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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.
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