Make sure the batteries last longer
Car battery corrosion occurs when sulfuric acid inside the battery releases hydrogen gas. This process creates a corrosive environment as the gases react with the surrounding atmosphere. Exposure to salt and moisture accelerates corrosion.
Engineers and other experts are working hard to improve electric vehicle (EV) batteries. These advancements include corrosion protection. Here are some of the possibilities to achieve this goal.
Use of special coatings
One of the challenges of EV battery design is that each has different needs to meet. However, manufacturers generally approach this reality by using special coatings. In addition to protecting the batteries from corrosion, these options provide fire and impact protection, and promote better thermal management.
Keeping batteries within the optimum temperature range is a critical component for them to function properly throughout their expected lifespan. Battery thermal management systems are complex and often reinforced with coatings.
Electroplating, powder coating and liquid coating are some of the methods often used for electric vehicle batteries. Some companies have explored ways to automate these techniques, making them easier to scale. Automating coating application options should also reduce the overall cost of EV battery production. Then cars become more affordable for consumers.
Perform lab tests
Many advances in corrosion protection happen in the lab before they have real-world impacts. For example, construction sites that require mechanically stabilized earth (MSE) backfill must measure the corrosivity of the surrounding soil. Soil resistivity indicates how easily electric current can flow through. The corrosion rate is lower in soils with higher resistivity.
The automotive industry commonly uses a process called Cyclic Corrosion Testing (CCT) to see how well various parts used in cars will resist degradation. Sometimes CCT involves immersing the materials in water. In other cases, components enter special chambers to be sprayed with materials. This process is often complex, especially when manufacturers wish to expose parts to various compounds.
A corrosion-related goal during these tests is to see if water can enter various parts of a battery or other EV components. Automotive components typically have an ingress protection (IP) rating of IP67 or higher. This indicates that they will stay waterproof against 30 minutes of exposure in 1 meter of liquid.
Addition of an effective sealant
People generally consider electric vehicles as sustainable vehicles. Basically, they are. However, there is work to be done to reduce environmental impacts batteries. Some companies are investigating how to make them easier to dismantle and recycle. That’s significant, but batteries will also become more durable when they include technologies that protect them from the elements.
An opportunity involves using a permanent and functional seal for the underbody of the car. For example, polyurethane sealing foam on the battery case can protect internal components from corrosion and moisture. The foam also has a vibration dampening effect while resisting exposure to chemicals and temperature variations.
Automakers should communicate with service providers to determine what sealing solutions they offer, how much they cost, and what application methods exist, among other necessities. This information will help them make informed choices.
Battery protection is a necessity
Electric vehicles are like other types of cars in that exposure to corrosion is a risk associated with typical use. However, when EV manufacturers and engineering teams use some of the strategies here, they will mitigate the threat.
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