Cell & Pack Manufacturing

Manufacturing Process Map - 3. Formation

Challenges

slow throughput due to long time required; fire (most factory fires occur here)

3050% of total manufacturing cost

FORMATION Electrochemical activation. SEI is formed on the anode

time

scrap rate

days

AGING Battery is stored at a consistent temperature and humidity to allow for corrosion mechanisms from potential contamination

CHARGING, DISCHARGING/ CAPACITY CHECK

Challenges

process time/throughput; factory footprint; quality escapes

Challenges

throughput; footprint

DEGASSING Challenges

residual gas inside the cell; seal quality; throughput (a lot of additional CAPEX due to dry room requirement)

Pouch & prismatic only. Gases formed during aging are cut off inside of a vacuum chamber (sacrificial gas bag). Typically in pouch, this is the final step. In some large cells, a secondary fill and subsequent charge is performed.

QUALITY CONTROL End of line check capacity, resistance, voltage, etc., + cosmetic

Challenges

cosmetic & variation in capacity; yield

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.