Advancements in Insulation Technologies for Electric Vehicle Battery Cells: A Review

The accelerating transition to electric vehicles (EVs) demands enhanced battery safety and performance, with insulation technologies being a critical factor. This review comprehensively examines the evolution of insulation technologies for EV battery cells, a critical component in ensuring battery safety and performance. It not only reviews traditional materials such as polyethylene terephthalate (PET)-based blue films but also explores innovative solutions like powder insulation coatings and ultraviolet (UV)-curable insulation coatings. The review assesses the challenges faced by conventional materials, including issues with impact resistance, adhesive bonding, and compatibility with high-voltage systems. It further discusses the formulation and application techniques for advanced materials, emphasizing their unique properties and potential to meet the stringent safety and performance standards of the EV industry. Specifically, this review highlights the latest advancements in UV-curable and powder coatings, which offer superior insulation properties and environmental sustainability. It also provides insights into the future direction of insulation technologies for EV batteries, emphasizing the importance of material innovation for the continued growth and sustainability of the EV market.