Novel process: Coating replaces foiling of battery cells
Battery cells used in electric vehicles are usually covered with a protective film. This is a complex and costly process. As an alternative, there is now a special UV coating that provides equally good protection for the sensitive cell modules.
Our engineers have developed a fully automated system solution for this new type of coating on behalf of a customer. Prismatic cell modules in various formats can be coated in a contactless continuous process. This has accelerated the entire battery cell production process and reduced costs.
Non-contact coating process at a glance
The entire process for coating battery cells includes ultra-fine cleaning, non-contact coating and immediate curing to enable efficient and precise further processing of the cells. The individual steps of the process are shown below:
Ultra-fine cleaning of the battery cells
Before coating, the battery cells are precision-cleaned using innovative open-air plasma technology to ensure perfect adhesion of the protective coating. This environmentally friendly and selective method removes dust, oil and grease from the surface so that the coating adheres seamlessly and a long-lasting bond is achieved.
Non-contact coating process
In the next step, the battery cells are coated with a special 100% UV protective coating in a fully automated, contactless process. The process protects the cells efficiently without the need for direct handling, which minimizes the risk of damage.
Protecting the terminals from overspray
During the coating process, a special workpiece carrier is used to protect the sensitive terminals and electrical poles of the battery cells from overspray. This enables clean and precise 6-sided coating in a single pass.
Minimization of paint consumption
Permanently installed spray guns work in the coating booth to remove excess paint from the belt and feed it back into the process. This reduces paint consumption and contributes to the efficiency of the entire process.
Immediate curing and further processing
After coating, the cell passes through a UV channel in which the coating is cured immediately. This rapid curing enables direct further processing of the cells, which speeds up the entire battery manufacturing process.
Flexible processing without retooling
The system is able to process battery cells in different formats without the need for retooling. This ensures a high degree of flexibility and continuous production without interruption.
Innovative process achieves top results and reduces sources of error
The finely tuned process of ultra-fine cleaning and coating delivers excellent results and minimizes sources of error in battery production. The result is a highly effective and efficient alternative to expensive, time-consuming film coating, which has met with a high level of satisfaction from our client.
This is because the increased strength of the paint coating in contrast to film wrapping results in a further advantage for the battery module manufacturer: the battery cells can be bonded directly to the housing base while complying with all safety requirements. All safety-relevant aspects are taken into account.
Technical challenges, goals and highlights
- Protection of the sensitive cell modules must be guaranteed
- No materials handling/turning/gripping -> no damage to the battery cells
- 6-sided coating of the battery cells in a continuous process
- Coating of different prismatic battery cell formats without retooling
- Immediate drying / hardening of the coated cells -> enables immediate further processing
- Paint recovery -> reduced paint consumption
- Reliable all-round protection of the cell edges
- Increased production speed
Conclusion: The entire battery cell production process has been accelerated and costs further reduced thanks to the new coating process.
We think Service 360° - holistically, across the entire life cycle of your system. From the initial consultation to long-term process optimization, we support you with technical expertise, digital support and reliable worldwide service.
Our goal: Service 360° keeps your system productive, safe and future-proof - right from the start.
- Advice & fast response times: Analysis, optimization and support - individually tailored to your production.
- Spare parts & remote support worldwide: Original parts, digital assistance and fast delivery safeguard your operations.
- Process optimization & training: Further technical development, increased efficiency and practical training for your team.
We are happy to advise you
Have we piqued your interest? Would you like to find out more about our battery cell coating process or other coating solutions?
Our team will be happy to advise you.
Gert große Deters
Business Unit Manager for General Industry & Automotive
Telephone: +49 5242 9603-184E-mail: ed.bokajnev@sretedessorg.treg
