Battery cell manu­fac­turingThe best condi­tions for battery produc­tion

Clean

In battery cell manu­fac­turing, even the tiniest impu­ri­ties can deter­mine whether a cell is a reject or func­tions prop­erly. Micro­scopic parti­cles can damage sensi­tive sepa­ra­tors or trigger chem­ical reac­tions. Mois­ture compro­mises mate­rial stability. At the same time, processes involve ultra-thin foils and sensi­tive coat­ings that are extremely suscep­tible to envi­ron­mental influ­ences. The solu­tion lies in consis­tently controlled produc­tion envi­ron­ments: clean­rooms and dry rooms with minimal particle and mois­ture loads, combined with reli­able, low-emis­sion automa­tion, provide the basis for consis­tent quality and reli­ably func­tioning cells. SCHUNK prod­ucts for battery cell manu­fac­turing feature high-quality anodized finishes and are certi­fied for clean­rooms and dry rooms. Special lubri­cants are lithium-free and retain their prop­er­ties even under extremely dry condi­tions.

Precise

Even the slightest devi­a­tions in posi­tioning lead to elec­trical imbal­ances and mechan­ical stresses in cell manu­fac­turing, resulting in rejects. Toler­ances in the microm­eter range are crit­ical when stacking anodes, cath­odes, and sepa­ra­tors, or when cutting extremely thin elec­trode foils. At the same time, deli­cate mate­rials are highly sensi­tive to even the slightest forces or vibra­tions. End-to-end preci­sion is there­fore essen­tial: accu­rate guid­ance and posi­tioning, repro­ducible motion sequences, and contin­uous moni­toring ensure the neces­sary repeat accu­racy along the entire process chain. SCHUNK grip­pers, for example, are designed to move compo­nents safely and posi­tion them precisely in line with require­ments such as maximum surface pres­sure or a defined grip­ping range.

Quick

The growing demand for battery cells is increasing the pres­sure on produc­tion speed and costs. High produc­tion volumes require extremely short cycle times – for example, when stacking, with each layer taking just a few tenths of a second. At the same time, speed must not come at the expense of quality, as errors have an imme­diate economic impact.

The key is the inter­play between speed and stability: highly dynamic, auto­mated processes, short setup times and down­times, and end-to-end process control enable high output while main­taining consis­tent quality. SCHUNK systems increase cycle speed through features such as parallel processing lines or extremely fast tool changes, for example in slit­ting. 

SCHUNK solu­tions
for the battery produc­tion process

Mixing

Homo­ge­neous mixing of active mate­rials and binders

Coating

Coating the elec­trode foils with active mate­rial

Drying

Drying the coated elec­trodes under controlled condi­tions

Calen­dering

Compressing the elec­trodes to achieve specific mate­rial prop­er­ties

Slit­ting

Cutting the elec­trode strips to the exact width

Preci­sion through hydraulic expan­sion tech­nology

In slit­ting, the key is to achieve consis­tently precise cut quality with high machine avail­ability. Even the slightest devi­a­tions have a direct impact on elec­trode quality. At the same time, knife changes must be performed quickly to mini­mize down­times. Hydraulic expan­sion tech­nology enables low-vibra­tion clamping of the cutting knives, ensuring stable processes, cleanly cut edges, and high effi­ciency during oper­a­tion.
 

Hydraulic
expan­sion arbor

Vacuum drying

Removal of residual mois­ture under vacuum condi­tions

Stacking

Stacking the anode, cathode, and sepa­rator in layers

Precise handling of elec­trodes for pouch and pris­matic cells

In stacking, posi­tioning accu­racy and cycle time deter­mine the quality of the cell stacks. Even minimal misalign­ments can lead to defec­tive layer struc­tures and result in rejects. Elec­trode layers can be posi­tioned precisely through care­fully controlled move­ments and synchro­nized sequences. Process steps conducted in parallel further increase speed and improve yield.
 

Stacking
unit

Pack­aging

Inserting the cell stack into the housing

Safe trans­porta­tion without displace­ment

After stacking, deli­cate cell stacks must be trans­ported reli­ably and with full process control. Even a slight misalign­ment of the layers will impair the cell’s func­tion. Stable mounting combined with gentle handling is there­fore essen­tial. Customized grip­ping and holding concepts reli­ably secure the stack, mini­mize mechan­ical stresses, and ensure consis­tently high quality throughout the process chain.

Handling
unit

Filling

Filling the cell with elec­trolyte

Format­ting

Initial charging to acti­vate the elec­tro­chem­ical processes

Effi­cient loading and unloading of battery cells

During the format­ting and aging process steps, the battery cells’ chem­ical func­tion is acti­vated. Handling large volumes of cells in short cycles places high demands on effi­ciency and process reli­a­bility. What is needed are flex­ible, auto­mated processes that enable a rapid flow of mate­rials while ensuring that the sensi­tive cells are handled with care.

Multiple
gripper unit

Degassing

Removing gases from the cell

Aging

Stabi­lizing cell chem­istry through controlled storage

Effi­cient loading and unloading of battery cells

During the format­ting and aging process steps, the battery cells’ chem­ical func­tion is acti­vated. Handling large volumes of cells in short cycles places high demands on effi­ciency and process reli­a­bility. What is needed are flex­ible, auto­mated processes that enable a rapid flow of mate­rials while ensuring that the sensi­tive cells are handled with care.

Multiple
gripper unit

Testing

Testing perfor­mance, safety, and quality