Cell & Pack Manufacturing

Manufacturing Process Map - 2. Cell Assembly - Prismatic WOUND PRISMATIC

ZSTACKING Challenges

anode, cathode, separator alignment

Stacking the cathode, anode, and two separator rolls. Welding the aluminum and copper tabs onto the cathode and anode respectively. SPEED 515 parts/min

HOT PRESS Challenges throughput

The hot press machine works on the principle of heat and pressure application to achieve a strong and reliable bond between battery components. SPEED DWELL TIME 10 seconds/unit

of total manufacturing cost

scrap rate

Challenges

cap to can alignment, missed laser welding spot; pinholes (leak)

CAP TO CAN WELDING The can to cap spot welding by laser source and followed by complete laser welding of the cap to can

Wind the slitted cathode, anode, and separator together by controlling speed, tension, etc. to create one or more jelly rolls. SPEED (consumer electronics) 30 parts/min; EV 10 parts/min

PRE WELDING & TRIMMING

The cathode and anode tab are aligned and U/S welded SPEED 1820 parts/min

ELECTROLYTE INJECTION

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

PRE CHARGE & FORMATION

After the filling pre charge is performed and cell is kept for RT aging and followed by formation & grading process. Note Large cells require open formation and second fill step

Challenges

uneven stress, burr issues, and powder loss; coating cracking

Challenges

anode, and cathode tab alignment

Challenges

electrolyte absorption due to density; pooling of electrolyte

Challenges throughput

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

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