Next level battery manufacturing:
New products, challenges, solutions

Components for battery production

Next level battery manufacturing - particle-free. Lubrication-free. IPA-approved

With the growing demand for electric cars, the need for high-quality lithium-ion batteries is also increasing. Battery manufacturing involves several critical components that are necessary for the production of batteries. Each component must contribute to maximising quality, safety and performance. With igus components such as plain bearings and linear technology as well as energy chains, efficiency can be increased, downtimes reduced and the automation of battery production plants improved.

Ideally, battery production takes place with minimum humidity and the greatest possible freedom from particles. Our cleanroom-compatible and dissipative cable guide systems for the dry cleanroom support this process and ensure reliable performance in battery production.

Areas of application: Material handling, electrode production, cell assembly, sealing and further processing as well as control and inspection

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battery_fullInnovative products for battery production

Products for the dry cleanroom Information material: Dry cleanroom test laboratory

Innovative products for battery production

Certified cable guide systems

Certification for the dry cleanroom
ISO Class 3 or 4
More than 15 million double strokes
High purity

To the dry cleanroom products

Slewing ring bearing PRT-04-100

60% lighter und 50% more space-saving
Wear-resistant und maintenance-free
Particle emission test at the Fraunhofer IAF-compatible cleanroom laboratory

To the slewing ring bearing PRT-04

xiros conveyor roller

Extremely resistant to chemicals
Ready-to-install system saves expensive in-house production
Lightweight, reliable and durable

To the PVC conveyor roller

iglidur plain bearings

Resistant to chemicals and media
Long service life and lowest coefficient of friction
PTFE-free materials tested for harmful PFAS

To the plain bearings

igubal flange mounted bearings

100% lubrication-free and maintenance-free
Compensation of misalignments
Long service life, low coefficient of friction
80% lighter than steel bearings

To the flange mounted bearings

iglidur bar stock

Self-lubricating and very low coefficients of friction
Extreme wear resistance
Produced in accordance with DIN EN 15860
Production of customised turned and milled parts

To the bar stock

drylin T guide carriage TW-42

PTFE-free
Sliding elements made of iglidur JPF
100% avoidance of external lubrication
Quick changeover due to identical dimensions

To the linear guide TW-42

drylin ZLW toothed belt axes

Lubrication-free toothed belt axes
For precise positioning and adjustment tasks
Long service life, precision and high reliability

To the toothed belt axes

Linear robots

Automate pick-and-place tasks
Precise and repeatable processes with consistent quality
Greater workplace safety by taking over non-ergonomic tasks

To the linear robots

ReBeL cobot

Precise movements for accurate positioning
Compact design for mobile applications and easy integration into existing workflows

To the cobots

Handling of battery cells

The automated handling of battery cells is a key factor in the optimisation of modern production processes. A room linear robot was used in a test setup to efficiently remove battery cells and position them precisely in holders. Working together with employees on the conveyor belt, the system consistently prepares assembled battery packs for the next process stage, reducing manual labour and increasing efficiency.

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Certified products for the dry cleanroom

What is a dry cleanroom?

A dry cleanroom for battery production is a special controlled environment that provides both extremely low humidity and a high level of particle-free air. There, the humidity is reduced to below 1%, often below 1% relative humidity, which corresponds to a dew point of -40°C. This ensures that no condensation takes place and no moisture gets into the materials. This is of great importance in some process steps of battery production because even small amounts of water can lead to battery fires.

Why is dry cleanroom important?

Higher product quality: reduced contamination leads to higher quality and reliability of battery cells
Longer service life: minimising chemical reaction extends battery life
Safer working environment: strict control over hazardous materials increases safety for personnel

Cable guide systems

Cable guide systems are essential for reliable energy and data transmission in dry cleanrooms, which are used in applications such as electrode coating and cell assembly. To ensure that our cable guide systems fulfil the requirements of the dry environment, we have tested them for durability and cleanliness together with the Fraunhofer IPA.

The result: High cleanliness over a test period of 10 months, 15 million double strokes and certification for ISO Class 3 or 4 dry cleanrooms.

Ribbon cable e-skin flat

Easily openable chamber design, hoses or stranding elements quickly replaced

Over 15 million double strokes
Best possible ISO Class 4 certification
No visible wear, abrasion-resistant

To the flat ribbon cable e-skin flat

ESD robot energy supply

The triflex TRC energy chains for 3D movement and strain relief are made entirely of ESD material.

ESD material tested with over 10 million cycles for the highest requirements
ISO Class 4-5 certification

To the ESD robot energy supply system

Energy chain series C6

The C6 for cleanroom applications shows hardly any measurable abrasion, even under high loads

For ISO Class 4 applications
Very smooth running and high stability thanks to a robust stop-dog system

To the C6 energy chain

Energy chains for high dynamics

Extremely quiet, low-vibration operation
ISO Class 4

E6 energy chain series

Two-piece corrugated tubes

Compact and easily openable
ISO Class 4

e-skin corrugated tube

Two-part corrugated tubes, ESD

Made from dissipative material
Cleanroom housing with ESD protection

Dissipitive e-skin corrugated tubes

Ribbon cable e-skin flat, ESD

Made from dissipative material
Cleanroom-compatible with ESD protection

e-skin flat ESD

SCARA energy supply, ESD protection

Made from dissipative material
ESD protection for ISO 1 cleanroom
High running performance

Clean SCARA Cable Solution, ESD

Multi-axis energy chain ESD with fibre-rod

Closed type
Fibre-rod generates constant pretension
No snagging and reduced skidding

triflex TRC, ESD

Fibre-rod module for TRC

TPE energy and signal cables

Our TPE cables are the perfect solution for energy and signal transmission in demanding battery production. Their abrasion-resistant TPE outer jacket reduces particle emissions and has been tested by the Fraunhofer Institute.

The flexible, resistant material guarantees reliability and durability even in dynamic energy chain applications. The cable material is characterised by its high resistance to mechanical stress, making it ideal for use in sensitive cleanroom environments. In dry environments, the material retains its flexibility as it only releases minimal moisture. This ensures that the outer jacket does not become porous and there is no risk of breakage.

All chainflex cables are specially developed for mobile applications and are tested and inspected in our in-house test laboratory spread over an area of 5,500m². In addition, all chainflex cables have a unique guarantee of up to four years, which emphasises their quality and durability.

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Tested quality for dry cleanrooms

Cable guide systems

Dry cleanroom: ISO Class 3 or 4

chainflex cables

Dry cleanroom: ISO Class 4 or 5

Slewing ring bearing PRT

Dry cleanroom: ISO Class 7

Fraunhofer IPA certifications for the dry cleanroom

Together with the Fraunhofer Institute, we have developed two new certificates that confirm the dry cleanroom suitability of our energy chains in long-term tests. The two new certificates are divided into pre-aging and aging behaviour.

The "pre-aging certificate", which we commissioned for our e-skin soft and E14 energy chain systems, certifies the systems after 15 million double strokes and 10 months in the dry cleanroom. Here we received the best possible cleanroom ISO Class 4 certification (see Table 2).

Two of our cleanroom energy supply systems, the E6.J and the e-skin flat, were tested over a period of 10 months on an endurance machine in the dry cleanroom. They completed over 15 million double strokes. The systems were tested and certified for their cleanroom class every two months. The e-skin flat system withstood the double strokes without any problems and received the best possible ISO cleanroom Class 4 certification. A higher certification is not possible as the test environment (ISO Class 3 dry cleanroom with a relative humidity of <1% corresponding to a dew point of -40°C) is not clean enough. The E6.J was able to maintain this result for four months, but then lost a cleanroom class and finished with ISO Class 5 (see Table 3).

Table 1: STANDARD dry cleanroom	v = 0.5 m/s a = 1 m/s	v = 1 m/s a = 2 m/s	v = 2 m/s a = 4 m/s
E6 (IPA report 2303-1408)	ISO 4	ISO 4	ISO 4
TRC.ESD + fibre-rod (IPA report 2309-1461)	ISO 4	ISO 4	ISO 5

Table 2: PRE-AGEING dry cleanroom	v = 0.5 m/s a = 1 m/s	v = 1 m/s a = 2 m/s	v = 2 m/s a = 4 m/s
SKS28 (IPA report 2411-1575)*	ISO 4	ISO 4	ISO 4
E14 (IPA report 2411-1575)	ISO 4	ISO 4	ISO 4

Table 3: AGEING BEHAVIOUR dry cleanroom	Time / double strokes
	Time: After running-in phase \| double strokes: 0	Time: After 2 months \| double strokes 3.2 million	Time: After 4 months \| double strokes: 5.1 million	Time: After 6 months \| double strokes: 7.5 million	Time: After 8 months \| double strokes: 10 million	Time: After 10 months \| double strokes: 15 million
e-skin*	ISO 4	ISO 4	ISO 4	ISO 4	ISO 4	ISO 4
E6*	ISO 4	ISO 4	ISO 4	ISO 5	ISO 5	ISO 5