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Manufacturing Process Map - 2. Cell Assembly - Pouch POUCH FORMING
Challenges
electrode alignment; balancing speed and accuracy
Minor Challenges sealing around tabs; overheating can cause pouch leaks
LAMINATION & STACKING
Stacking notched anode & cathode sheets with separator between. (Some lines heat-press layers after stacking.)
INSERT STACK INTO POUCH + INITIAL SEALING Stack is placed inside the formed pouch. Three edges are heat-sealed, leaving one open for electrolyte injection.
15-35% of total manufacturing cost
Challenges
maintaining a clean edge for sealing cell after degassing
parts/min
speed
scrap rate
FORMATION → VACUUM DEGASSING → FINAL SEAL During formation, gas collects in the gas pocket. After formation, the pocket is cut open, the cell is vacuum-degassed, and sealed.
Forming the pouch cavity from laminate using a draw-form press.
TAB WELDING
Ultrasonic welding of electrode tabs and attaching tab extensions. Tabs are wrapped with insulating tape to stay isolated from aluminum pouch.
ELECTROLYTE INJECTION + TEMP. SEAL
Electrolyte is metered into the pouch through the open edge, then sealed.
FINAL EDGE FOLDING
Pouch edges are folded to create a compact cell. These folds help slow moisture ingress.
Challenges
corner cracking
Challenges
foil damage; coating adhesion/cohesion
Challenges
dosing & distribution accuracy; no electrolyte residue in sealing area; temp. seal integrity
Challenges
damaging cell corners
*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.
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