Energy Storage

You want to improve your throughput because the demand for energy storage is massive — we can help with that.
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We build the automation equipment that produces energy storage parts — like flow batteries.

Looking to partner with an equipment supplier that can help you improve throughput to ramp up the production of your energy storage products? Our plastic welding technologies and custom automation expertise help you make parts faster and better. Our engineers will help you at every step — from design and prototyping to validation and production.

Technologies that help you manufacture batteries

Hot-Plate Welding

Hot plate welding is a process that is used for welding two plastic parts together. This process is beneficial for manufacturing iron flow batteries for the energy storage market because it creates strong hermetically sealed welds.

Stack Welding

When manufacturing flow batteries, you need to be able to weld several layers of components on top of each other. That’s where stack welding comes in. Stack welding is hot plate welding multiple layers of parts together. Extol’s servo-driven hot plate welders are perfect for this task. To start, the machine welds the first two layers together. Then, you or a robot loads the next layer on top of the two welded layers. The welding machine measures the height of the stack, reprograms itself, and welds the new layer to the stack. This process is repeated over and over again to make stacks that are 10, 20, and even 40+ layers.

Heat Sealing

Heat sealing is another important technology used for manufacturing iron flow batteries. This technique is used for welding thin parts to plastic. It works by using heat to melt the plastic, and then pressing it together so that it fuses.

Laser Welding

Some components in a flow battery system need to be welded very cleanly and precisely. Laser welding is a good option because it uses an extremely accurate infrared laser to create welds without any particulate. Laser-welded parts are also very strong and durable, making them perfect for use in flow battery systems.

Validate your high-quality parts.

Extol can help with validating flow battery parts. We have services like burst testing, leak testing, and tensile testing to ensure that everything meets the requirements for optimal performance.

Burst Testing

Burst testing reveals how much internal pressure a flow battery can withstand before it breaks apart. We fill the welded part with water and pressurize it until it fails.

Leak Testing

Leak testing is done to determine the rate at which air or fluid leaks out. We use this method on flow batteries to prevent any performance issues that could be caused by a leak. There are various methods of leak testing, with the most basic being to fill the part with air, submerge it underwater, and look for bubbles.

Tensile Testing

Tensile testing is a way to measure how strong a welded part is. Depending on the size, we can either test an entire part or sample by cutting a small section from a larger part. The process entails pulling the two halves until breakage and measuring the force with a load cell.

Let Extol help you with your energy storage application.

COLLABORATE – At Extol, we work with you to gain a deep understanding of the needs of your specific application.

DESIGN – We help you design your parts for the best results with welding. Not only do we provide guidelines to get you started, but we review your design and provide specific recommendations. Beyond that, we validate your design by welding and testing the assembly with equipment in our lab.

CONFIGURE – Using what we’ve learned about you and your application, we help you select the right manufacturing technology. From there, we configure a solution that is perfect for your needs.

DELIVER – We design, build, and deliver your equipment. But we don’t stop there. Our exceptional team supports you from launch through the life of the program.

Interested? Let’s talk.

We can help you wherever you are in your process. Whether you want help with design, prototyping, or automation equipment, we’ve got you covered.

Let us know what you need.