Power Starts at the Surface: Plasmatreat Shares Atmospheric Plasma Breakthroughs
Elgin, IL — September 11, 2025 — At The Battery Show North America 2025, Plasmatreat will demonstrate how the “invisible” surface layer can make or break electric vehicle battery performance. With its industry-leading Openair-Plasma® and PlasmaPlus® technologies, the company is sharing solutions that help manufacturers overcome some of the toughest challenges in EV battery production: from adhesion and corrosion to contact reliability and insulation.
“Power starts at the surface—and so do failure points,” says Hardev Grewal, President & CEO at Plasmatreat North America. “Our plasma technologies are enabling OEMs and suppliers to engineer those surfaces for strength, conductivity, and long-term durability—without adding costly, chemical-intensive steps to production.”
Plasma Innovations for Next-Generation Batteries
Cell-to-Cell Bonding for Structural Strength
Plasma activation creates high-energy surfaces that dramatically improve adhesion between cells. This enables both structural bonds and thermally conductive joints—delivering safer, stronger modules with more effective heat dissipation.
Surface Activation with Openair-Plasma®
Dry, inline plasma treatment prepares metals, foils, and polymers for high-strength bonding and sealing—without primers or wet chemicals. The result is uniform surface energy and robust adhesion across pouch, cylindrical, and prismatic formats.
Reliable Electrical Connections
Microfine plasma cleaning removes oxides and residues from bonding pads, busbars, and terminals. This ensures low-resistance, stable connections for ultrasonically bonded cylindrical cells and consistent wire bonding for sensitive contact points.
Corrosion Protection with PlasmaPlus® & AntiCorr®
As EV packs face harsh environments of heat, salt, and moisture, plasma-applied AntiCorr® nanocoatings provide critical protection. This transparent, ultra-thin (25–500 nm) film resists acidic, alkaline, and electrolyte exposure—delivering 960 hours of salt spray protection (DIN ISO 9227) on aluminum die-cast alloys without corrosion or seal migration.
Innovative Insulation Processes
Plasma treatment also enables direct coating applications as an alternative to costly film wrapping. This approach reduces materials, streamlines production, and opens new design possibilities for next-generation battery packs.
Leadership, Expertise, and Global Impact
Plasmatreat is more than a technology provider—it is a global partner to leading battery and automotive manufacturers who rely on plasma processes in daily production. With decades of expertise in atmospheric plasma, Plasmatreat has built a reputation for solving critical challenges in adhesion, conductivity, corrosion prevention, and process reliability across diverse industries.
Today, the company supports well-known EV battery producers worldwide, ensuring that plasma-enabled solutions contribute to safer, longer-lasting, and more sustainable energy storage systems. By combining deep application know-how with global engineering resources, Plasmatreat helps manufacturers scale production and accelerate innovation in the fast-growing electric mobility market.
Integration Without Compromise
All Plasmatreat plasma processes are VOC-free, fully automatable, and production-ready. With no drying times or intermediate storage, they integrate seamlessly into high-volume manufacturing lines while improving quality and lowering total cost of ownership.
Visit Plasmatreat at The Battery Show
Plasmatreat experts will host live demonstrations and engineering consultations at Booth #3305, showcasing how plasma technology is helping EV manufacturers tackle bonding failures, contact degradation, and seal corrosion—ensuring stronger, safer, and more reliable batteries for the road ahead.
