FLEX Stacked Lithium—Power That Changes Everything
Apr. 29, 2024
FLEX Stacked Lithium—Power That Changes Everything
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Overview of Lithium-Ion Battery Stacking Technologies
Lithium-ion battery stacking technologies can be broadly categorized into four main types: Z-fold stacking, cut-and-stack integration, thermal composite stacking, and roll-to-stack integration. Among these, Z-fold stacking and cut-and-stack integration are commonly used in domestic applications. Thermal composite stacking offers enhanced quality and production speed but involves higher technical complexity. Internationally, companies like LG New Energy employ roll-to-stack integration, which boasts high efficiency but is protected by LG's patents.
1. Z-Fold Stacking Technology
Z-fold stacking technology is one of the most common stacking methods. It involves moving the separator between stacking platforms in a zigzag pattern, allowing the anode and cathode tabs to cross-stack.
Z-fold stacking has certain drawbacks, including separator deformation and low stacking efficiency. Separator deformation can occur due to the swinging motion of the separator, resulting in asymmetry and inconsistent deformation. The varying tension during stacking leads to non-uniform stretching and deformation of the separator, affecting the battery's quality. Moreover, the stacking process is time-consuming, as it requires swinging the separator and can only achieve single-layer stacking, resulting in limited efficiency.
2. Cut-and-Stack Integration Technology
Cut-and-stack integration is essentially an improvement over Z-fold stacking. It aims to enhance yield rates and stacking efficiency. By consolidating multiple steps into a single machine, it reduces the risk of cell damage during transportation and handling.
Traditional production methods involve using a stacking machine to retrieve and stack sliced electrodes from a material box. During retrieval, electrodes may collide, bend, or fold. In contrast, cut-and-stack integration combines electrode cutting, Z-fold stacking, and adhesive thermal pressing into a single process. This integration eliminates bending and picking issues and, by reducing the number of steps and transfers, reduces the risk of collision and improves yield rates.
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3. Thermal Composite Stacking Technology
Thermal composite stacking involves simultaneous cutting and stacking of the positive and negative electrodes and separator, followed by hot pressing. This technology achieves a significant improvement in stacking quality and production rates. However, it comes with greater technical challenges.
In thermal composite stacking, the electrodes and separator are simultaneously fed into a heating device. After heating, a hot roller presses the composite, cutting the separator to form individual stacking units. These units are then mechanically stacked, creating electrode assemblies.
One notable advantage of thermal composite stacking is that the separator and electrodes maintain consistent tension, direction, and speed throughout the process, ensuring uniformity. This results in a higher-quality battery. While it presents higher technical difficulty compared to Z-fold stacking, it is suitable for high-energy-density batteries.
4. Roll-to-Stack Integration Technology
Roll-to-stack integration technology, exemplified by LG's Stack & Folding patent, offers high efficiency but is not available for external sale. This method involves cutting positive and negative electrodes into units and adhering them separately to a separator. Subsequently, the electrodes are wrapped around the separator, creating interleaved electrode layers. This approach achieves high speed and efficiency.
In conclusion, the choice of #lithium-ion battery stacking technology depends on various factors, including battery size, energy density, and production scale. Each method has its advantages and challenges, impacting the quality and efficiency of the battery manufacturing process. Innovations in stacking technology continue to play a crucial role in improving the performance and safety of lithium-ion batteries.
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