Battery value chain/Process/Cell manufacturing/Packaging

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Production process

• To package the pouch cell, the current collector foils (anode - copper and cathode - aluminium) are first contacted with the cell tabs using an ultrasonic or laser welding process.
• The cell stack is then positioned in the pouch foil. For this purpose, the pouch foil is deep-drawn in an earlier process step.
• The pouch cell is usually sealed gas-tight on three sides in an impulse or contact sealing process.
• One side of the cell (often the bottom of the cell) is not finally sealed in order to be able to fill the cell with electrolyte in the next process step.
• The packaging materials are generally to be regarded as purchased parts.
• The deep drawing of the pouch foil is carried out either directly in the production line or in a separate process.

Process parameters & requirements

• Deep drawing: up to 6 mm
• Ultrasonic welding with approx. 15 kHz - 40 kHz
• Packaging material: aluminium composite film (polyamide/aluminium/polypropylene)
• Rule of thumb: "1 mm sealing seam width corresponds to approximately one year of cell lifetime".

Technology alternatives

• Book folding process: Instead of two individual pouch foils, a foil with two deep drawn cavities can also be used for insertion into the packaging. After the stack has been inserted, the foil is folded like a book and then sealed.

Quality influences

• Reduction of thermal stress during contacting and sealing process
• Seal seam width
• Sealing temperature and pressure

Quality features

• Low contact resistance as well as low mechanical and thermal stress during the welding process
• Fatigue strength and tightness of the sealing seams

Source

Heimes, H.H.; Kampker, A.; Lienemann, C.; Locke, M.; Offermanns, C.; Michaelis, S.; Rahimzei, E. (2018) Lithium-Ion Battery Cell Production Process; PEM of RWTH Aachen and VDMA, 3rd Edition, ISBN:978-3-947920-03-7

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Subject	Property	Object
Cell manufacturing/Packaging	HasPredecessor	Cell manufacturing/Stacking
Cell manufacturing/Packaging	HasSuccessor	Cell manufacturing/Electrolyte Filling

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