Cell & Pack Manufacturing

Manufacturing Process Map - 2. Cell Assembly - Pouch POUCH FORMING

Challenges

electrode alignment; balancing speed and accuracy

Minor Challenges sealing around tabs; overheating can cause pouch leaks

LAMINATION & STACKING

Stacking notched anode & cathode sheets with separator between. Some lines heat-press layers after stacking.)

INSERT STACK INTO POUCH + INITIAL SEALING Stack is placed inside the formed pouch. Three edges are heat-sealed, leaving one open for electrolyte injection.

1535% of total manufacturing cost

Challenges

maintaining a clean edge for sealing cell after degassing

parts/min

speed

scrap rate

FORMATION VACUUM DEGASSING FINAL SEAL During formation, gas collects in the gas pocket. After formation, the pocket is cut open, the cell is vacuum-degassed, and sealed.

Forming the pouch cavity from laminate using a draw-form press.

TAB WELDING

Ultrasonic welding of electrode tabs and attaching tab extensions. Tabs are wrapped with insulating tape to stay isolated from aluminum pouch.

ELECTROLYTE INJECTION TEMP. SEAL

Electrolyte is metered into the pouch through the open edge, then sealed.

FINAL EDGE FOLDING

Pouch edges are folded to create a compact cell. These folds help slow moisture ingress.

Challenges

corner cracking

Challenges

foil damage; coating adhesion/cohesion

Challenges

dosing & distribution accuracy; no electrolyte residue in sealing area; temp. seal integrity

Challenges

damaging cell corners

Graphics courtesy of LG Energy Solution. Reproduced with permission. Source: LG Energy, BCG, RWTH PEM, internal expertise

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