Battery value chain/Process/Cell manufacturing/Stacking

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Production process

• During the stacking process the separated electrode sheets are stacked in a repeating cycle of anode, separator, cathode, separator, etc.
• A wide variety of stacking technologies exist, which are usually patented by specific manufacturers.
• A classic variant of stacking is the so-called Z-folding.
• The anode and cathode sheets are inserted alternately from the left and right into the z-shaped folded separator. The separator is used in the form of an endless tape and is cut off after the * stacking process.
• The cell stack is finally fixed with adhesive tape.
• The exact positioning of the individual sheets is considered as the central quality criterion.
• The sheets are usually transported and positioned by vacuum grippers.
• Depending on the cell specification, a cell stack can consist of up to 120 individual layers.

Process parameters & requirements

• Z-folding: Individual anode and cathode sheets are placed laterally in the Z-folded separator web
• Single-sheet stacking: Separator is available as a sheet for stack formation
• Stacking accuracy: ± 200 μm - 300 μm
• Z-folding and single-sheet stacking : cycle times of 1 s/sheet

Technology alternatives

• Lamination process: The individual electrode and separator sheets are laminated onto each other in a continuous process and are then usually pressed together by a heat press.
• Pocket Stacking: The cathode sheets are placed in a separator pocket. Afterwards cathode and anode sheets are stacked alternately.

Quality influences

• Position detection and alignment of sheets of different sizes with a vacuum gripper
• Mechanical pre-tensioning of the separator

Quality features

• Positioning accuracy of the anode and cathode sheets
• Damage-free electrode surfaces and edges
• Avoidance of electrostatic charging

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/Stacking	HasPredecessor	Cell manufacturing/Vacuum Drying
Cell manufacturing/Stacking	HasSuccessor	Cell manufacturing/Packaging

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