Thermal instability remains one of the most serious risks in lithium-ion battery design. As batteries become more powerful and compact, internal temperatures rise faster, and the margin for error gets smaller.
In many systems, a small increase in heat can trigger a chain reaction. Pressure builds, materials break down, and flammable gases form. If unchecked, this leads to thermal runaway and the risk of fire or explosion.
The risks aren’t just a concern for large-scale storage or electric vehicles; they apply equally to consumer electronics, industrial systems, and defense applications.
To reduce that risk, engineers are turning to the materials inside the battery itself. More specifically, they’re turning to binders and coatings that manage heat, support structural integrity, and slow the progression of failure under thermal stress.
Learn more about how these coating materials enhance thermal stability in lithium batteries.
The Role of Coatings in Battery Safety and Stability
Let’s start with the anatomy of a typical lithium-ion battery.
What’s in a Lithium-Ion Battery and Why It Can Overheat
Each lithium-ion battery is composed of layered materials: cathodes, anodes, separators, and electrolytes. These components need to function in close proximity without degrading under pressure, vibration, or elevated temperatures.
The problem is that without a material that holds these components together, the battery as a whole can overheat. To prevent the risks of heat damage and instability, engineers and OEMs are now resorting to engineered binders and coatings.
The Solution: Engineered Coating Materials and Binders
Binders and coatings protect internal battery components from heat stress, helping maintain structural alignment and chemical balance during repeated use. These materials act as a protective layer that slows the onset of heat-related breakdown and helps prevent the escalation into thermal runaway.
How APV Coating Materials Can Help You Achieve Better Lithium-Ion Battery Stability
We offer a specialized product line of binders and coatings designed to improve thermal performance across the battery system. Because of how they minimize the risks of overheating, these materials contribute to longer battery life, safer operation, and better performance in demanding environments.
Here are some of the ways our coatings are changing the game for battery engineers and manufacturers everywhere.
Increased Thermal Resistance at the Cell Level
APV’s materials preserve component integrity even at elevated temperatures. This reduces deformation in critical areas such as electrode interfaces, making the battery more resilient under fast charging and high-current loads.
Delayed Onset of Thermal Runaway
By increasing the heat tolerance of the battery’s internal layers, these coatings extend the time before thermal events escalate. The result is a safer system because there’s more time to react and mitigate ignition.
Stronger Mechanical Stability Under Stress
Thermal cycling can lead to cracking or separation of internal layers. APV’s binders help components flex without failure, maintaining conductivity and structural cohesion during operation.
Space-Efficient Protection for Compact Designs
Modern battery packs are compact, with little room for passive cooling. These coatings provide high-performance thermal protection without increasing volume or weight.
Seamless Integration into Production Lines
Manufacturers don’t need to redesign their processes to implement APV coatings. These materials are compatible with existing coating and drying systems, reducing barriers to adoption.
Precision Processing for Consistent Quality
Beyond performance, the consistency and purity of binder and coating materials are critical to battery safety and efficiency. APV employs advanced processing techniques to ensure every batch meets the highest standards for uniformity and cleanliness.
Our production methods combine high- and low-shear mixing technologies to achieve a precisely controlled slurry or binder formulation. State-of-the-art filtration systems remove particulates and contaminants, while strict moisture controls prevent degradation of sensitive battery components. The result is a binder with uniform particle size distribution, optimized for smooth application, predictable performance, and extended battery lifespan.
Support for Regulatory and Environmental Goals
With low VOC content and minimal odor during application, these coatings contribute to safer workplace conditions and help organizations comply with tightening environmental standards.
Industry Applications: Where the Technology Performs
APV’s thermal-stable coatings are already in use across several high-risk, high-value sectors.
Electric Vehicles (EVs)
Automotive batteries must remain safe under repeated fast charging, outdoor temperature swings, and crash conditions. APV coatings support safety goals by reinforcing thermal and structural stability at the cell level.
Consumer Electronics
High-capacity lithium-ion cells in tablets and phones generate localized heat. These coatings help protect thin battery layers, improving lifespan and reducing the likelihood of expansion or fire.
Stationary Energy Storage Systems
Grid-connected batteries operate under long-duration loads with limited passive cooling. APV’s coatings enhance reliability and reduce the risk of thermal events in modular storage units.
Aerospace and Defense
Mission-critical battery systems demand materials that perform in extreme temperatures and harsh environments. APV’s technology helps meet those demands while preserving weight and volume efficiency.
Stable Batteries Start With Safer Materials
As lithium-ion batteries become more powerful, managing thermal stability and structural integrity becomes more critical. Heat generation, mechanical stress, and the risk of structural failure are common challenges that can be effectively mitigated with the right engineered coatings and binder systems.
APV provides expert technical and production support for lithium-ion battery processing, offering custom blending of binder solutions tailored to your current needs and future developments.
With emerging alternatives and evolving performance demands, the future of binder technology is rapidly changing. APV is ready to collaborate with you and develop forward-thinking, application-specific solutions to help you achieve your goals in performance, safety, and sustainability.
Interested in coating materials that can improve your system? Reach out for a free sample.
