed to support the drive towards net zero and solutions have been proven in top-flight electric motorsport. The range features individual coatings that provide dielectric, flameproofing and EMI shielding. Zircotec engineers have also developed a fourth ‘OMNI SHIELD’ coating that provides all-in-one protection.

All products are lightweight, can be easily packaged into existing automotive design infrastructures, protect against water ingress, corrosion and chemical attack, and provide the highest performance and adherence levels during normal operating conditions.

The specific features of each product are:

ElectroHold DIELECTRIC

Available as a lightweight polymer-based coating or a ceramic coating with a polymer sealant. Prevents electrical conductivity between components to ensure safety and eliminate the risk of short-circuiting and overheating of batteries and battery cells. Coatings provide high dielectric strength on various components, offering up to 42 Kv/mm or 10 Kv/mm coupled with good thermal conductivity to aid heat removal.

ElectroHold FLAMEPROOF

A proven, lightweight, high-performance thermal barrier coating for battery boxes and covers that gives short-term flame protection at 1,400°C and extended protection at 700°C. Suitable for use on steel, aluminium, composite and plastic substrates without any post-application electrical impact being caused.

ElectroHold EMI SHIELD

An electrically-conductive battery box and cover coating that both prevents EM leakage and protects critical components from EM interference. These high-integrity, metallic-based coatings are ultra-thin (~50 μm), lightweight (~135 grams per m2), and can operate up to temperatures of 600ºC.

ElectroHold OMNI SHIELD

A unique product that provides flameproof, dielectric and EMI shielding protection in a single coating. This high-integrity application is lightweight and applied in multiple layers, meaning specific parameters can be used to secure application-specific requirements. Suitable for use on various components, including battery boxes, cooling plates, and inverter housings.

Dominic Graham, Zircotec Engineering Manager, said: “Our skills and experience in developing thermal management solutions for OEMs and top-flight motorsport, including F1, are well known. But the Electric Vehicle market is an area we’ve been focusing on heavily during the last 12 months by developing out our current thermal science so a new breed of solutions can be created and used across EV applications.

“Our ElectroHold range gives OEMs and niche manufacturers easy access to a high-performance and versatile set of both ceramic and polymer coatings that can either be used in isolation to achieve specific flameproofing, dielectric or EMI shielding results – or in a single solution that delivers all three forms of protection.

“Our product development work is set to continue as we expand the ElectroHold range and seek further performance gains. The EV sector is a strategically-important area of growth for Zircotec and we’re looking forward to unlocking further innovation that will significantly benefit vehicle makers.”

To discover more: www.zircotec.com/solutions/ev-solutions