eSOLATE® highV
Universal coating process for the electrical insulation of components in battery modules, battery packs, battery storage systems and other components in high-voltage areas.
Reliable insulation in electric vehicles is essential to protect the various elements of an electric vehicle platform architecture from partial discharges and to shield against leakage currents. Electrically conductive components that are live must be insulated to ensure their functionality on the one hand and to avoid potential hazards on the other.
eSOLATE® highV
Electrical insulation coating
with high dielectric strength
Shift system description
eSOLATE® highV is a two-layer powder coating system for the electrical insulation of components. Electrically insulating coatings have now become established for this safety-relevant application, as complex component geometries can often be best mapped with dimensionally stable coatings. In addition to adjustable coating thicknesses, powder coatings have excellent adhesion properties.
This universal high-voltage insulation system eSOLATE® highV uses a variety of coating media from different suppliers, and we are also happy to cater to your specific requirements. For different dielectric strength requirements, this coating system can be applied precisely and reliably in a range from 120 µm to 350 µm.
Our extensive capacities enable price-sensitive series coating of your components.
Electrical insulation coating
eSOLATE® highV
Universal coating process for the electrical insulation of components in battery modules, battery packs, battery storage systems and other components in high-voltage areas.
EV battery
Floor cooling
EV battery
Snake cooling
EV battery
Busbars
EV battery
Cell housing
Performance and applications
The selection of a suitable insulating coating system is primarily determined by the required dielectric strength, the geometry of the component and the nature of the surface. The focus here is on puncture-prone edges, ridges, holes, breakouts and defects within the component surface.
In our current projects for high-voltage insulating applications, we coat heat exchangers, heat sinks, floor cooling modules, cooling coils, battery housings, enclosures and tie rods/tension plates/cell holders for the EV platform architectures of international OEMs.
Electrical insulation coating
eSOLATE® highV
Coating system with the highest dielectric properties. For installation in challenging situations and with an optimized thermal conductivity coefficient
- universally applicable
- Further specifications can be displayed
Do you only need partial coatings for your components? We mask your components according to your requirements.
Masking is a crucial step in the powder coating process in order to specifically exclude certain areas from the coating. Heat-resistant adhesive tapes, silicone covers or plugs are used to reliably protect sensitive or functional surfaces - even with complex geometries.
This method protects threads, sealing surfaces, contact points and fits from unwanted coating and thus ensures the full functionality of the components after the painting process.
Professional masking is largely responsible for the quality, accuracy of fit and aesthetic appearance of the end product. At the same time, it reduces the amount of reworking required and minimizes rejects.
Production process
We coat eSOLATE® highV in a fully automated powder coating system. The pre-treatment runs through an 8-stage wet-chemical process that is tailored to your component requirements.
Robot pre-coating
Automatic powder coating
Process flow
With the help of an effective system control, we can apply both powder coating layers inline without the need for further manual handling of the components.
- Simple to complex masking options
- Assembly, packaging and labeling of goods and assemblies
- End of line dielectric strength tests
- Dimensionally stable insulation protection for different geometries
- High dielectric strength
- universally applicable
- Additional functionalizations are available
- 8-stage pre-treatment for lasting adhesion
- Robot-assisted pre-coating - fully automatic coating machines
- Double powder coating inline without additional component handling