Specialist surface coating techniques for powder coating on EV battery assemblies

Danecca, based in Silverstone Park, develops and makes EV batteries for both mass and niche markets. The company has extensive experience in battery design and works to a high level of engineering proficiency. The firm chose Powdertech when expertise in specialist coating techniques was required.

Precision coating for EV battery assembly components

Danecca’s client, a major heavy vehicle manufacturer, required them to produce steel battery assemblies that would need specialist coating techniques to provide electrical insulation as well as protection from corrosion. A complex component like a battery assembly also has areas that must be left uncoated. Furthermore, a thick coating on the entire part was also to be avoided as this would mean that certain areas would not slot back together again when the component was fitted into the final assembly.

Masking for powder coating

Protecting particular areas from the application of coating is achieved by a procedure known as masking where certain areas of the metal part are shielded using masking tape or film, silicone plugs and caps. Masking small, often difficult to access areas is a job demanding utmost precision, a technique in which Powdertech has a lot of experience. The right tape must be selected, resilient to the high temperatures used in the coating process but not too thick where the areas to be covered are small and irregularly shaped.

Masking must be carried out at the correct stage in the coating process which is usually after chemical pre-treatment when the part is completely dry. After masking, the parts are powder coated in the usual way, the tape and plugs/caps remaining in place when the part enters the curing ovens, at over 200 degrees Celsius.

Powdertech pre-treated the components, then masked the designated areas and coated the steel EV battery components with Interpon Resicoat. All areas of every component were tested for edge-to-edge coating and electrical insulation to the required level. The parts fulfilled all evaluations by the client and full production commenced.