Fully Automatic UV Dielectric Coating Line for EV Battery
Contact Us

As a result of increasing requests in the market for Cell-to-Pack (CTP) and Cell-to-Chassis (CTC) battery designs, insulation coatings on EV battery cell housings are required to fulfill the requirements of high dielectric strength, strong adhesion, electrolyte resistance, production line takt time, and precise coating on complex parts such as battery terminals, vent valves and QR codes.

The fully automatic UV dielectric coating line integrates UV spray coating and UV inkjet printing into one automated EV battery dielectric coating system.

  • UV Spray Coating
    Applied on the bottom and four side surfaces of battery cells, achieving continuous, uniform coating layer formation on large surface areas.
  • UV Inkjet Printing
    Applied on the terminal surface to deposit insulation coating selectively according to the battery cell profile and designated areas.

By combining large-area UV spraying coating with selective UV inkjet printing, this automatic UV dielectric coating line eliminates complex masking steps, and enables insulation coating on all six surfaces of EV battery cells.

Integrated UV Spray Coating and Inkjet Printing Process
  • Surface Preparation
  • 5-Face UV Spray Coating
  • Leveling
  • UV Curing
  • 100% Inspection
  • Terminal Face UV Inkjet Printing
  • Final UV Curing
  • UV Spray Coating
    5 faces (bottom and four side surfaces), 50PPM, adjustable coating thickness, with electrolyte and thermal shock resistance.
  • UV Inkjet Printing
    Terminal surface, precise avoidance of terminals, vent valves and QR codes, no need for masking, utilization rate over 98%.
Integrated UV Spray Coating and Inkjet Printing Process
Advantages
  • VOC-Free UV Coating Process
    100% solids, zero VOC and wastewater, fully compliant with EU carbon regulations.
  • Photosensitive Resin
    UV curing within 3-5 seconds, substrate temperature at ≤50°C, energy saving of 70%, precise thickness of 80-150μm (±10μm), compatible with all cell types.
  • High Adhesion for CTP/CTC
    Coating adhesion of ≥9MPa with cohesive failure, interfacial cracking <5% (vs. 32% for conventional process), shear strength of 9-15MPa, direct cell-to-chassis (CTC) bonding.
  • High-Voltage Safety & Thermal Management
    Coating thickness of 120μm withstands 5000V DC, with leakage current below 0.1 mA and zero degradation after 300 cycles; Thermal runaway propagation resistance of 2 hours (vs. 30 minutes for PET), with peak temperature reduced by 40%.
  • Global Compliance & Seamless Deployment
    The automatic UV dielectric coating line is configured with a multilingual HMI interface, and can be operated within a temperature range of -40°C~85°C; 12 certifications (UL, IEC, JIS) for tariff-free market access in the EU, US, and Japan, with delivery lead time shortened by 40%.
  • Modular Design & Automation
    The modular design helps reduce factory footprint by 60%, while achieving OEE of 92%, and a yield rate of 98%; The cell cost is lowered by 30%, and carbon footprint is reduced by 42%.

Note: All data verified by third-party testing on our 50 PPM pilot line.

  • Pull-Off Adhesion Test (ISO 4624) Pull-Off Adhesion Test (ISO 4624)
  • Dielectric Withstand Test Dielectric Withstand Test
  • Insulation Resistance Test (Sample Test) Insulation Resistance Test (Sample Test)
  • Insulation Resistance Test Insulation Resistance Test
  • ＞16MPa
    Pull-off adhesion (ISO 2409), 60% above National standard (≥10MPa), Class 0, zero flaking
  • 7kV / 3.7μA
    Dielectric withstand, 107μm coating thickness, 7kV DC for 60s, leakage current 3.7μA (far below the 0.1mA limit), with no breakdown or flashover
  • ＞300 GΩ
    Insulation resistance, actual measured value, providing an ample safety margin for battery systems
  • ＞1000h Electrolyte Resistance
    85°C immersion for 1000 hours with no blistering, peeling, or discoloration; 39% above industry benchmark (≥720h)
  • ＞100 Thermal Shock Cycles
    100 thermal shock cycles (-40°C~85°C), no adhesion loss, meeting full-lifecycle vehicle extreme conditions
Comparison of Insulation Coating Processes
Comparison Integrated UV Spray Coating + Inkjet Printing Independent UV Spray Coating Independent UV Inkjet Printing PET Blue Film Wrapping
Insulation Withstand Voltage ≥6000V DC ≥6000V DC ≥4000V DC ≤2800V DC
Production Line Takt Time 50 PPM 50 PPM ＜10 PPM 6 PPM
Material Utilization Rate ＞ 96% ~ 95% ~ 98% ~ 90%
Terminal / Vent Processing Digital precision selective coating (no tooling required) Requires complex masking tooling Digital precision selective coating Complex die-cut openings required
Shear Strength ≥ 10MPa ≥ 10MPa ≤ 8MPa ~ 2MPa
VOC Emissions 0 VOC 0 VOC 0 VOC ＞ 0 VOC
Total Lifecycle Cost <30% reduction compared to conventional processes Moderate Relatively high Moderate
37 Years of Engineering Experience, from Validation to Delivery
  • Risk Reduction First
    37 years of equipment engineering and overseas EPC experience, supported by our team of seasoned engineers. Our in-house 50 PPM pilot line allows customers to validate the process before mass production.
  • Quality You Can Rely On
    Optional in-house AI vision enables cell positioning, selective coating on terminal surfaces, and in-line defect inspection. Dielectric withstand testing can be integrated for automatic detection and rejection of unqualified battery cells.
  • Production Data & System Integration
    End-to-end traceability of spray, curing, and inspection data, with OEE analytics, alarm logs, and recipe management, supporting seamless MES/ERP integration for smart factory.
  • Global Project Delivery & Service
    Seven global service centers support turnkey project delivery, including project design, manufacturing, FAT, shipping, overseas SAT, and on-site support.
  • Modular Design for Future Expansion
    The semi-custom, modular design supports future upgrades without rebuilding the entire production line.
Changhong Intelligence's core business covers automated automotive painting equipment, intelligent welding systems, conveying systems, and general assembly lines. In the body shop area, we design and manufacture robotic welding lines, main body welding lines, and sub-assembly welding lines. In the paint shop area, we provide complete project planning and construction, including PT & ED equipment, spray booths, ovens, and conveying systems. In the general assembly area, we deliver automated assembly lines that build complete vehicles according to defined assembly specifications and sequences. Our technical services span the entire project lifecycle - from process planning, equipment design, and manufacturing to on-site installation, automation commissioning, and long-term after-sales support.