Zircotec Receives Funding to Advance Lightweight Ceramic Coating Technology for EV Batteries

Zircotec has obtained substantial government funding from the Advanced Propulsion Centre UK (APC) to create an exclusive ceramic coating. This innovation will enable the use of lightweight materials, such as aluminum and plastic composites, in EV battery enclosures and cooling plates.

The government-backed 'CeraBEV' (Ceramics for BEVs) project will run for 12 months and is part of efforts to keep the UK at the forefront of battery technology. Zircotec has been appointed as the lead partner, with Cranfield University handling the testing and evaluation of the ceramic coating.

Currently, most EV battery enclosures are made from heavy steel, contributing to the vehicle's overall weight. To improve EV range and reduce weight, lighter materials like aluminum and plastic composites are essential. However, the performance of aluminum cooling plates in battery packs is limited by the need for electrical insulation and their generally low thermal conductivity.

Major improvements in cooling plate efficiency are possible with the use of thin, high-performance electrical insulation that offers superior thermal conductivity.

Dominic Graham, Zircotec engineering director, said, “The key to unlocking the use of new, lightweight materials across battery enclosures and cooling plates in EVs is being able to develop and effectively apply high-performance coatings that ensure the safe thermal and electrical operation of the substrate."

“The Advanced Propulsion Centre ‘CeraBEV advanced route to market demonstrator’ project allows our engineers to develop world-first, all-in-one dielectric and flameproof ceramic coatings that will address and overcome the significant thermal management and electrical insulation challenges associated with the lightweight materials OEMs want to use on their vehicles.”

To advance its research, Zircotec plans to enhance its existing ElectroHold® coating line, aiming to deliver superior dielectric performance, flame resistance, and electromagnetic compatibility (EMC) shielding capabilities.

The current products are lightweight and seamlessly integrate into existing automotive design frameworks, offering protection against water intrusion, corrosion, and chemical damage. They deliver exceptional performance and adhesion under typical operating conditions and have been proven to excel in top-tier electric motorsport.

Andrew Donachie, Zircotec COO, said, “We’re delighted to be selected to receive this APC funding which will not only enable Zircotec to extend its current ceramic coating expertise within the EV sector, but will also accelerate the UK’s battery energy storage technology capability through ceramic coating research that has the power to transform material use in the battery electric vehicle sector.”

Dominic Graham added, “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 ElectroHold® solutions. This proven technology will provide the platform for our work towards delivering the CeraBEV project.”

Source: Zircotec