Batteries: Precision for the Energy Storage Systems of the Future
Electromobility, portable electronics, and stationary energy storage systems are rapidly driving global demand for high-performance batteries. A decisive factor for their efficiency and safety is the precise manufacturing of materials and multilayer systems. With its isobaric double belt presses, HELD Technologie provides the foundation for reproducible, scalable, and sustainable battery material production, from thin films to finished cell components.
The requirements for modern battery technologies continue to rise: higher energy density, longer service life, and maximum safety. HELD Technologie’s isobaric double belt presses enable the reproducible and precise production of components for lithium-ion, sodium-ion, and solid-state batteries.
Precisely controlled temperature and pressure profiles create materials with homogeneous structures and stable layer properties. This forms the basis for high-performance electrodes, separators, electrolyte layers (in the case of solid-state batteries), and component stacks such as mono-cells. Maximum precision is essential for uniform current density, improved charging cycles, and safe cell performance.
HELD’s press technology also enables the processing of thermoplastic and composite films used in battery module and cell housing production. In addition, thermal interface materials (TIMs) for heat dissipation and mechanical stabilization can be produced continuously and used, for example, in separators or between cells and modules. These solutions are ideally suited for applications in e-mobility, energy storage, and stationary battery systems.
Applications in Battery Manufacturing
With HELD double belt presses, functional layers, laminates, and composite films can be manufactured continuously and with high precision.
Typical applications include:
Electrode manufacturing: Uniform structure and particle distribution for improved conductivity and energy efficiency.
Separator films: Defined pore structure and high dielectric strength for optimal safety.
Mono-cell or half-cell production: Highly precise electrode–separator lamination.
Electrolyte layers: Uniform layer thickness for stable ion conductivity in solid-state and hybrid batteries.
Thermal Interface Materials (TIMs): Thermally conductive layers for effective cooling of battery modules and power packs.
Insulation and protective films: Thermally and electrically stable materials for cell and module separation.
Innovative Manufacturing Technology for High-Performance Lithium-Ion Batteries
The growing demand for high-performance lithium-ion batteries (LIBs) requires advanced production processes to manufacture electrode–separator laminates with maximum energy efficiency and safety. Conventional calendering reaches its limits in this context: a single compression step often results in insufficient uniformity and can negatively affect the interfacial integrity between layers.
The solution is the isobaric double belt press. This continuous roll-to-roll process ensures uniform pressure distribution over an extended period of time. As a result, particle rearrangement, adhesion, and interfacial properties are significantly improved.
As a result, customers benefit from:
Stronger adhesion between electrode and separator
Lower interfacial resistance
Improved wettability, leading to
Higher cell performance and longer resistance
Current experimental data show that a constant process temperature and sustained, uniform pressure are critical for achieving high bond strength in the production of electrode–separator laminates for lithium-ion batteries. Hi-Pot tests have confirmed that the lamination process is completely damage-free and that electrical insulation strength is maintained up to 400 V DC.
These results demonstrate the capability of the isobaric double belt press to manufacture high-quality, process-stable battery laminates, a key technology for efficient, safe, and scalable battery cell production of the future.
Homogeneous material properties across large areas.
Minimal tolerances in thickness, density, and surface quality.
High reproducibility in series production.
Flexible process control for thermoplastic and thermoset systems.
Integrated process steps such as coating, laminating, or structuring in a single pass.
Importance for the Energy Transition
The precision of material manufacturing is crucial for the performance, service life, and safety of modern batteries. Uniformly produced laminates, separators, and electrodes help to:
increase energy density,
extend charging cycles,
improve thermal stability,
maintain consistent cell quality across large production volumes.
Films: Separator films made of polyolefins (PP, PE) with defined porosity and high thermal stability, as well as battery functional layers.
Fabrics: Glass, aramid, or carbon fabrics for reinforcing battery housings or composite covers. Conductive fabrics for dissipating static charges or serving as carriers for functional layers.
Nonwovens: Microporous nonwovens used as separator or filtration layers, as well as thermally stabilized nonwovens for electrode composites or as insulating interlayers.
Granulates: Thermoplastic polymers (e.g. PVDF, PA, PEEK) for manufacturing cell housings, insulation plates, and structural components; compound granulates with additives for thermal conductivity, flame retardancy, or chemical resistance.
Powders: Electrode materials (e.g. NMC, LFP, graphite) for coating films in electrode laminates.
Composite layers: Electrode–separator laminate structures for lithium-ion and solid-state batteries, as well as multifunctional layers with integrated heat dissipation and electrical insulation.
HELD – Your Partner for Innovative Battery Manufacturing
HELD systems ensure consistently high quality in lithium-ion and solid-state batteries, which is essential for industrial applications. Precise temperature and pressure distribution across the entire material web enables homogeneous material properties, high reproducibility, and minimal tolerances in terms of thickness, density, and surface quality.
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