Manufacturing the batteries of tomorrow

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Dominance of Lithium-ion batteries (LIBs) as the mainstream battery technology today is obvious, largely due to attractive raw material costs and superior energy density the batteries have at a lower weight compared to other battery chemistries.

Battery Manufacturing: A Simplified Overview

More refined and well-structured compared to early days when the technology was first stabilised, making Li-ion batteries is not as complicated as imagined!

STEPS	CHALLENGES
1 MAKING CATHODES & ANODES Formulate an electrode slurry by combining materials	Ensure homogeneity of slurry mixture Monitor parameters such as viscosity, density and mixing time
2 COATING Applying the electrode slurry to the copper and aluminium foils	Maintain uniformity of the electrode coat thickness in a mass production environment
3 CALENDARING Compress coated foils to ensure a consistent thickness & enhance battery density
4 SLITTING & DRYING Electrode foils are slit to required size and dried to evaporate away the solvents	Prevent burrs usually found on the edges
5 WINDING / STACKING Separators are inserted between the cathodes and anodes and the layers are either wound together or stacked	Check for layers’ alignment and prevent the puncturing of the separators
6 TERMINAL WELDING & CANNING Prepare ready "battery containers" through tab welding, assembly, canning and sealing	Control welding temperatures to prevent contamination
7 FILLING Inserting the electrolyte liquid into the batteries under vacuum conditions	Ensure ppm control of the production environment, injection pressures of the vacuum and accurate electrolyte fill volumes
8 PRE-CHARGING Charging for first time before aging storage at controlled temperatures	Maintain strict environmental conditions
9 FINAL CELL SEALING & TESTING

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