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The transportation industry is undergoing a significant transformation driven by technological advancements, shifting consumer demands, environmental concerns, and regulatory pressures. At the forefront of this change is the rapid rise of electric vehicles (EVs), autonomous driving technologies, and shared mobility solutions. Traditional modes of transportation, such as internal combustion engine (ICE) vehicles and private car ownership, are increasingly being challenged by these emerging trends.
Electric vehicles are becoming more mainstream as governments push for decarbonization and automakers invest heavily in EV development. Countries around the world are setting ambitious targets to phase out fossil-fuel-powered vehicles, incentivizing consumers with subsidies and building charging infrastructure to support this transition. Alongside EVs, innovations in battery technology promise longer ranges, faster charging times, and reduced risk of overheating.
In the not-too-distant future, autonomous driving technology has the potential to reduce accidents, alleviate traffic congestion, and create new business models for transportation, including autonomous ride-hailing and delivery services. The concept of shared mobility, encompassing ridesharing, car-sharing, and micro-mobility options like electric scooters and bikes, is gaining popularity as urbanization and concerns about sustainability grow. Many urban residents are now opting for more flexible, on-demand transportation solutions rather than owning personal vehicles. This shift is transforming city planning and infrastructure development, with an emphasis on reducing traffic congestion and pollution. The rise of e-commerce has intensified the demand for efficient last-mile delivery solutions, encouraging companies to adopt drones, electric vans, and even autonomous robots for parcel delivery.
(Courtesy of V. Scarborough)
The transportation industry’s landscape is also being shaped by environmental regulations aimed at reducing emissions and tackling climate change. Governments and international organizations are introducing stricter standards for vehicle emissions and promoting cleaner fuel alternatives. This regulatory pressure is encouraging the industry to innovate in ways that align with sustainability goals.
The coatings industry has been serving the transportation industry since the introduction of the Ford Model-T. Many traditional coatings used today can be used on electric vehicles, but EVs represent a major engineering pivot from mechanically driven to chemically driven vehicles.
As climate change pushes further regulatory changes to reduce fossil fuels, EVs will continue to gain market share. This requires the coatings industry to respond with new products and innovations that address the needs of EVs and their vastly different architecture. New opportunities exist in not only providing color and aesthetics but also in protecting EV components, improving energy efficiency, and ensuring longevity.
Driving Change: The Regulatory Environment & Funding
As part of the 2021 Bipartisan Infrastructure Law, $500 MM in grants was provided for demonstration projects focused on advanced smart community technologies and systems that improve transportation, efficiency, and safety. As a result, the U.S. Department of Transportation (DOT) developed a grant program called Strengthening Mobility and Revolutionizing Transportation (SMART). The funding opportunity is open to the public for transportation projects in the following areas:
- Coordinated automation
- Connected vehicles
- Sensors
- Systems integration
- Delivery and logistics
- Innovation aviation
- Smart grid
- Traffic signals
In addition, the DOT has authorized $50 MM per year in funding to establish research initiatives that accelerate the development of disruptive technologies with high-impact potential. This amount of funding will drive the development of new technologies and will likely require the coatings industry to respond with its own new products and innovations.
Protection and Durability
While the net number of cars being sold may stay relatively constant, the coating types per vehicle will grow based on the increased number of EV components per unit that require coatings. For example, there are at least 100 more electronic control units per EV than found in ICE cars. While each model may look different, the overall design of an EV has three basic areas where coatings are useful:
- Battery packs
- Power conversion components
- Electric drive systems
Paints and coatings are critical for ensuring that EVs are resilient under various environmental conditions. This is especially important because EV components, particularly batteries and electric powertrains, are sensitive to external factors like temperature, humidity, and corrosion. Corrosion-resistant coatings are essential for protecting the metal components of EVs, particularly the underbody, where moisture, salt, and road debris can cause significant damage. Traditional cars benefit from these coatings, but EVs require additional protection for key components like the battery pack housing, which is often exposed to harsh conditions. Epoxy primers and ceramic-based coatings are commonly used for corrosion protection, ensuring long-term durability and safety.
For the battery enclosures in EVs, thermal management coatings play a crucial role. Since EV batteries can overheat under high-stress conditions like fast charging or long driving conditions, coatings designed to manage heat dissipation and prevent overheating are vital. These coatings help maintain battery efficiency and reduce the risk of thermal runaway—a critical concern for both safety and performance.
Safety and Environmental Sustainability
In addition to their protective roles, coatings in the EV market contribute to safety and sustainability. Intumescent coatings may protect from fire damage if batteries fail, overload, and start a fire. These coatings create an additional safety layer by slowing the spread of fire and reducing the risk of catastrophic damage. This is such a frequent problem that many insurance companies will not issue homeowners insurance if EVs are parked in the garage.
Lowering the overall carbon footprint is a key consideration of the EV industry during vehicle production. Traditional paints and coatings have contributed to volatile organic compound (VOC) emissions during the application process, which are responsible for about 90% of the air pollution in a paint factory, increasing the health risks for workers. However, with the rise of EVs, manufacturers are increasingly adopting eco-friendly coatings with low VOC content. Water-based paints and powder coatings are becoming popular alternatives to reduce environmental harm while providing high-quality finishes.
Many EV manufacturers are also turning to sustainable coating processes that minimize energy consumption and waste. For instance, the use of UV-cured coatings is gaining traction because they cure quickly under ultraviolet light, reducing the need for energy-intensive baking processes.
One significant innovation that has gained prominence in recent years is the development of performance paint films (PPFs). These films, applied over a vehicle’s exterior, serve as protective layers designed to preserve the car’s finish, enhance durability, and offer a range of benefits that go beyond aesthetics.
As the auto industry seeks sustainable solutions and efficient ways to extend vehicle lifespans, PPFs have emerged as a valuable tool in achieving these goals. Performance paint films extend the life of a vehicle’s paintwork, reducing the need for repainting and, consequently, the environmental impact associated with it. Fewer trips to the body shop, less repainting, and lower demand for paint-related chemicals mean fewer VOCs are released into the atmosphere. Additionally, by protecting the vehicle’s surface, the need for intensive cleaning involving chemical detergents is reduced, contributing to a lower overall ecological footprint.
EV Battery Coatings
The global market for EV battery coatings is projected to be $1 billion by 2028, growing at a CAGR of 15%. This growth is driven by government incentives to purchase EVs. Each manufacturer has its own battery pack design, with a unique set of needs and challenges. Regardless of the construction of the pack, they all need fire protection, corrosion and impact protection, temperature management, and electrical shielding.
The battery pack contains polyelectrolytes, which are highly flammable. Thus, temperature control is essential to maintaining battery efficiency and durability over time. Innovative thermal management coatings can provide a partial solution by helping to control temperatures, whether they are too hot or too cold.
Innovative new solutions in battery design can also help control thermal runaways that cause fires. For example, a startup company called COnovate (https://conovateinc.com/) has developed the first sustainable carbon-based bio-sourced nanomaterial that is the world’s only form of solid carbon monoxide (CO) battery anode material with reduced propensity to overheating. Aerogels are also being explored for advanced battery fire safety. Aspen Aerogels (www.aerogel.com) has developed an amorphous silica-based thermal runaway propagation barrier called PyroThin®. Adionics (www.adionics.com), a startup company in Israel, has developed a novel 3D battery structure that minimizes the internal resistance and improves both mechanical longevity and thermal stability. The goal of all of these materials is to exhibit extremely low thermal conductivity and low density to maintain weight efficiency and energy density.
Battery packs also require protection from electromagnetic interference. Coatings with dielectric properties can help prevent arcing between metal parts. Polyvinylidene fluoride (PVDF) is the preferred dielectric material in coatings used to prevent arcing between metal parts. Coatings technologies such as atomic layer deposition, chemical vapor deposition, and plasma-enhanced chemical vapor deposition are used for anodes, cathodes, and electrolytes, but they come at a higher price than is often desired.
Sensor Technology and Coatings
EVs are designed with hundreds of sensors, all of which need protection from wear. Clear protective coatings can be used, but they cannot diminish signal transfer. In addition to the EV itself, developments in autonomous vehicle technology have demonstrated the need for road improvements, particularly in the requirement for consistent, easily visible pavement markings. If not properly marked, it is harder for an autonomous vehicle to know exactly where it is on the road.
Here, coating manufacturers can play a role in providing traffic paints that potentially communicate with the EV. Photonic pigments can be added to coatings to help provide guidance on road position. Thus, smart traffic coatings can be formulated to help talk to the EV. Autonomous vehicles are also programmed to read road signs. Similarly, coatings that contain near-infrared (NIR) transparent or reflective functional pigments can deliver a signal response back to the EV and improve object recognition. Several pigment manufacturers already have products available for this purpose. In addition, sensor cleanliness is important, and top coatings that are self-cleaning and repel dirt are needed to maintain efficient operation and help the EV know where it is on the road.
The Future State
The transportation sector is at a crossroads, with technological innovation, environmental imperatives, and evolving consumer preferences driving a major shift. This transformation promises to create a more efficient, sustainable, and accessible transportation ecosystem for the future. However, challenges related to infrastructure, regulation, and societal adaptation will need to be addressed as the industry navigates this period of rapid change.
As the EV market continues to grow, the role of paints and coatings becomes more critical than ever. These materials are not just about improving aesthetics—they also contribute to the safety, durability, energy efficiency, and sustainability of electric vehicles. From corrosion protection to thermal management, lightweighting, and environmental friendliness, innovations in coatings are driving advancements in EV technology. As automakers push the boundaries of design and performance, the development of cutting-edge paints and coatings will continue to be an essential part of the electric vehicle revolution.
For more information, contact the author at vscarborough@chemquest.com.
References
1. J. Billington, “The Heat is On,” Electric Hybrid Vehicle Technology Magazine, July 2024, ehv.mydigitalpublication.co.uk/july-2024?m=63184&i=826412&p=22&ver=html5.
2. U.S. Department of Transportation, Strengthening Mobility and Revolutionizing Transportation (SMART), www.transportation.gov/grants/SMART.
3. J. Rush, “Coatings Drive Electric Vehicles Further,” Products Finishing, January 21, 2021, www.pfonline.com/articles/coatings-drive-electric-vehicles-further.
4. “Advancements in Coatings for Electric Vehicle Battery,” A&A Thermal Spray Coatings, www.thermalspray.com.
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