Advanced Silica Gel/Sulfonated Polymer Composites for Electric Vehicle Thermal Management by Sorption Technology

This study explores novel silica gel/sulfonated polymer composite coatings for enhanced thermal management in electric vehicles via sorption technology. Leveraging the cost-effectiveness of silica gel as a filler and a readily available, water vapor-permeable sulfonated polymer as the matrix, we developed and characterized these materials. Mechanical assessments revealed varied performance: coatings with lower silica gel content (80 and 85 wt%) demonstrated suitable scratch resistance (damage width ~1100 µm at 1300 g load) and superior impact resistance (damage diameter ~2.4 mm). Pull-off adhesion strengths for these batches were 1.26 MPa and 1.36 MPa, respectively, though higher filler loading (90 and 95 wt%) led to a ~30% reduction and a shift to cohesive failure for high-filler-content batches. Thermogravimetric analysis confirmed thermal stability up to 280 °C. Adsorption studies revealed that the composite coating with 95 wt% of silica gel achieved the highest water uptake (just under 30 wt%), with all batches exhibiting capacities comparable to commercial adsorbents. This comprehensive characterization confirms that these composites offer a compelling balance of mechanical robustness, reliable adhesion, and high adsorption efficiency, positioning them as promising, cost-effective solutions for EV thermal management.