Chemical-Free Contaminant Removal
Plasmatreat (Elgin, IL) has expanded its portfolio with HydroPlasma, an innovative solution for the gentle, intensive, and efficient removal of stubborn contaminants from glass and metal surfaces. This advanced technology combines the proven benefits of Openair-Plasma technology with the chemical reactivity of water, setting new standards in surface preparation for subsequent production steps. Even the slightest contamination can impair adhesion in subsequent processes such as bonding, printing, painting or coating, thus jeopardizing the quality of the end product. This innovative technology uses ionized water to efficiently remove even the most stubborn contaminants such as oil, salt, and grease — completely chemical-free and environmentally friendly. The cleaning process is based on the direct injection of water into the plasma jet, where it is ionized and converted into a highly reactive jet. A specially designed nozzle directs the jet onto the desired substrate surface. The ionized water molecules achieve a cleaning effect comparable to that of detergent in warm water, reliably dissolving and removing residues. HydroPlasma is particularly suitable for industries with high purity requirements and can be used for industrial processes such as battery production or applications in the electronics industry.
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Programmable AC-DC Power Supplies
TDK Corporation (Neptune City, NJ) has introduced 3000-watt TDK-Lambda brand HWS3000G programmable AC-DC power supplies. The nominal output voltages and output currents are fully programmable (CV/CC) from zero up to their maximum rating. These new models have an /HD option for board coating and the ability to meet MIL-STD-810G Shock and Vibration in harsh environments. The /RF option provides the ability to have the airflow direction reversed for compatibility with the user’s end system. The HWS3000G can deliver 1500W with a low-line single-phase input voltage (85 to 132V) and 3000W at high-line (170 to 265V). Four nominal output voltages, 24V, 48V, 60V and 130V, can be programmed to provide 0-28.8V, 0-52.8V, 0-66V, and 0-156V. Up to three units can be connected in series, or ten units in parallel. The output voltage slew rate can be digitally programmed and monitored, along with information regarding cumulative operating time, fault log, and product identification information. Digital programming can be performed without turning the power supply on. Output programming can be achieved using a serial RS485 interface (MODBus protocol) or analog 1-5V or 4-20mA signals. These very compact products also feature a variable speed fan with typically 45dB audible noise at <70 percent load, and a 25 °C ambient temperature.
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Ceramic Coatings
Zircotec (Oxfordshire, U.K.) has unveiled a new range of proprietary ceramic coatings that make it possible for EV manufacturers to replace heavy-duty steel battery enclosures and cooling plates with lightweight aluminum and plastic composite materials — without compromising safety, thermal management or electrical insulation. The ‘ElectroHold’ coatings integrate dielectric, flameproofing, and thermal properties into a single coating system. This allows OEMs to use lighter materials for battery enclosures and to improve cooling plate efficiency by pairing thin, high-performance electrical insulation with enhanced thermal conductivity. The result is greater design flexibility, reduced vehicle weight and extended driving range. The new coatings have been subjected to rigorous electrical, thermal, and durability testing, simulating the demands of modern EV motoring. This included a full-scale simulated ‘UL2596 Method A’ thermal runaway test event for the battery box coating where the battery module was deliberately driven to failure to replicate the most severe safety scenario an EV might encounter. During this test, the Zircotec-coated carbon fiber enclosure passed comfortably, maintaining its structural integrity, preventing flame egress and continuing to provide electrical isolation — demonstrating its ability to increase all-important protection time for vehicle occupants and surrounding systems under extreme heat and pressure. During other tests, simulations and evaluations, Zircotec’s latest cooling plate coating delivered a four-fold increase in dielectric strength over a previous iteration.
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Thermal Management Fluids
At The Battery Show North America, Prestone (Lake Forest, IL) showcased its Prestone EVX™ collection of electrified vehicle (EV and hybrid) thermal management fluids that meet newly implemented industry standards. Engineered to help vehicle OEMs address the ever-increasing demands of EV charging time, driving range, safety and overall performance, Prestone’s EVX™ formulations offer low conductivity, extended corrosion protection, and excellent chemical stability for light-and-heavy-duty EVs. Having undergone rigorous real-world testing to ensure low-current levels for safety in high voltage applications, the fluids serve as the next generation of thermal management for electrified transportation. Prestone’s EVX™ fluids help meet EV coolant specifications that are currently going into effect in China. Previously expected to take effect in 2026, the GB29743.2 standard went into effect October 1, 2025. The standard, which will likely be implemented globally within the next few years, is aimed at enhancing safety in EVs by reducing the electrical conductivity of coolants. Prestone’s EVX™ fluids not only meet the requirements for the GB29743.2 standard but also for the ASTM D8566 standard — which focuses on low electrical conductivity to minimize potential harm caused by coolant contacting batteries — helping automakers comply with and be prepared for vital requirements now, strengthening the company’s role as a critical partner in the EV supply chain.
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Modular Bidirectional DC Power System
The Sorensen™ Modular Intelligent-Bidirectional Energy AMplified (Mi-BEAM) Series is the newest addition to the AMETEK Programmable Power (San Diego, CA) portfolio of high-power testing solutions. The new Mi-BEAM Series features full DC source and sink capabilities with power levels from 12.5kW up to 37.5kW. The Mi-BEAM Series is fully scalable up to 1.2MW with parallel systems. The available voltage ranges of 600V and 2,000VDC in a 4U rack height chassis provide full power with up to 150A per channel. The Mi-BEAM Series can be operated from the intuitive, front panel touchscreen that enables the user to easily setup, control, and monitor the output programming parameters, supervisory and set point limits, measurements, and system settings. Additionally, a variety of standard communication control interfaces are available including; LAN, USB, and RS-232 and Optional IEEE-488 are available. The Mi-BEAM Series is designed for testing today’s complex, high power electronics for the automotive, energy storage, industrial, and aerospace markets in a variety of applications. This platform covers all test needs through the product life cycle from advance research and development, to design validation, and production test requirements.
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Twin-Screw Extruder
Thermo Fisher Scientific (Waltham, MA) has expanded its solutions for battery manufacturers. The new Thermo Scientific™ Energy 16 PROTECT Glovebox with integrated Energy 16 Twin-Screw Extruder enhances battery electrode processing, a critical aspect of battery performance and efficiency. With continuous working processes that reduce inconsistencies, the Energy 16 saves labor resources and prioritizes safety with containment solutions. Lithium-ion battery materials need to be processed under dry or inert conditions to protect the sensitive chemicals involved. To fulfill this need, the Energy 16 solution combines twin-screw extrusion capabilities and a precisely controlled atmosphere within a user-friendly setup for easy handling during battery manufacturing. The Energy 16 enables solvent-free or solvent-reduced electrode processing, which reduces, or may even eliminate, energy-intensive solvent evaporation and recycling, as well as the use of hazardous and expensive volatile solvents. Its flexible configuration allows battery manufacturers to adapt to a wide range of applications from granulation, polymeric solid-state electrolytes and dry electrode materials to wet slurries. Additionally, it offers users increased throughput, precise process control with eight controlled temperature zones along the barrel, simplifying complex processes and offering high reproducibility for improved material efficiency and consistency.
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Liquid-Cooled On-Board Charger
Bel Fuse Inc. (Santa Clara, CA) has launched BCF19-700-8, a 19.2 kW liquid-cooled on-board battery charger for hybrid (HEV) or full electric (EV) vehicles, as a part of the Bel Power Solutions portfolio. The high-efficiency AC charger has an output voltage of 450 – 900 VDC to cover a wide range of high-voltage batteries. Providing a typical full load efficiency of 94 percent, the on-board charger has an output power of up to 18 kW with over-temperature, output over-voltage, and over-current protection. Its CAN bus serial interface provides seamless onboard communication for reliable monitoring and control signals. The BCF19-700-8 can be powered by standard EVSE charging stations directly from the public grid in custom systems, including single-phase or splitphase 100 – 277 VAC. This liquid-cooled unit is engineered to deliver robust performance and seamless integration with HV battery systems. Its compliance with industry standards such as SAE J1939 and UL 2202 ensures reliability and safety, addressing the critical needs of system integrators and vehicle manufacturers. Its 19.2 kW output, high efficiency, and wide voltage accelerate charging times and ensure compatibility with a broad spectrum of HV battery systems, giving providing performance and flexibility.
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Cell Contacting System
ENNOVI’s innovative cylindrical cell contacting system, ENNOVI-CellConnect-Round, achieves excellent current density spread. This helps extend the lifespan of battery packs by reducing the stress on individual battery cells. The ENNOVI-CellConnect-Round integrates seamlessly into an organized system and can be customized to meet customer specifications. From design complexities to assembly efficiencies and space constraints, the CellConnect-Round is designed to overcome them all. It has a thin, tough structure, resulting in an excellent current density spread, which ensures consistent performance and efficient, low-loss energy transfer. With patented U-Turn technology, ENNOVI-CellConnect-Round ensures that current density is distributed as evenly as possible for multiple configurations. It provides the flexibility to create designs for battery modules or new advanced cell-to-pack and cell-to-chassis configurations. Despite being especially thin, ranging from 0.17 mm to 3 mm, ENNOVI-CellConnect-Round is tough enough for large current collectors, up to 2.5-m long. EV batteries tend to develop hot spots across conventional collector plates. ENNOVI-CellConnect-Round addresses this issue with patented U-Turn technology, which yields a uniform distribution of current density. By reducing stress on individual battery cells, U-Turn helps batteries perform better, go further, and live longer.
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