2025-07-22   Lankwitzer

UV Spraying: The Lithium-Battery Industry's “Light-Speed”

 Leap into the New Insulation Era

When 800 V, 4C fast charging, and CTC structures have become the “default settings” in tender documents, the insulation systems of power 

batteries are still patching up with PET blue film from 20 years ago. Today, the real anxiety in the industry is not whether the “technology works,” 

but whether it can be “adopted quickly enough.”UV spraying technology has already put a single-choice question in front of all lithium battery

people with its hard indicators of 3-second curing, 99 % yield, and 6000 V dielectric strength: embrace it immediately, or be left behind.

I. Comprehensive Performance Overhaul: From “Passive Protection” to “Active Safety”

Voltage Withstanding Leap: UV coating passes the breakdown test above DC 6000 V, easily matching the 800 V and even 1000 V high-voltage platforms.

Bonding Strength: After curing, the shear strength is ≥ 16 MPa, twice that of PET blue film, completely solving the risk of insulation layer detachment 

under thermal cycling.

 Weather Resistance and Flame Retardancy: No abnormality after 1000 h in an environment of 85 ℃ / 85 % RH, with flame retardancy rating reaching 

UL 94 V0, providing long-term resistance to electrolyte erosion.

II. Disruptive Process Innovation

1–3 seconds for single-cell insulation: Air spraying + LED-UV instant curing, with a single-piece takt time of < 3 s and a yield of > 99 %; the production

 line length is shortened by 30 % compared with blue film.

Zero-waste production: UV spraying can be done without trimming or lapping, with a material recycling rate as high as 95 %, completely eliminating

 the waste of blue film scraps.

Intelligent production line revolution: Laser + plasma cleaning → online film thickness / dielectric strength / appearance inspection → data closed 

loop, realizing unmanned high-speed production.

III. Accelerating onto the UV Implementation Fast Lane: Converting Every Hesitant Minute into Lagging Capacity

CATL, BYD, and EVE’s pilot lines have already lit up with the blue-purple UV lamps; in the battery packs of BMW’sentire range of new energy vehicles, UV 

coatings are quietly

 in service. The new national standard will be fully implemented in 2026, with stricter requirements for insulation, flame retardancy, and thermal runaway 

indicators. The window of opportunity for small and medium-sized manufacturers is ticking down to 12 months.

IV. The “Emotional Value” of Embracing UV: Exciting Customers, Investors, and Engineers Alike

 Customers: High range and fast charging on the 800 V platform, with UV insulation spraying as a safety barrier.

 Investors: Yield of 99 % VS blue film’s 95 %, with a single GWh gross profit increase of 30 million; the capital market is willing to give UV technology a premium.

 Engineers: No more being woken up in the middle of the night by “blue film curling edges,” UV coatings cure like a ceramic layer, pulling the line OEE from 80 % to 92 %.

V. Immediate Action: Three Key Steps for the Industry to Embrace UV Spraying Technology

1. Accelerate technology validation:

 Immediately start small batch production line testing to verify the compatibility of UV spraying with existing cell designs.

 Establish a rapid evaluation system of “mechanical impact + damp heat aging + electrochemical testing.”

2. Optimize process parameters:

Jointly debug key parameters such as spray gun trajectory and curing energy with equipment manufacturers.

Develop a universal spraying solution applicable to different cell sizes.

3.Build a strategic supply chain:

 Lock in the production capacity quotas of top material suppliers such as Germany’s Lankwitzer.

Co-build the next-generation intelligent spraying production line standards with equipment manufacturers.