Assembly methods and technology for high-capacity lithium-ion batteries. Assembling high-capacity lithium-ion batteries is a complex process; it's not easy, but it's not particularly difficult either, though it's still a technical skill. Want to learn about the assembly methods for high-capacity lithium-ion batteries? Then you need to understand battery cells first. Because high-capacity lithium-ion batteries are generally assembled from individual lithium-ion battery cells.
High-capacity lithium-ion battery assembly method
For example, if you want a 6000mAh, 16V high-capacity battery, and if each cell has a voltage of 4V and a capacity of 1200mAh, then you would need 20 cells. This means you would need 4 cells connected in series to form a 16V lithium-ion battery pack, giving it a capacity of 1200mAh. Then, you would connect 5 such lithium-ion battery packs in parallel to obtain a 6000mAh, 16V high-capacity lithium-ion battery pack.
Issues to be aware of when assembling large-capacity lithium-ion batteries
1. The voltage difference of the lithium-ion battery cells used should not be too large, preferably within 20mV;
2. It is not recommended to use the same type of cells from different lithium-ion battery manufacturers for assembly, because differences in production technology and battery material formulas between manufacturers can lead to inconsistent working efficiency between cells, which can easily damage the battery.
3. Even when using lithium-ion battery cells from the same manufacturer, old and new cells should not be mixed.
4. Even if the cells are from the same manufacturer, it is recommended to use cells from the same batch.
Important steps in lithium-ion battery assembly
1. Lithium-ion battery slurry preparation: Special solvents and binders are used to mix the powdered positive and negative electrode active materials separately. After high-speed stirring, the positive and negative electrode materials are made into a slurry.
2. Lithium-ion battery coating: The prepared slurry is evenly coated on the surface of the metal foil, dried, and then made into positive and negative electrode sheets respectively.
3. Lithium-ion battery assembly: The positive electrode sheet, separator, negative electrode sheet, and separator are arranged in the order from top to bottom, and then wound to form the battery core. After the electrolyte is injected and the battery is sealed, the assembly process is completed and the finished battery is produced.
4. Formation: The finished batteries are tested using specialized battery charging and discharging equipment. Each battery is tested to select qualified finished lithium-ion battery packs for shipment.
What is a high-capacity lithium-ion battery pack?
"High-capacity lithium-ion battery" is a common term used to describe lithium-ion battery packs with relatively large capacities. There's no specific definition of what voltage and capacity constitutes a high-capacity lithium-ion battery. According to our statistics, lithium-ion battery packs with a capacity of 5Ah or higher can generally be considered high-capacity lithium-ion batteries.
Lithium-ion battery assembly technology
Precise positioning
The necessary positioning technology and experience are required to achieve an efficient calibration system tailored to the needs of mechanical positioning and image processing. To maintain long-term accuracy, precise positioning, including installation design, is essential, requiring control of the camera or positioning stage.
Laser welding
If possible, based on individual needs, knowledge and results of various lasers such as CO2, YAG, LED, and fiber can be used for applications such as laser welding of battery foil, welding of throttle valve housings and caps, and resin welding to replace metal. The most suitable welding method will be recommended based on specifications and the welding machine selected.
Press
We possess the technical expertise and relevant experience to handle various presses, such as air, hydraulic, and servo presses. Our achievements range from testing production levels with robotic arms pressing onto machine platforms to producing high-precision, high-quality products with controlled speed and torque using servo motors.
Size measurement
Dimensional measurements are performed using various methods, including laser displacement gauges, image processing equipment, and contact and non-contact sensors. However, in production machinery, accurate dimensions cannot be measured using measuring equipment alone. Therefore, comprehensive accuracy must be maintained, including considerations such as installation vibrations.
Resistance welding
The quality and accuracy of resistance welding related to production machinery have a significant impact on the loading process. Given this, we select the most suitable welding method based on specifications, recommended welding machine materials, and other relevant factors.
Image processing
Experience in various image processing areas is required, such as localization, missing parts, and scratches. This involves combining the most suitable camera, lighting, and processing equipment to respond to the shape, accuracy, and sensitivity of objects, and to responding to advanced image processing techniques. Furthermore, continuous image processing of long objects using a licensed camera is also necessary.
This concludes the introduction to the assembly methods and technologies for high-capacity lithium-ion batteries. Have you learned it?
