New Energy Battery Insulation Sheet Extrusion Line (JWS Series) – From Our Workshop to Your Production Floor

The global new-energy vehicle and energy-storage sectors continue to grow rapidly, driving ever-higher demands on battery safety and reliability. Insulation sheets – the critical isolating components between cells and between cells and modules – directly affect short-circuit protection, thermal-runaway suppression, and the stable performance of batteries throughout their entire life cycle.

With over 20 years of experience in plastics extrusion equipment, Jwell Machinery has developed the JWS Series battery insulation sheet extrusion lines specifically for this application. The series is engineered entirely around the demanding process requirements of polycarbonate (PC) insulation sheets for prismatic and pouch cells, delivering high precision, high output, and long-term operational stability. Whether it is thickness tolerance, surface quality, or production efficiency, the JWS Series meets the qualification standards of Tier-1 automotive suppliers.

2. Product Selection Logic – How We Help You Find the Right Model

Choosing an extrusion line is essentially choosing your production flexibility, return on investment, and operating costs for the next few years. The JWS Series currently includes two main models – JWS 120 and JWS 130 – both dedicated to PC insulation sheets but differentiated by target output and expansion strategy.

We recommend evaluating from three angles: target daily output, existing plant conditions, and order forecasts for the next 2–3 years.

Our direct recommendation:

If you want to keep initial investment under control, we suggest JWS 120. It fully covers normal capacity and offers exceptional precision for 0.125 mm thin sheets.

If you have already signed a long-term framework agreement with major OEMs and need high single-line output for fast delivery, JWS 130 is the more economical choice – its maximum output is 25% higher than JWS 120 (500 kg/h vs. 400 kg/h), allowing one line to support a larger supply share.

Note: Both models share the same effective product width (1100 mm) and thickness range (0.125–0.43 mm).

3. Our Core Technical Advantages

Battery insulation sheets tolerate no defects. Thickness fluctuations, surface scratches, internal stress, or local degradation can lead to serious issues during battery assembly or in service. For this reason, we have focused the JWS Series on the following critical technical aspects.

3.1 High-Torque, High-Wear-Resistant Extruder (Ø120/38 and Ø130/38)

Both models are equipped with a 38:1 L/D ratio screw and barrel assembly. The longer L/D ratio delivers tangible benefits:

More thorough plasticisation: longer residence time ensures complete melting and homogeneous mixing of PC resin (including a certain percentage of regrind), eliminating “fish eyes” or unmelted specks that could compromise dielectric strength.

Robust drive system: our self-designed high-torque gearbox maintains stable screw speed even when processing high-viscosity flame-retardant PC, with minimal extrudate pressure fluctuation.

Extended wear life: the barrel and screw surfaces are coated with a bimetallic alloy layer specifically designed to resist abrasive wear from flame retardants (especially halogen-free phosphorus-based types). Practical service life is more than double that of conventional nitrided treatments.

3.2 Die and Thickness Closed-Loop Control

Achieving a thickness tolerance of ±0.005 mm across a 1100 mm width is a capability we are proud of. The core elements are:

Automatic die lip adjustment system: a transverse thickness gauge continuously scans the full-width profile; any deviation triggers micro-adjustments of the die lip via a thermal-expansion bolt array, providing closed-loop correction.

Anti-stick coating inside the die: the melt flow channels are specially treated to prevent PC stagnation and degradation, ensuring consistent sheet appearance and performance during prolonged continuous production.

3.3 Mirror-Finish Polishing Rolls

For the downstream three-roll calender, we use high-hardness chrome-plated rolls with a surface roughness Ra < 0.02 μm – optical-grade mirror quality. Benefits:

Both sides glossy: the sheet surfaces are free from shadows or roll marks, ensuring uniform heat transfer and pressure distribution during stacking.

Independent temperature control: each roll is equipped with its own PID temperature control unit, allowing operators to independently adjust cooling curves for different thicknesses and speeds, effectively reducing internal stress and producing flat, warp-free sheets.

3.4 Intelligent Control System (Industry 4.0 Ready)

We use Siemens PLC as the core control platform, but that is only the foundation. We place greater emphasis on:

One-click recipe recall: up to hundreds of process parameters for different PC grades can be stored, reducing grade-change time to less than 15 minutes.

Remote assistance capability: with your authorisation, our engineers can log in remotely to quickly diagnose software or parameter issues – no need to wait for on-site travel, significantly reducing downtime.

Full data traceability: the system automatically logs all critical process parameters (melt pressure, melt temperature, zone temperatures, line speed, thickness variation, etc.), meeting the documentation requirements of IATF 16949 for quality traceability.

4. What Overseas Customers Care About Most

We serve customers in Europe, the US, Southeast Asia, and the Middle East all year round, and we are well aware of regional pain points. Below are the targeted designs we have made for actual operating conditions in different regions.

5. Complete Technical Data Sheet

Detailed technical data for both JWS models are listed below for your reference.

6. Frequently Asked Questions (FAQ)

Q1: Can this line produce narrow strips for cylindrical cells?

Yes. The master roll width is 1100 mm, and downstream we can equip a slitter-rewinder to cut it into narrow rolls of various widths – fully suitable for insulation wrapping of cylindrical batteries.

Q2: How is the PC dried, and what drying equipment do you supply?

PC must be dried to a moisture content below 0.02%. We include an integrated dehumidifying dryer with a dew point of –40 °C, and the drying hopper is interlocked with the extruder feed.

Q3: Can this line be converted later to produce PMMA or PET?

The screw geometry is designed specifically for PC, but by changing to a dedicated screw and adjusting die temperature control, it can be made compatible with PMMA. For PET, an additional crystallisation and drying system would be required.

Contact Us – Let’s Plan Your Next Production Line Together

Electrification and energy storage are the big trends, and insulation-sheet production capacity is becoming a critical bottleneck in the battery supply chain. Jwell Machinery has already provided reliable extrusion solutions to over 200 battery companies worldwide. We are not just equipment manufacturers – we are your process partners.

You can reach us in the following ways:

Request a quotation – tell us your target capacity (kg/h), product drawings, sheet thickness, and raw material grade, and we will send you a detailed quote within 48 hours.

Visit our factory for a trial – welcome to our Haining plant (or our European demonstration centre) to run a test with your own material and see the results live.

Online technical meeting – schedule a video conference with our extrusion process engineers to discuss your plant conditions, utilities, and staffing in depth.