Prismatic Cell Insulation: Blue Film Wrapping vs. UV Coating
Release time:
2025-11-25
Battery Blue Film Wrapping (BFFW) is an insulation process using pre-formed PET or PI films with thickness ranges between 0.15mm and 0.2mm to maintain consistent dielectric strength over the lifecycle of an EV battery module assembly process.
Battery Blue Film Wrapping (BFFW) is an insulation process using pre-formed PET or PI films with thickness ranges between 0.15mm and 0.2mm to maintain consistent dielectric strength over the lifecycle of an EV battery module assembly process. As opposed to UV spray coating, blue film wrapping ensures 100% thickness uniformity with superior mechanical scratch resistance for high volume battery module assembly operations.
Engineers of Prismatic battery modules know that electrical insulation is their first line of defense against potential electrical shock hazards, with two popular approaches available today being "Battery Blue Film" Wrapping and UV Spray Coating.
However, which solution best meets your production line needs? Here is our impartial engineering comparison between these solutions types.
1. The Case for Blue Film (The Industry Standard)
Blue film (usually PET or PI) is the tried-and-tested choice.
Dielectric Strength: Physical films offer guaranteed uniform thickness (e.g. 0.15mm). Unlike spray, physical film doesn't experience "thin spots" due to gravity or uneven drying that might create "thin spots."
Mechanical Protection: Film adds scratch-resistance that liquid coatings cannot.
Cost: Consumable costs associated with film are often 30-35% lower than UV epoxy per cell.
2. The Case for UV Coating (The Challenger)
UV Coating uses ultraviolet radiation to coat cans directly. It sprays an insulating barrier directly onto their surfaces for insulation purposes.
Pros: Benefits include improved heat dissipation (through its thinner layer) and weight savings.
Cons: Requiring complex masking (to keep terminals clean), high equipment maintenance costs (clogged nozzles), and reduced mechanical durability.
3. Why Our "Blue Film" Solution Wins on Speed
Film has always had one key drawback - speed - which made wrapping cells perfectly without air bubbles time-consuming and frustrating. Our High-Speed Blue Film Wrapping Equipment was developed to address this challenge.
Speed: Our equipment can achieve 12-20 PPM for matching assembly lines at high speeds.
Bubble-Free: With our advanced rolling mechanism, air pockets are completely eliminated to provide an ideal platform for module stacking.
Vision Inspection: Integral cameras provide instant verification of 100% overlap and edge alignment.
(Comparison Table)
|
Feature |
Blue Film Wrapping |
UV Coating |
|
Insulation Consistency |
⭐⭐⭐⭐⭐ (Excellent) |
⭐⭐⭐ (Risk of thin spots) |
|
Mechanical Strength |
⭐⭐⭐⭐⭐ (High) |
⭐⭐ (Low) |
|
Production Speed |
⭐⭐⭐⭐ (High with automation) |
⭐⭐⭐ (Medium) |
|
Maintenance Cost |
Low |
High (Nozzles/Cleaning) |
Battery Blue Film remains the superior solution in most applications requiring reliability and cost efficiency, such as electric vehicle (EV) charging or energy storage system (ESS) storage applications.
Watch Our Machine in Action:Battery Blue Film Wrapping Equipment.
AUTHOR:
The Huiyao Laser Engineering Team :A collective of solution architects and process engineers at Huiyao Laser, 100% dedicated to solving the core bottlenecks in EV and ESS battery manufacturing.
© 2025 Huiyao Laser Technology Co., Ltd. All Rights Reserved.No part of this content (including text, data tables, or original diagrams) may be reproduced without written permission.
key word:
Previous
