Winding cores with cut-resistant sufrace in battery foil production

Winding cores with cut-resistant surface for abrasive electrode materials

In the processing of abrasive electrode materials – such as highly filled slurry mixtures with ceramic or metallic particles like LiFePO₄ (LFP), NCM, or LMO – conventional winding cores are quickly pushed to their limits. Typical substrates like coated aluminium or copper foils, anode and cathode materials, or separator foils cause considerable stress due to sharp edges, elevated web temperatures, and cyclic pressure loads. Standard cores often show cuts, delamination, or premature signs of wear.
The cut-resistant variants of the WinCore^® winding cores from INOMETA were specially developed for such high-load conditions – as a durable, cleanroom-compatible solution with optimized cut resistance and maximum process reliability.

Contact our sales team today for expert advice on WinCore^® winding cores and other first-class roller solutions from INOMETA, the leading manufacturer from Germany. Make your inquiry now!

Cut-resistant surface for process-critical materials and high web dynamics

The functional surfaces of the cut-resistant WinCore® winding cores are designed to reliably withstand repeated edge contact and abrasive particles – without structural damage. Depending on the version, hard-coated or specially treated surfaces are used, which are both cut-resistant and cleanroom-compatible.
The mechanically high-load core bodies are made of reinforced fiber composites or special alloy aluminium – individually designed depending on web width, material weight, and winding dynamics. The high concentricity ensures precise web guiding even at high speeds, variable tensile tensions, and tight winding radii – for instance in the dry room environment after the dryer exit.
Due to their special design, the cores are media-resistant, insensitive to moisture, and easy to clean – a considerable advantage in the context of highly sensitive cell manufacturing areas with ultra-thin functional foils and complex material structures.

The cut-resistant WinCore^® winding cores can be precisely tailored to machine and material requirements:

• Inner diameter: 3″ / 6″ / 8″ / 10″
• Length: up to 6,000 mm
• Wall thicknesses adapted to load and web width (e.g., ≥ 2.5 mm for Ecoline)
• Concentricity: ≤ 0.3 mm/m (Proline series)
• Surface: bare, anodized, or functionally coated (PROTEK^®)
• Thermoresistance: suitable for oven-adjacent winding processes (depending on variant > 80 °C)
• Media resistance: resistant to IPA, NMP, cleaning agents
• Additional functions: RFID integration (INOid^®)

Special features of our WinCore^® winding cores

Compared to conventional cores – especially those made of cardboard, paperboard, or non-reinforced plastic – the WinCore^® variants offer the following advantages:

• High cut resistance against abrasive electrode materials such as LFP, NCM, LMO, or graphite – even with sharp-edged substrates
• No core delamination in high humidity or temperature fluctuations – unlike cardboard cores, which can swell or soften
• No abrasion like with cardboard cores, making them more suitable for cleanrooms or sensitive drying processes
• Resistant surface even with repeated edge contact and mechanical stress
• Compatibility with automated winding processes – cut-resistant surfaces remain dimensionally stable even with machine-foil contact
• Better energy transfer in oven-adjacent winding processes – due to higher dimensional and temperature stability
• High concentricity and dimensional stability even at high winding speeds
• High strength and rigidity with low dead weight
• Specifically designed materials for process-reliable use with electrode and separator foils
• Oil-, solvent-, and chemical-resistant – insensitive to IPA, NMP, and humidity
• Reusable over many cycles – significant reduction of waste, storage, and logistics costs
• Even narrow windings can be realized on wide cores – reducing core variety in storage
• Exact concentricity and reduced tolerances – more mechanically precise than standard solutions
• Reduced storage and logistics costs due to longer usage cycles and reusability
• Better handling during web breaks or machine stops – no splitting or material embrittlement
• Optionally RFID-capable for digital traceability (INOid^® compatible)

Technological edge thanks to surface – hygienic, cut-resistant, low-maintenance

The cut-resistant WinCore^® winding cores combine a robust coating with functional smoothness to ensure a consistently clean winding quality, even under high mechanical stress – even with coated electrode foils, multilayer separator structures, or metallized carrier webs.

The specialized surfaces provide:

• A cut-resistant structure that permanently withstands contact with utility knives and substrate edges
• Residue-free operation – adhesive residue, particles, or web contamination can be effortlessly removed
• Minimized maintenance effort – less cleaning, less replacement
• Hygienic safety – FDA-compliant coatings are optionally available

Individual design to meet your requirements – WinCore^® winding cores

INOMETA supports you in selecting the optimal winding core – tailored to materials, winding parameters, system configuration, and environmental conditions. Whether as a standard solution or a custom-made product: Our cut-resistant core solutions increase the cost-effectiveness of your production, improve substrate quality, and ensure reproducible processes – even with demanding materials.

As your partner for winding cores, rollers, and digital solutions, we optimize and automate your production processes using state-of-the-art technology, ensuring maximum safety, and leveraging a broad portfolio of roller types. Contact our sales team to discover more about our customized winding and roller solutions.

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