The majority of the costs for lithium ion cells and batteries are due to their manufacture. The performance characteristics of a battery are most strongly influenced in electrode and cell production. Through production research with innovative machines and systems as well as new processes, more efficient and more powerful cells can be produced. The objective is the development and prototypical representation of economical production processes within the research factory. In addition to optimizing the process step of calendaring, research into novel stacking processes for cells is a current component of the tasks at hand. Due to the variously production variety of batteries and their applications in the future, early adaptation of the cell format production can be met.
In the SmartBatteryMaker, cell formats and material systems of different sizes are examined along the entire process chain of electrode and cell production. In a robotic cell with a micro-environment, cell stacks are to be formed, contacted and packaged without tool changes. A hydraulic press will be used to analyze the behavior of pouch cell foil during deep drawing. In addition, new packaging concepts for cell housings will be tested. To further minimize costs, the process chain of cell production will be optimized as part of the HoLiPress project. The integration of all process steps involving a lifting movement into a press line is being designed. A reassembly system, which was developed in the InnoDeLiBatt project, makes it possible to replace individual - defective - prismatic cells of a battery module.
Within the framework of the PoLiS excellence cluster, new battery materials for the "post-lithium era" are being researched due to the worldwide shortage of lithium resources. The wbk is investigating the scalability and reducibility of these novel cells. Parallel to the development of innovative and holistic solutions for machines, systems and process technology, a quality assurance system is being established. This should contribute both to an increase in the holistic understanding of processes and process optimization and to an increase in production efficiency by reducing rejects.
Contact: M.Sc. Janna Hofmann (wbk)