The shift towards energy storage necessitates advancements in battery and hydrogen technology. IPCO’s technology supports the production of fuel cells and solid-state batteries with high-precision film casting systems, scattering and composite equipment. Our continuous systems significantly enhances the process, allowing for the manufacturing of products with extremely narrow tolerances and industrial scale output.
Beyond battery separators and ceramic tape, our technologies also produce:
Bio based films
PVOH (Polyvinyl alcohol)
CE (Mixed cellulose ester)
These have a huge variety of uses in the electronics, pharmaceutical, packing and medical industries, plus many more, highlighting the versatility and innovation of IPCO’s battery technology solutions.
Thin film casting for fuel cell and battery separators
Batteries and fuel cells both require a separator or membrane that sits between the anode and cathode. And whatever type is used – polymer electrolyte, solid oxide electrolyte or solid state ceramic separator – the production process involves high quality film casting.
Our continuous film casting system incorporates an innovative Venturi dryer and dramatically improves the casting process, enabling production to exceptionally narrow tolerances. This makes it ideal for the high-precision films, membranes and ceramic tapes used as separators in fuel cells and solid state batteries.
Our Venturi dryer technology offers a substantial enhancement in product quality and thermal/heat transfer performance compared to traditional dryers. Notably, it contributes to a significant reduction in the length of the drying section, thanks to the availability of a wider belt (up to 2m) and an even distribution of airflow across the width. This leads to an increase in production capacity, with customers achieving double the speed.
Pressing for consolidation, calibration, lamination and more
A key focus in the development of new batteries is the use of different materials to create the electrodes and solid separators/electrolytes capable of delivering higher density batteries. Combining these materials is typically carried out by calendaring but pressure and heat are only applied momentarily. If the process requires a longer pressure/temperature profile, you need a press.
As one of the world’s leading manufacturers of double belt press systems, we are uniquely placed to support you. Our ThermoPress systems are used for consolidating, compressing, laminating and densifying, and we have the systems and technical expertize to help you find the most effective way to produce your next generation solid state materials.
Scattering for uniform, distribution of powder materials
When materials used to develop safer, more efficient solid state batteries are handled in powder form, special technology is required. We are a world-leading manufacturer of high precision scattering systems and are already supporting a number of partners in the development of non-woven separator membranes.
Key to successful production is the ability to handle powder-like materials uniformly – no clumps – and distribute them in a constant layer with maximum surface homogeneity, without breaking up the all-important fibrils. Our ScatterPro systems and extensive experience can help you achieve this.
Our solvent-based casting process gives you precise control over line speed, temperature distribution, moisture, and air speed, ensuring optimal membrane formation and drying. Our process maintains a high level of tolerance, guaranteeing the roundness of the drum within 5 µm and precise tolerances for belt thickness and flatness. This leads to efficient continuous production, significantly reducing faults and imperfections in your final product.
IPCO’s steel belt-based film casting process ensures the delivery of a consistent and homogeneous layer of liquid product onto a steel belt, providing exceptional thickness uniformity. The cast layer is then efficiently transported through the Venturi drying unit, resulting in a stable, high-quality product.
Steel belt membrane manufacturing
IPCO’s steel belt-based membrane manufacturing also uses a casting system that ensures a uniform layer of liquid product onto a steel belt. The cast layer is subsequently conveyed through the steel belt unit’s conditioning sections, yielding a stable and high-quality product with remarkable efficiency.
Continuous, high-rate production
All processes ensure an efficient continuous production, with precise tolerances for membrane thickness and flatness, as well as uniform conditions for the phase separation process, considering temperature and humidity variables. The resulting membrane exhibits a consistent and uniform porous structure.
Our high steel belt specification
• Belt grade: -1000 SA VAR for PI, Tac, PVA, PC -1200 SA VAR for acrylic -1200 SA AOD for ceramic, medical membrane -1650 SM for PP, CCL, ceramic -1850 SM for ceramic up to 300mm
• Typical belt thickness: 1.1mm • Belt width: up to 3 meter (2 meter in single strip) • Belt width tolerance: ±0,5mm to max ±1mm • Thickness tolerance: ± 10 µm • Surface roughness: Ra < 0,1µm • Polishing grade: PF0, PF1, PF2) • Precise belt tracking system: ± 1,0 mm
Battery technology in numbers
Belt width
~3m
Or 2 meters in single strip
Tolerance
+/-10
µm. Steel belt thickness tolerance.
Temperature
+/- 1.0
K. Heating/cooling accuracy.
Streamline your R&D at our Productivity Centers
Research into new battery technologies and associated production processes requires pilot solutions that can be quickly scaled up and industrialized. The investment we have made in our Productivity Centers in Europe, North America and Asia gives you access to the equipment and technical expertize to carry out detailed testing, feasibility studies and process optimization with minimal risk.
Film casting Productivity Center
Our advanced R&D facility in Fellbach, Germany is home to a complete film casting system incorporating heated slot dies of different sizes, a 700 mm wide polished steel belt with heating, one Venturi dryer and two impingement sections. This pilot plant is available to you for process assessment and product testing, and our technicians and engineers will provide all the support you need.
Our state of the art Productivity Center in Goeppingen, Germany is a 1600 m2 facility showcasing our ThermoPress double belt press ranges, with systems based on steel belts, PTFE belts and a combination of both. See it as an extension of your R&D work for customized product development, process testing and prototype production. Customers in Asia can also visit our Productivity Center in Kobe, Japan.
Our Productivity Center in Goeppingen is also the base for ScatterPro-based R&D, product testing and small scale batch production. In addition to our in-house test systems, we can also provide units for process development at your own facility, enabling testing in production conditions (e.g. dry rooms) or using potentially hazardous materials. We also have scattering systems at our Productivity Center in Pine Brook, USA.
