Cell & Pack Manufacturing

Manufacturing Process Map - 4. Pack Assembly Challenges

surface cleaning; cell-to-current collector bond quality; cell matching

Challenges

damage due to placement (primarily pouch); large machinery required due to module mass & dimensions; avoiding cell damage during assembly; safety at high voltages

CONNECTING BATTERY CELLS Battery cells are placed into the module arrangement and connected to current collectors after surface cleaning

MODULARIZATION The cells are attached to the module case, before or after connection to current collectors

Challenges

ensuring cable flexibility; avoiding cell damage during handling

PACK ASSEMBLY The modules are put in the battery pack and connected, including voltage sense and thermal connections

Design Challenges

i. Ensuring low resistance connections between modules and other connections to prevent fire ii. Maintaining creepage and clearance distances for high voltage elements iii. Preventing arcing due to contact with metallic objects during assembly

FINAL INTEGRATION The battery packs are then used in Electrical Vehicle EV) and Battery Energy Storage System BESS

APPLYING BMS A Battery Management System is applied to battery pack; modules typically interface with the pack BMS

CHALLENGES

difficult & time consuming to test in a high-throughput environment

FINAL TEST A series of electrical tests are performed to ensure the highest quality, including verification of cell connections, isolation, and BMS function

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

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