High-end batteries

With short-cycle and in-line plasma pre-treatment for state-of-the-art battery systems

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Long-term stable battery modules

The battery is the heart of an electric vehicle. In addition to the automotive industry, batteries are now an essential component in many industrial sectors, such as the PV industry (solar storage), mobile devices (smartphones, tablets, battery-powered tools), etc. The demands on the battery cell are therefore particularly high. Connections and thus the adhesion of the individual components not only influence the tightness, but also ensure battery thermal management, which defines the service life and efficiency of a battery system. From the production of the individual cells, starting with the anode and cathode, through process steps such as calendering, drying and cell assembly to cell finishing and thus the finished battery/battery module, Diener electronic's plasma and vacuum technologies are the recipe for success.

In many cases, it is necessary to subject the carrier film to plasma cleaning and activation before coating with the slurry. In principle, the material of the film (copper, aluminum, PEEK, etc.) is irrelevant and can be pretreated either in roll-to-roll low-pressure plasma systems or inline with rotating atmospheric pressure plasma nozzles(PlasmaBeam RT).
After coating and drying the carrier film and subsequent calendering, it must be cleaned and activated again. This ensures constant cell performance. The quality requirements for particle-free ultra-fine cleaning are also enormous for separator sheets and contacting. This makes the use of plasma technology the ideal pre-treatment step in terms of process reliability, environmental friendliness and cost efficiency.

The subsequent module production requires a high degree of activation of the individual components in many production steps. For example, the finished cells must have optimum surface properties to enable reliable bonding or potting. Similarly, the contacts (pins) for the electrical connection of the battery cells(wire bonding) must be absolutely free of dust and grease. The use of our plasma devices for surface activation/cleaning is therefore not so much recommended as necessary in order to produce high-quality battery modules. Both atmospheric pressure plasma systems (PlasmaBeam) and low-pressure plasma systems are suitable for this pre-treatment. Plasma systems in the low-pressure range have decisive advantages over atmospheric pressure systems. For example, the removal of oxide layers on copper or nickel surfaces with vacuum plasma is child's play and is already a standardized process in many industrial sectors. In contrast, such results can hardly be achieved with atmospheric pressure systems.

The final battery pack production also requires pre-treatment of the components in many respects. For example, in safety and performance-related matters, such as the adhesive bond of the thermal management plate or the complete sealing of the battery housing. However, aesthetic and optical processes such as painting, printing or gluing the housing also require the use of plasma for VOC/primer-free activation.

In addition to the inline integration of atmospheric plasma nozzles, short-cycle vacuum plasma systems are target-oriented pre-treatment methods. The advantages of low-pressure plasma are impressive with a holistic, even more effective 3D treatment of the component, and all without the nitrogen oxides (NOx) and ozone produced by atmospheric plasma.

Your advantages

Low-pressure and atmospheric-pressure plasma treatment is a superior solution to the challenges of wetting, sealing, foiling, bonding and painting.

Vacuum systems in battery production

Apart from the use of plasma in battery production, vacuum systems can also be found in the process chain. We also offer appropriate solutions for this. Our vacuum drying systems (vacuum dryers) are used in battery cell production afterslitting the electrode strip(mother coil). The smaller electrode strips (daughter coils) are rolled up for several hours in the vacuum oven (vacuum dryer), where the residual moisture is removed and solvents are degassed. In addition, batteries (e.g. lithium-ion batteries) must undergo UN 38.3 testing and certification after completion. This is sometimes carried out in altitude simulation systems (negative pressure test), whereby the batteries and rechargeable batteries are exposed to a pressure of 116 mbar for six hours. Your advantage: We can supply you with atmospheric pressure plasma, low-pressure plasma and vacuum systems from a single source.

More information

Vacuum storing, vacuum degasing, altitude testing

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