Coating battery cells instead of wrapping them in foil

In a new process, battery cells for e-mobility are coated with a special paint instead of being wrapped in a film. They are first cleaned with plasma and prepared for coating.

Plasmatreat GmbH (Steinhagen) and Venjakob Maschinenbau GmbH & Co. KG (Rheda-Wiedenbrück) are now making battery production more efficient and reliable thanks to a new process. For reliable electrical insulation, plasma-cleaned battery cells are given a special coating instead of a complex film coating. Battery manufacturers benefit from the close proximity of the two companies from East Westphalia-Lippe (NRW), which work together to simulate processes under realistic conditions and manufacture small series.

The e-mobility segment is looking for solutions that further increase the reliability of batteries and improve safety. One starting point for optimization is electrical insulation. In the conventional way, battery cells, especially prismatic cells, are coated with a film. The process is costly and time-consuming and is prone to errors. Now an innovative process is making battery production more efficient, faster and more reliable: the battery cells are coated with a special lacquer instead of foil. The companies Plasmatreat and Venjakob have pooled their expertise to achieve this.

Perfect paint adhesion thanks to ultra-fine cleaning

Plasmatreat is the global market leader for atmospheric plasma technology and has developed the open-air plasma technology. In this case, it is used for ultra-fine cleaning of the bare battery cell and enables reliable, long-term stable paint application. The open-air plasma is applied precisely to the metal surface of the battery cells in a plasma treatment unit (PTU) under atmospheric pressure using simple compressed air and electricity through specially developed nozzles. Compared to conventional cleaning methods, the process is significantly more environmentally friendly, selective and inline-capable. The surfaces of the battery cells are reliably cleaned of wafer-thin layers of dust and residual traces from the production process, e.g. oil or grease. This allows the protective coating to be applied without any gaps. Long-term adhesion is achieved.

Non-contact coating, minimizing sources of error

The mechanical engineering company Venjakob, which specializes in coating lines, has developed a fully automated system for a continuous non-contact coating process. Here, the battery cells in various formats are coated with a 100% UV coating after ultra-fine cleaning using open-air plasma. A specially developed tool carrier ensures that sensitive areas and the electrical poles of the battery cells are reliably protected from overspray. As the process requires no gripping, turning or further handling, the risk of damage to the battery cells is minimized. The non-contact process also allows for increased production speed. The immediate curing of the UV coating means that the cells can be processed immediately. This speeds up the entire battery manufacturing process.

Successful alternative battery cell manufacturing process

Various analyses confirm the high effectiveness of the innovative insulating coating, which achieves adhesive strength values of over 15 MPa in tensile shear tests. The two partners attribute the success of the project above all to the best possible match in key aspects. These include comprehensive technological expertise, uniformly high quality standards, flexible adaptability to changing customer requirements and intensive communication based on mutual trust. In this case, the joint customers also benefit from the geographical proximity, which has made it possible to present and evaluate ultra-fine cleaning and coating in a near-series process in Steinhagen and Rheda-Wiedenbrück. (OM-6/24)

Contact

Plasmatreat GmbH
Queller Straße 76-80
33803 Steinhagen (Germany)
www.plasmatreat.com

About Plasmatreat

Plasmatreat is an international leader in the development and manufacture of atmospheric plasma systems for the pre-treatment of material surfaces. Whether plastic, metal, glass or paper - the properties of the surface are modified in favor of the process requirements through the industrial use of plasma technology.

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