Electrolube UVCL: the coating that increases the durability of the electric vehicle management system

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Electrolube UVCL: new generation of UV curable conformal coatings

With the increasing demand for electric and hybrid vehicles, protecting battery systems from harsh environments has never been more critical. The key to improving battery performance, safety and reliability lies in the application of the most effective electrochemical protection materials, especially given the growing trend towards high capacity, fast charge battery packs. Electrolube’s extensive portfolio of resins, protective coatings and thermal management solutions supports the complete protection of electric vehicle batteries.

An electric vehicle customer in India recently contacted Electrolube to help solve a problem with an existing coating used by another supplier for their Battery Management System (BMS). The BMS continuously monitors parameters such as temperature, voltage and current flowing into and out of the battery to ensure that it is operating in safe conditions at all times. The BMS is a critical system that is responsible for the thermal management of the battery and not only adjusts the cooling, but more importantly, can trigger other safety mechanisms to stop operations and minimise risk. For example, if the BMS detects a battery overheating, the vehicle’s power is automatically limited and the vehicle is put into a safety mode.

The electric vehicle battery customer required a robust, high performance, scratch resistant, solvent free coating that offered the highest level of protection against harsh environments. The new generation coating, UVCL, which is part of a wider range of UV cured coatings from Electrolube, was chosen to protect the BMS with excellent results. As the customer did not have an in-house UV curing facility, Electrolube’s customer service team in India found a reputable supplier to assist. After a few iterations, a prototype sample was prepared and the unit was tested in the field.

The low viscosity, single component UVCL offers the highest level of protection for electronic circuits at high production rates. The coating also cures in seconds when exposed to the right amount of UV light and has a highly effective secondary curing mechanism, triggered by moisture, to ensure curing in shadow areas. UVCL eliminates the use of solvents, being both VOC-free and non-flammable, and is applied via selective spray equipment. It has been extensively tested with excellent results and demonstrates ease and speed of application in an automated process, allowing high speed surface curing.

The UVCL coating allows relatively thin films to be applied and requires no thinning, so it is ready for instant use. It also offers excellent storage stability and a long shelf life. With the highest level of flexibility, the coating offers the ultimate 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 easy inspection and offers excellent electrical properties with a wide operating temperature range of -65°C to +135°C.

Ron Jakeman, Managing Director of Electrolube, comments: “We are very pleased to have provided such a successful solution for this electric vehicle application, particularly given the critical nature of the BMS. Electrolube is facing increasing demand from electric vehicle battery designers and manufacturers, and we provide effective solutions that are tried and tested to solve heat, performance and protection issues. We’ve always enjoyed a challenge, which is what drives us to constantly innovate, and the EV battery industry is increasingly looking to us for solutions that protect every conceivable aspect of an EV battery to ensure they tick all the boxes for safety, reliability and performance.”

 

Electrolube’s conformal coating applications

 

Source: Samaro, Article 2021

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