Zircotec and the world-first ceramic coatings for EV

Zircotec has been active in thermal management for decades and is entering the world of electric applications by targeting the “mother” of all technologies: the passenger car. The news, which POWERTRAIN International reads between the lines, is that these coatings will eventually find their way into industrial applications. We mentioned it in this article last year.

Coatings? Yes, Zircotec has launched proprietary ceramic coatings that allow EV manufacturers to replace heavy-duty steel battery enclosures and cooling plates with lightweight aluminum and plastic composite materials. According to the company, this can be done without compromising safety, thermal management, or electrical insulation.

Zircotec and CeraBEV project

The coatings are the result of the partly government-funded CeraBEV (Ceramics for BEVs) project, comprising a consortium led by Zircotec and with Cranfield University as a key project partner. Delivered with the support of the Advanced Propulsion Centre UK (APC), CeraBEV’s remit was to accelerate the UK’s capability in safe battery energy storage technology.

Developed by the Zircotec engineering team in Abingdon, Oxfordshire, the ‘ElectroHold’ coatings integrate dielectric, flameproofing and thermal properties into a single coating system. This allows OEMs to use lighter materials for battery enclosures and to improve cooling plate efficiency by pairing thin, high-performance electrical insulation with enhanced thermal conductivity.

Putting the Coating to the Test

Zircotec’s new coatings have been subjected to rigorous electrical, thermal and durability testing, simulating the demands of modern EV motoring. This included a full-scale simulated ‘UL2596 Method A’ thermal runaway test event for the battery box coating where the battery module was deliberately driven to failure to replicate the most severe safety scenario an EV might encounter.

According to the official, the Zircotec-coated carbon fibre enclosure passed comfortably, maintaining its structural integrity, preventing flame egress and continuing to provide electrical isolation – demonstrating its ability to increase all-important protection time for vehicle occupants and surrounding systems under extreme heat and pressure.

During other tests, simulations and evaluations, conducted in partnership with Cranfield University and HORIBA MIRA, Zircotec’s latest cooling plate coating delivered a four-fold increase in dielectric strength over a previous iteration. The coatings also proved resistant to mechanical stress, corrosion, chemical attack and a wide range of temperatures, confirming their suitability for both high-performance and mass-market automotive applications. Thermal conductivity measurements were carried out using equipment accessed via the Royal Institute in Sheffield, while BeonD contributed to battery propagation safety testing.

In Their Own Words

“We’ve used our thermal management expertise to develop multifunctional coatings that address the new challenges of electrification,” Dominic Graham, Zircotec Engineering Director, explained. “They provide outstanding protection against heat and flame, ensure greater electrical insulation needed for safety, and improve thermal transfer. That’s a combination that has the potential to transform the EV industry by unlocking the use of lightweight materials across battery boxes and cooling plates.”

Terry Graham, Zircotec CEO, said: “As thermal technologists that have defined the science of heat management for more than 30 years, we’re delighted with the results of the CeraBEV project. Thanks to our strong collaboration with Cranfield University and other industry partners, we firmly believe these proprietary coatings have the potential to revolutionise the global EV market by unlocking the use of prized lightweight materials.

“This technology is now ready for OEMs to integrate into their production programmes and we’re proud that it’s been UK material science, coating and engineering expertise and collaborations that have led us to this transformative position.”

Dave Matthews, Senior Project Delivery Lead, APC said: “Drawing upon a rich legacy of innovation in thermal management, Zircotec is now focusing its expertise on the advancement of new energy vehicles. Reducing mass is vital, and leveraging alternative materials plays a pivotal role in achieving lightweighting. Advanced coatings not only support the use of these innovative materials but also uphold safety and structural integrity.”