New Energy Battery Insulation Sheet Extrusion Line

The JWS120 and JWS130 new energy battery insulation sheet extrusion lines are specifically designed for high-precision, large-scale production of polycarbonate (PC) insulation sheets used in electric vehicles and energy storage lithium batteries.

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Application

The PC insulation sheets produced by these lines have a width of 1100 mm and a thickness range of 0.125 mm to 0.43 mm – dimensions that match common prismatic and pouch cell specifications.
Typical end uses include:
Insulation layer between cells and cooling plates in cell-to-pack (CTP) designs.
Top and side insulation sheets for battery modules.
High-voltage isolation film inside battery packs (PC's inherent flame retardancy meets UL94 V-0).

Real-world example:
A German Tier 1 electric vehicle battery manufacturer replaced a previous imported production line with one JWS130 unit. Using PC resin at 480 kg/h (close to the maximum capacity of 500 kg/h), they produce insulation sheets with a thickness of 0.28 mm ±0.008 mm at a line speed of 25 m/min. The 1100 mm width allows them to slit three 320 mm strips at once, reducing downstream slitting waste by 18%.

Advantages

Parameter	JWS120	JWS130	Benefits
Screw diameter	Ø120 mm	Ø130 mm	Higher torque and output
Length/diameter ratio L/D	38:1	38:1	Excellent PC plasticization and devolatilization
Maximum output	400 kg/h	500 kg/h	Scalable for medium to high-volume production
Product width	1100 mm	1100 mm	Covers standard battery cell widths
Thickness range	0.125–0.43 mm	0.125–0.43 mm	Capable of producing ultra-thin to medium-thickness insulation sheets

What these numbers mean for battery insulation sheets:
Ø130/38 extruder – The 38 L/D ensures full drying and plasticization of PC without yellowing (critical for dielectric strength). The 130 mm screw achieves melt uniformity index <2% even at 500 kg/h.
1100 mm width – Optimized for battery industry standard widths. Eliminates oversized dies that waste material.
0.125 mm capability – Enables production of thin, flexible insulation sheets for high – energy – density cells with very tight clearances.
Other field-proven advantages not listed in the table:
Automatic thickness gauge with transverse adjustment (die lip heating) maintains thickness tolerance within ±0.005 mm.
Energy efficiency – AC drives and barrel heating zones consume ≤0.32 kWh per kg of PC (JWS130 at 80% load).
Fast roll changes – Screen changer/filter downtime <8 minutes.

Process

Every insulation sheet must pass rigorous electrical, mechanical, and thermal performance tests. Our online and offline quality control processes include:
Online monitoring

Test item	Equipment	Target value
Thickness profile	Beta gauge / laser scanner	±0.005 mm across 1100 mm width
Width shrinkage	Optical edge sensor	<1.2% at 120°C
Surface defects (gels, black spots)	4K line scan camera	Reject defects >0.1 mm²

Offline tests (according to ASTM / IEC standards)
Dielectric strength – Samples from 0.25 mm sheet must withstand ≥28 kV/mm (typical PC value 30 – 32 kV/mm).
Flame retardancy rating – UL94 V – 0 at 0.2 mm thickness (verified every 8 hours).
Tensile elongation – MD >90%, TD >80% (for 0.2 mm sheet).
Heat shrinkage – 30 min at 150°C, <1.5% in both directions.
Real – world quality outcome:
A Korean battery cell manufacturer using a JWS120 line achieved 99.3% first – pass yield over six months, with zero insulation – related field failures across more than 200,000 modules.

Parameters

Model	JWS 120	JWS 130
Material	PC	PC
Extruder Specification	Ø120/38	Ø130/38
Products Width(mm)	1100 mm	1100 mm
Products Width(mm)	0.125-0.43 mm	0.125-0.43 mm
Capacity(Max.)(kg/h)	400 kg/h	500 kg/h

Q1: Can this line process materials other than PC?
A: Yes – the 38:1 screw is optimized for PC but can also process PET, PP, or PC/ABS alloys by adjusting the temperature profile. For flame – retardant PC (FR – PC), the higher torque of the JWS130 is recommended to handle the increased melt viscosity.

Q2: How is thickness uniformity maintained at 0.125 mm across the 1100 mm width?
A: The die uses an automatic flexible lip adjustment with 35 heating bolts. Combined with feedback from the online beta gauge, the system compensates for melt temperature and pressure fluctuations every 50 ms. Actual deviation on the JWS120: ±0.006 mm at a target thickness of 0.125 mm.

Q3: What is the energy consumption per ton of product?
A: Taking the JWS130 producing 0.3 mm sheet at 450 kg/h, the total installed power is approximately 210 kW, but actual average power consumption is 135 – 145 kW (including chiller and haul – off). This equates to 300320 kWh per ton of PC sheet.

Q4: How often does the screw/barrel need to be replaced when processing filled PC (e.g., 10% glass fiber)?
A: A standard nitrided steel screw lasts 8,000 – 10,000 hours when processing unfilled PC. For glass – fiber – reinforced PC, we offer a bimetallic barrel + tungsten carbide screw, which extends replacement intervals to more than 15,000 hours. Customers using the JWS130 with 10% glass – filled PC report no noticeable wear after two years.

Q5: Can this line produce sheet wider than 1100 mm?
A: 1100 mm is the standard die width. Custom widths up to 1500 mm are available, but for battery insulation sheets, 1100 mm is the industry – optimal choice (fits most prismatic cell lines without secondary trimming).

Q6: Is drying required before extrusion?
A: PC is hygroscopic. We supply a desiccant dryer (dewpoint ≤ – 40°C) as part of the line. For the JWS130 at 500 kg/h output, the dryer capacity is 600 kg/h with three hoppers for continuous operation.