Cell & Pack Manufacturing

Cell & Pack Manufacturing Challenges

anode, cathode, separator alignment; tabing, taping, cutting accuracy; tab welding quality (can introduce safety issues)

20% of total manufacturing cost

Manufacturing Process Map | 2. Cell Assembly | Cylindrical

Manufacturing Process Map | 2. Cell Assembly | Cylindrical Winding & Tab Welding Winding the cathode, anode, and two separator rolls. Welding the aluminum and copper tabs onto the cathode and anode respectively. SPEED: 30 parts/min

Through CT and/or X-Ray, the battery cell is analyzed to detect potential defects.

Tab Shaping & Canning metal contamination

Electrolyte is injected into the vacuumed can. The can is pressurized to accelerate electrolyte absorption and then sealed

Physical Inspection

scrap rate

Challenges

Electrolyte Injection

The jelly roll is put in the cylindrical can and then fixed through welding. High-speed mechanical deformation process SPEED: 300-600 parts/min

Degassing/ Pre-Charge Optional process to remove gas

Challenges

electrolyte absorption due to density; pooling of electrolyte

Challenges

speed of analysis doesn’t allow real-time analysis

Challenges

exhaust gas treatment Avoiding residual gas during sealing and folding steps

*Graphics courtesy of LG Energy Solution. Reproduced with permission.

Source: LG Energy; BCG; RWTH PEM

Extracted from the PDF; charts and images may read imperfectly.