How are batteries made?

In recent years, demand for batteries, particularly lithium-ion, has begun to outpace supply. Its global availability is becoming a strategic asset that determines competitiveness and development in a growing number of economic sectors, for example, in the manufacture of power tools or in energy storage systems. The manufacturing process of lithium-ion cells is complex and depends on a number of factors, the most important of which are the quality of the raw materials used for production, sustainable development goals and the possibility of increasing production capacity. . Published: 07-21-2023 The structure and principle of operation of batteries. Batteries produce electrical energy through the chemical reaction that occurs inside the cell. The key to carrying out this reaction is the movement of electrons. Electrons are negatively charged particles that generate electricity as they move. This flow is possible with the use of two different metals that act as conductors. By connecting the metals together, the movement of electrons between them starts, which is caused by the electrons being attracted to the metals which are known as cathode and anode. Electrons will always be attracted stronger to the cathode. The metals inside a battery are interconnected by a substance capable of conducting electrons, called an electrolyte. Electric vehicles use batteries built with interconnected cells. The power systems used differ from each other mainly by their service life, chemical composition and weight.



The electric vehicle battery market is changing dynamically. Currently, lithium-ion batteries are among the most popular types. Its production is complex and requires maximum quality at each stage. The most popular lithium-ion batteries are those whose cells are based on metals such as nickel, cobalt or manganese. The most commonly chosen types of lithium-ion batteries for electric vehicles include lithium-nickel-cobalt-manganese (NMC) batteries. Lithium-manganese (LMO), lithium-iron-phosphate (LFP) and lithium-nickel-cobalt-aluminum (NCA) batteries are of much less interest. How is CZ Leads a battery made? The manufacturing of lithium-ion and other cells is characterized by its complexity and a high degree of automation. The production of batteries depends on their type, but the main stages and processes are similar. Simply put, the entire manufacturing process can be divided into three main "blocks": 1. Electrode production Regardless of the format and shape of the battery that is produced, the first step is to manufacture the electrodes. At this stage, it is important to avoid cross contamination between different materials, so in practice there is a separate line to produce the cathode and a separate line for the anode. The anode is produced from a copper sheet coated with graphite, while the cathode is made from an aluminum sheet coated with a selected metal.







The most important production phases include: Mixture, which consists of producing the so-called suspension, which is a mixture of powders (active substances) with a solvent and other chemical substances that act as binders. Coating and drying: A ready slurry is pumped to the coating area, where it is applied onto a metal sheet. The sheet is then sent to a drying oven, where the solvent evaporates and the active substance adheres to the sheet. Calendering: The process of finishing coated rolls. They move between two heated elements that provide proper compression of the material by pressing the rolls against the sheet, thus maintaining a stable thickness and density and better adhesion. Cutting: The metal sheet passes through a system of blades that cut it into many smaller pieces whose sizes fit the electrodes to be produced. 2. Cell assembly Cell assembly requires a dry environment to avoid the formation of moisture that can cause degradation and a significant drop in electrode efficiency. At this stage, the electrodes are cut and placed in covers. Cell assembly covers the following steps: Cutting: Rectangular electrodes are produced during the cutting process. Cutting is done mechanically or with a laser. Arrangement: In a battery case, the electrodes are arranged alternately: anode, separator, cathode. The most popular shape is the half. Assembly: Properly arranged electrodes are connected and attached to the main clamps by welding. The cell with electrodes thus produced is placed in packaging material and sealed, leaving an open edge for filling with electrolyte. 3. Training and quality control. An assembled battery then goes through the conditioning phase.