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Manufacturing Process Map - 1. Electrode Production COATING & DRYING
Challenges
dispersion uniformity; viscosity consistency; reaction time of mixing team to batch variation
Challenges
wrinkling/elongation of substrate & cracks/tears of electrode from thickness variation; managing target density; electrode waste
MIXING
Slurries are formed from active material, binder, solvent, and additives that improve dispersion and viscosity control. Mixing order, speed, tooling, and material variability all affect the final slurry and may require recipe adjustments to hit viscosity specs.
SLITTING & NOTCHING
CALENDARING
Electrodes are densified to a target value
Electrodes are cut into singulated segments or pancake rolls. Uncoated areas are cut out leaving the parts where tabs will be grounded. Detection & marking of electrode defects occurs here. For contamination: must contain proper brush clearance & vacuum systems.
Thickness is verified here, but primary quality screening occurs during slitting.
60-100 m/min
depending on patch design
depending on calculation method & other factors
of total manufacturing cost
pouch film speed
cylindrical (pattern coating) film speed
scrap rate
m/min
Slurry is coated onto the current collector (~54% of electrode cost). Operators must continuously adjust pump speed, die gap, and die-lip settings as slurry viscosity varies with temperature and batch changes. In-line gauges enable tight control, but poor reactions lead to foil breaks and long oven/die-head downtime.
VACUUM DRYING
Removes residual water that would react with electrolyte and cause HF / swelling. Not needed when electrodes are made in dry rooms.
Challenges
electrode uniformity; processing time; utilization loss (lengthy oven cool down & heat up cycles due to broken foil pieces); Finally, operator training and reaction time to all these issues
Challenges
edge quality due to blade edge wear (burrs are dangerous), difficult to inspect at speed; tool wear; lowest OEE of any process due to lengthy marking process; contamination
Challenges
processing time; large footprint; mostly batch; usually Karl Fischer titration is used for water-content checks
*Graphics courtesy of LG Energy Solution. Reproduced with permission. Source: LG Energy, BCG, internal expertise
Extracted from the PDF; charts and images may read imperfectly.
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