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How to Design a Lithium-ion Pouch Cell Lab Line?
Jan 21 , 2025
Battery Gas Generation
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Before designing a battery production line, we need to comprehensively consider multiple aspects including product, capacity, process, equipment, regulations, supply chain, cost, safety, environmental protection, quality control, plant layout, automation, data management, maintenance, human resources, project management and market, etc. We ensure that all factors that may affect the production lin...read more
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In the cutting process, issues such as rapid mold wear, long mold change times, poor flexibility, and low production efficiency often lead to unstable processes, resulting in inconsistent electrode cutting quality and reduced battery performance. Laser cutting, due to its advantages of no vibration deviation, high precision, good stability, and no need for mold replacement, has gradually become ma...read more
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Lithium-ion batteries (LIBs) are the powerhouse of modern electronics and electric vehicles (EVs), and their performance hinges on the cathode materials. Among these, ternary cathode materials such as NCM (Nickel-Cobalt-Manganese oxides) and NCA (Nickel-Cobalt-Aluminum oxides) dominate due to their balanced energy density and stability. However, varying the ratios of nickel (Ni), cobalt (Co), mang...read more
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In the manufacturing process of lithium-ion batteries, formation is a critical procedure. This article discusses the impact of formation conditions (e.g., formation current, formation voltage, formation temperature, and external pressure) on battery performance, including internal resistance, capacity, and cycle life. TOB NEW ENERGY provides battery formation machine of various specifications to m...read more
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1. Process Principles Stacking Process: Anode and cathode sheets are cut to specified dimensions, then laminated with separators to form unit cells. These unit cells are stacked in parallel to create battery modules. Winding Process: Pre-cut anode sheets, separators, and cathode sheets are wound in a defined sequence around a fixed mandrel, compressed into cylindrical, elliptical, or prismatic sha...read more
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Analysis of Causes for Low Cells CapacityApr 15 , 2025Low cell capacity is an intuitive judgment based on comparing the post-formation discharge capacity with the design value. If the measured capacity falls below the design specification, the first step is to verify whether the formation process parameters are correctly set (e.g., discharge current, charge duration, cutoff voltage, and formation temperature). ① If the formation steps are confirmed c...read more
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The voltage of a lithium battery is closely related to the electrode potentials of its cathode and anode materials. Variations in voltage among lithium batteries using different materials primarily stem from the following factors: Impact of Electrode Materials’ Chemical Properties Lithium batteries operate through the movement of lithium ions between the cathode and anode during charging and disch...read more
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Lithium-Ion Battery Capacity Degradation MechanismsMay 09 , 2025A lithium-ion battery is primarily composed of a cathode, anode, electrolyte, and separator. During charging, lithium ions de-intercalate from the cathode material, migrate through the electrolyte, and intercalate into the anode material. During discharging, lithium ions move in the reverse direction, de-intercalating from the anode and returning to the cathode through the electrolyte. This repeat...read more
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Non-destructive Methods to Detect Lithium PlatingMay 22 , 2025Lithium plating refers to the detrimental phenomenon where lithium ions fail to intercalate into the graphite anode during charging processes, instead undergoing electrochemical reduction to form metallic lithium deposits. This results in the formation of characteristic silver-gray lithium metal layers or dendritic lithium crystals on the anode surface. Conventionally, battery disassembly has been...read more
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In lithium battery manufacturing, the often-overlooked A/B-side coating misalignment issue during the coating process significantly affects battery capacity, safety, and cycle life. Misalignment refers to inconsistencies in the positional alignment or thickness distribution of coatings on the front and back sides of electrodes, which can lead to risks such as localized lithium plating and mechanic...read more
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Fineness Requirements for Lithium-Ion Battery SlurryJun 16 , 2025In lithium-ion battery manufacturing, the fineness of the slurry (mainly referring to the electrode slurry) is a key parameter affecting electrode performance (such as capacity, rate capability, cycle life, safety) and process stability. Different battery types have significantly different fineness requirements for the slurry (usually measured by particle size distribution indicators such as D50, ...read more
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I. Characteristics and Advantages of Polyacrylate (PAA) Binders Minimal Swelling in Electrolyte Solvents: Exhibits low swelling, maintaining structural integrity of electrode sheets during charge/discharge cycles. High Proportion of Carboxyl Groups: The high density of polar carboxyl groups forms strong hydrogen bonds with hydroxyl-containing active materials, enhancing dispersion stability. Conti...read more
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Reasons for Self-Discharge in Lithium-Ion BatteriesJul 15 , 2025Self-discharge in lithium-ion batteries refers to the phenomenon where the battery's charge/voltage naturally decreases when disconnected from an external circuit (i.e., in an open-circuit state). This is an inherent characteristic of all batteries, though the degree varies. Lithium-ion batteries exhibit a relatively low self-discharge rate but are still affected. The primary causes can be categor...read more
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Lithium-ion Battery Stacking TechnologiesJul 28 , 2025Lithium-ion battery stacking technology is a critical process in cell manufacturing, directly impacting performance, safety, and production efficiency. At TOB NEW ENERGY, we specialize in providing turnkey battery production line solutions and cutting-edge equipment tailored to optimize these advanced processes. Currently, four primary stacking technology routes dominate the industry: Z-Folding, C...read more
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In the pursuit of higher energy density for lithium-ion batteries, silicon-based anodes have emerged as a promising candidate. However, their commercialization is hindered by challenges such as significant volume expansion and, critically, non-uniform lithiation. This article explores the causes, detrimental effects, and advanced solutions to mitigate this issue, a key consideration for anyone inv...read more
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I. Precise Deconstruction of Task Objectives Task objective deconstruction is a foundational aspect of cell development. Whether for new product development or the ongoing maintenance of mass-produced products, clearly and logically breaking down goals is crucial. Complex indicators must be layered and refined, then systematically assigned to relevant departments. This ensures each department unde...read more
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I. Structural Design of Power Battery Systems The structure of a power battery system comprises cells, modules, and battery packs. The cell is the most fundamental unit, and its structural design and material selection are decisive for battery performance. Mainstream cell types currently available include cylindrical, prismatic, and pouch cells, each offering certain advantages in terms of energy ...read more
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The lithium battery separator acts as a protective barrier between the positive and negative electrodes, conducting ions but not electrons. In the ideal state after electrolyte filling and formation, the separator should maintain complete and flat contact with the electrodes. However, when we disassemble batteries, we often find severe wrinkling of the separator. (This can also be clearly observed...read more
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Defects in lithium-ion battery coating originate from three main parts: the coating slurry, the coating window, and the coating drying process. In the slurry preparation process, incomplete dispersion introduces agglomerated particles; insufficient iron removal filtration introduces metal debris; and incomplete vacuum deaeration leaves behind numerous bubbles. Corresponding coating defects include...read more
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One-Stop Solution Guide for Battery Binder IssuesNov 27 , 2025On the production frontlines of lithium battery slurry mixing, coating, and subsequent assembly, slurry sedimentation, gelation (jelly-like consistency), and coating head blockages are three persistent "ailments" that trouble process engineers. These issues can further trigger chain reactions like electrode cracking, film delamination, and battery deformation. Such instabilities not only lead to p...read more
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