KCC Develops Thick Powder Coating to Target Secondary Battery and Electric Power Markets

Powder coating process shortened to a single application at 250μm thickness
Meets insulation and corrosion resistance requirements for secondary batteries and more

KCC has developed a thick powder coating that can reduce the painting process by half, aiming to target the secondary battery and electric power markets.

Sample applying the thick coating powder coating developed by KCC (left) and sample with a single coating of conventional powder coating (right). KCC

On January 28, KCC announced the launch of a powder coating that can achieve a coating thickness of over 250μm with just one round of electrostatic painting. This new product more than doubles the maximum coating thickness of approximately 120μm that conventional powder coatings could achieve in a single application. It has been developed to meet the insulation, flame retardancy, and high corrosion resistance required for key components such as secondary batteries (EV/ESS) and power control devices.

Unlike conventional liquid paints, powder coatings are "powder-type" coatings that do not use volatile solvents or thinners. The process involves using a spray gun to attach negatively charged powder coating to positively charged metal, then applying heat to form the coating layer. Since the powder adheres and solidifies, there is less risk of the coating running or wrinkling, resulting in excellent workability. Unattached powder can be recovered and reused, which reduces waste generated during the process, making it both environmentally friendly and cost-effective.

Typically, powder coatings form a thickness of about 60-80μm per application, and even when adjusting painting conditions such as voltage or air pressure, the maximum achievable thickness is around 120μm. When a certain thickness is exceeded, electrostatic repulsion occurs between the already attached powder and the newly sprayed powder, making it impossible to apply a thicker coating. For markets such as secondary battery (EV/ESS) components, power control and conversion devices, and high corrosion-resistant structures, where a coating thickness of over 250μm is required, two painting steps or a preheating process has been unavoidable.

The product developed by KCC incorporates technology that controls the electrostatic repulsion limit, enabling the formation of a thick coating of up to 250μm in a single application without preheating. In addition, it features enhanced leveling technology that maintains coating smoothness even at a thickness of 250μm, further improving work quality.

By using this product, powder coating companies can shorten the painting process and reduce production costs through energy savings during the preheating and curing stages. With the process reduced to a single step, work efficiency is improved. The exposure time of the coated surface to external air and dust is also shortened, decreasing the likelihood of contamination by foreign particles.

KCC has significantly shortened the process while ensuring insulation performance and flame retardancy at or above the level of existing products. In particular, it has further enhanced dielectric strength reliability, which is directly linked to the safety of secondary batteries (EV/ESS) and high-voltage power components.

With the expansion of the electric vehicle market, demand for highly reliable insulation coatings for batteries and power components is expected to continue to grow. In particular, insulation coatings with a thickness of over 250μm are a key factor in the competitiveness of EV components, as they must simultaneously ensure fire safety and durability.

A KCC representative stated, "As the electric vehicle market grows, the demand for insulation and heat resistance in batteries and power components is increasing, while manufacturing process efficiency is becoming a core element of competitiveness. We will continue to develop customized products that simultaneously meet the performance and process efficiency required in the fields of EV components and high-reliability industrial materials."

This content was produced with the assistance of AI translation services.