ThinPack Battery Manufacturing Process
Battery manufacturing is a complex process that involves multiple steps from component sourcing to testing and packaging. The process starts with obtaining the raw materials, such as lead, sulfuric acid, and electrolytes, which are then combined to form the active components of the battery. These components are then arranged into a cell structure and connected with the necessary wiring. The cells are then assembled into the desired battery form and undergo quality checks to guarantee they perform well. Finally, the battery is sealed and tested for safety, efficiency, and overall performance before being packaged and shipped.
1. Preparation: Raw materials such as graphite, aluminum, copper, and other metals are prepared to create the electrode slurry. This slurry is then mixed with a binder to form a paste.
2. Coating: The paste is then spread onto a metallic current collector to form the electrode. The coating process can be done by hand, using a doctor’s blade, or by using a coating machine.
3. Drying and Curing: The electrode is then dried and cured at a controlled temperature.
4. Calendering: The electrode is then subjected to a process called calendering, which is a process that applies pressure to the electrode to ensure uniform thickness and density.
5. Punching: The electrode is then punched and cut into the desired shape and size.
6. Assembly: The electrode is then ready to be assembled with other components in the battery.
Equipment Used in Electrode Manufacturing
- Slitting Machine
- Coating Machine
- Punching Machine
- Pre-forming Machine
- Folding Machine
- Shaping Machine
- Drying Oven
- Calendaring Machine
- Drying Machine
- Impregnation Machine
Cell Assembly Process
· Start by constructing the positive and negative plates. This includes stacking the plates, welding the lugs, and applying a thin layer of paste to the top and bottom of each plate.
· Plates are placed in a container and filled with a solution of sulfuric acid and water. Then the lid is placed on the container and seal it.
· The container is placed in a curing oven and it is heated to the proper temperature for the desired curing time. After the battery has cured, we remove it from the oven and let it cool.
· We connect the positive and negative plates together with a positive and negative lead. Insert the positive and negative terminals into the cell casing.
· Fill the cell casing with the appropriate electrolyte solution. Seal the cell casing and inspect it for leaks.
· Place the cell casing in a testing chamber and run the appropriate tests to ensure that the battery is functioning properly.
· Place the completed cell in its final packaging and label it with all of the necessary information.
Machines Used in Cell Assembly Process
The equipment used in battery cell assembly includes assembly machines, welders, testers, laser cutters, spot welders, stacking machines, crimpers, winding machines, and presses. In addition, other tools such as screwdrivers, soldering irons, wrenches, and tweezers may be necessary to complete the assembly.
Battery Cell Finishing
Battery cell finishing is the process of preparing a battery cell for its intended use. This involves a variety of tests and treatments such as cell balancing, discharging, charging, heat cycling, quality control, and final assembly of the cells into a battery pack. The goal of this process is to ensure that the cells are safe, efficient, and reliable.
The equipment used in the battery cell finishing process includes a battery tester, battery pack assembly machine, lead forming machine, welding machine, ultrasonic welding machine, shrink wrap machine, and battery cell sorting machine.