eSOLATE® highV plus
Coating system with the highest dielectric properties. For installation in challenging situations and with optimized heat transfer capability
Electrically insulating coatings are primarily used for the safe electrical isolation of cells, modules and housings to prevent short circuits and dangerous voltage breakdowns, especially in high-voltage systems of 400-800 V and more. eSOLATE highV plus is our most powerful protection for your components.
eSOLATE® highV plus
Electrical insulation coating
with maximum dielectric strength
Layer system description
eSOLATE® highV plus is a two-layer powder coating system for the electrical insulation of installed components. Thanks to our decades of experience in series coating, we achieve dimensionally stable insulating layers with extremely reliable adhesion.
eSOLATE® highV plus is designed for high continuous and peak temperatures as well as rapid temperature changes, such as those that occur in EV batteries. For different requirements for dielectric strength and thermal conductivity, this coating system can be applied reliably between 80µm-350µm.
Our extensive capacities enable price-sensitive series coating of your components.
Electrical insulation coating
eSOLATE® highV plus
High-performance coating process for the electrical insulation of components in battery modules, battery packs, battery storage systems and other components in high-voltage applications.
EV battery
Cooling plates
EV battery
Floor cooling
EV battery
Snake cooling
EV battery
Cell holder
EV battery
Cell housing
Performance and efficiency
The selection of a suitable coating system is mainly determined by the required dielectric strength, the geometry of the component and the condition of its surface. The focus here is on puncture-prone edges, burrs, holes, punch-outs and defects within the component surface.
In this area, eSOLATE® highV plus is our best-performing protection system. It provides a reliable insulation effect even with thin layers in challenging installation situations or where the component has been machined with sharp edges. Since layer thicknesses affect both dielectric behavior and thermal conductivity, eSOLATE® highV plus is the optimum combination of electrical protection and improved heat dissipation.
Electrical insulation coating
eSOLATE® highV plus
Coating system with the highest dielectric properties. For installation in challenging situations and with an optimized thermal conductivity coefficient
- High performance even with thin layers
- Suitable for machining metal components with a high degree of porosity
Why is the right masking work so crucial to the success of an electrically insulating coating
Masking is a crucial step in the process of electrical insulation coating in order to specifically exclude certain areas from the coating. Heat-resistant tapes, covers or plugs are used for this purpose, which reliably protect sensitive or functional surfaces even with complex geometries.
This protects threads, sealing surfaces, contact points and fits from unwanted coating and ensures the full functionality of the components after the coating process.
Production process
We coat eSOLATE® highV plus 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
Thanks to effective system control, we can apply both powder coating layers inline without the need for further manual component handling.
- Simple to complex masking options
- Assembly, packaging and labeling of goods and assemblies
- End of line dielectric strength tests
- Dimensionally stable insulation protection even for complicated geometries
- Highest dielectric strength
- Optimized for edges, burrs, drill holes, cut-outs
- Thermal conductivity reduced to 0.65 W/(mK)
- 8-stage pre-treatment for lasting adhesion
- Robot-assisted pre-coating - fully automatic coating machines
- Double powder coating inline without additional component handling