Developing a Protective PCM Layer for an Aluminum Sheet

As electric vehicles (EVs) become increasingly prevalent, improving the thermal safety of battery systems is essential. This study investigates the development of a high-temperature-resistant coating for aluminum sheets, aimed at mitigating thermal runaway events by incorporating carbonate-based phase change materials (PCMs). Using a PTFE binder and calcium carbonate as the primary PCM, the coating was applied via airbrush to maintain a thin, even layer. Initial results showed the coating was thermally resilient but suffered from poor adhesion and mechanical strength, as demonstrated by failed hardness tests and inconsistent thermoconductivity data. Surface etching with sulfuric acid improved visual adhesion, suggesting potential benefits for coating durability. However, the binder’s low scratch resistance indicated the need for stronger alternatives. Future work will explore new binders, improved application methods like blade coating, and surface pretreatments to enhance coating performance. These refinements aim to produce a coating that enables aluminum casings to resist extreme heat during battery failure, contributing to safer and more robust EV battery systems.