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Manufacturing Process Map - 2. Cell Assembly - Prismatic WOUND PRISMATIC
Z-STACKING Challenges
anode, cathode, separator alignment
Stacking the cathode, anode, and two separator rolls. Welding the aluminum and copper tabs onto the cathode and anode respectively. SPEED: 5-15 parts/min
HOT PRESS Challenges throughput
The hot press machine works on the principle of heat and pressure application to achieve a strong and reliable bond between battery components. SPEED (DWELL TIME): >10 seconds/unit
of total manufacturing cost
scrap rate
Challenges
cap to can alignment, missed laser welding spot; pinholes (leak)
CAP TO CAN WELDING The can to cap spot welding by laser source and followed by complete laser welding of the cap to can
Wind the slitted cathode, anode, and separator together by controlling speed, tension, etc. to create one or more jelly rolls. SPEED: (consumer electronics) 30 parts/min; (EV) 10 parts/min
PRE WELDING & TRIMMING
The cathode and anode tab are aligned and U/S welded SPEED: 18-20 parts/min
ELECTROLYTE INJECTION
Electrolyte is injected into the vacuumed can. The can is pressurized to accelerate electrolyte absorption and then sealed
PRE CHARGE & FORMATION
After the filling pre charge is performed and cell is kept for RT aging and followed by formation & grading process. Note Large cells require open formation and second fill step
Challenges
uneven stress, burr issues, and powder loss; coating cracking
Challenges
anode, and cathode tab alignment
Challenges
electrolyte absorption due to density; pooling of electrolyte
Challenges throughput
*Graphics courtesy of LG Energy Solution. Reproduced with permission. Source: CATL, RWTH PEM, internal expertise
Extracted from the PDF; charts and images may read imperfectly.
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