Core Responsibilities of Battery Cell Research and Development

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 understands its direction and priorities.

If a department fails to meet its assigned objectives, accountability is clear. Conversely, if all departments successfully achieve their decomposed goals but the overall target remains unmet, it is necessary to reevaluate whether the cell development department’s objective decomposition was biased or unreasonable.

For example, when developing high-energy-density cells, the energy density target must be broken down into specific aspects such as positive and negative electrode material selection, electrode thickness design, and electrolyte formulation, with these tasks assigned to materials R&D and process design departments.

In larger battery companies, cell development begins by addressing customer needs. After gaining a deep understanding of customer requirements for cell performance, size, and cost across different application scenarios, comprehensive and detailed target decomposition analysis is conducted. In smaller battery factories, while top management may directly set key goals and strategies, junior employees can still learn the methods and logic of indicator decomposition from the company’s OKRs (Objectives and Key Results). This process not only helps employees understand the company’s overall strategic layout but also provides macro-level guidance for their work.

II. Rigorous Product Development Process

(1) Demand-Based Design Planning

At the outset of new product development, the structural dimensions of the cell must be accurately designed based on customer requirements. Different application scenarios, such as electric vehicles, energy storage power stations, and consumer electronics, have vastly different demands for cell size. Simultaneously, comprehensive and precise electrical performance indicators must be established based on the characteristics of the application scenario, including energy density, charge-discharge rate, cycle life, and self-discharge rate.

For instance, cells for electric vehicles need to prioritize energy density and charge-discharge rates to meet requirements for long range and fast charging, while cells for energy storage stations focus more on cycle life and safety. During the design and planning phase, collaboration with system departments is also essential to develop comprehensive system solutions, including quality management systems and production process systems, laying a solid foundation for subsequent sample production.

(2) Sample Production and Iterative Optimization

After completing the design planning, the process moves swiftly into custom battery equipment sample production. Each round of sample production must undergo rigorous and comprehensive testing, including electrical performance tests, safety tests, and environmental adaptability tests. Based on the test results, design and process parameters are adjusted promptly, and the next round of validation begins. This iterative process continues until the cell performance targets are perfectly achieved.

Once the electrical performance of the cell meets the standards, further validation is required if the final product is a system module. Modules involve multiple cells connected in series or parallel, requiring consideration of complex factors such as cell consistency, thermal management, and electrical connections.

For newcomers entering the field of cell development, the primary task initially is to shadow battery production lines. On the production line, newcomers can visually learn the entire detailed manufacturing process of cells, from raw materials to finished products, including key steps such as electrode coating, winding or stacking, electrolyte injection, and encapsulation.

As experience accumulates, newcomers can gradually take on the role of experiment lead, fully responsible for cell production and standardizing the output of process reports. After samples are completed, they act as commissioners, sending samples to professional testing institutions and producing detailed specialized reports based on the test results.

While shadowing production lines, various on-site issues are inevitable, such as material defects, process fluctuations, and equipment failures. This requires continuous accumulation of experience to gradually enhance problem-solving skills. This process also involves validation work for various battery materials. While not as specialized as materials department professionals, newcomers can still grasp basic characteristics and application essentials.

For tested cells, teardown analysis or other failure analysis is necessary. Although not as in-depth as professional failure analysis departments, key information can still be extracted to aid product optimization.

III. Scientific Product Application Strategy Formulation

(1) Performance Exploration and Strategy Formulation for Newly Developed Products

Newly developed cell products must undergo a series of comprehensive and in-depth basic electrical performance tests, including capacity tests, internal resistance tests, and cycle life tests under different temperatures and charge-discharge rates.

Based on these tests, detailed baseline matrix test results are generated, and precise charge-discharge current limitation tables are formulated. These tables serve as critical references for subsequent BMS (Battery Management System) strategy development. The BMS must reasonably control charge-discharge currents based on the cell’s characteristics to ensure safe and efficient operation.

For cells with potential material system shortcomings or failure to fully meet standards, testing strategies must be flexibly adjusted. For example, for cells prone to expansion, pre-tightening force can be applied to suppress expansion and ensure performance. For cells with weaker charge acceptance, stepped charging methods can be attempted to improve charging efficiency.

(2) Maintenance and Optimization of Mass-Produced Products

Mass production maintenance is complex and critical. It may involve cost-reduction material replacement validation, seeking more cost-effective raw materials without compromising product performance, thereby enhancing market competitiveness. Simultaneously, aging cells must undergo charge-discharge capability validation to assess the gap between actual operational lifespan and laboratory lifespan, providing data support for product lifespan prediction and optimization.

Additionally, customer complaints require reproduction validation, in-depth root cause analysis, and practical improvement measures. These tasks vary depending on the company’s business focus and customer needs.

For newcomers, the product application phase primarily involves learning specific testing procedures, thoroughly understanding the purpose and design principles of each test step. After mastering testing methods, accurate data processing, in-depth analysis of test results, and output of professional specialized reports are required. If the company’s products are modules, module testing must also be undertaken.

Module testing is more complex than cell testing. Beyond the cell’s own performance, consistency issues arising from multiple cells connected in series or parallel must be addressed. This ensures that parameters such as voltage, capacity, and internal resistance are similar across cells during charge-discharge, preventing overcharging or over-discharging of individual cells.

Additionally, module temperature rise issues must be resolved by designing reasonable thermal management systems to ensure modules operate within suitable temperature ranges under various conditions. Furthermore, the application strategy of BMS in modules must be thoroughly studied to achieve precise management and protection. This is undoubtedly a profound and extensive field, requiring practitioners to continuously accumulate knowledge and deepen their understanding through practice.

In new energy battery factories, cell development is like a long and complex marathon. If practitioners have the opportunity to fully follow a project, deeply participating in every stage from demand analysis and product development to application maintenance, they can not only comprehensively master cell development skills and accumulate rich experience but also gain a great sense of achievement when the product successfully reaches the market and meets customer needs.

Of course, this process is also fraught with challenges. Overtime becomes the norm, and work pressure is significant. However, it is through such high-intensity challenges that practitioners continue to grow and contribute to the thriving development of the new energy battery industry.

At TOB NEW ENERGY, we support cell development at every stage—from battery lab line, battery pilot line setup to full-scale battery production line solutions. We provide and a wide range of battery materials, backed by expert battery technical support for emerging technologies like solid-state, sodium-ion, and lithium-sulfur batteries. We look forward to more peers sharing their experiences in the comments section to collectively enhance our understanding of cell development responsibilities.