Case Study: 100Ah Pouch Cell Pilot Line rau University Laboratories thiab Research Institutes

Author: PhD. Dany Huang
CEO & R&D Leader, TOB New Energy

PhD. Dany Huang

GM / R&D Leader · CEO of TOB New Energy

National Senior Engineer
Inventor · Battery Manufacturing Systems Architect · Advanced Battery Technology Expert

Hu rau Dr. Huang

Qhov tseem ceeb cuam tshuam ntawm kev tshawb fawb roj teeb thiab kev lag luam kev lag luam feem ntau tau sau tseg hauv ib qho kev ntsuas: Ampere- teev (Ah). Tau ntau xyoo lawm, cov chaw kuaj mob hauv tsev kawm ntawv tau tso siab rau CR2032 npib ntawm tes (feem ntau 0.002 Ah) lossis ib qho me me - txheej hnab hnab (0.1 txog 1 Ah) kom siv tau cov khoom siv cathode tshiab, silicon -carbon anodes, thiab cov khoom- xeev electrolytes. Txawm li cas los xij, thaum cov kws tshawb fawb tau nthuav tawm cov ntaub ntawv xov tooj ntawm tes no rau cov tsheb OEMs lossis qib-ib lub xov tooj ntawm tes, cov lus teb yuav luag zoo ib yam: "Qhia peb cov ntaub ntawv hauv loj- hom xov tooj ntawm tes."

Lub physics ntawm 100Ah Hluav Taws Xob Tsheb (EV) qib hnab ntawm tes yog txawv kiag li ntawm lub xov tooj ntawm tes. Thermal dissipation, mechanical stress thaum lub sij hawm volumetric expansion, cov roj tiam thaum lub sij hawm tsim lub voj voog, thiab cov hluav taws xob faib thoob plaws cov khoom loj tam sim no tsis tuaj yeem ua qauv raug ntawm milliampere nplai. Txhawm rau hla qhov "Valley of Death," sab saum toj - cov tsev kawm qib siab tam sim no tau koom tes nrog ib qho - nres cov chaw muab roj teeb los tsim lawv tus kheej nruab nrab - mus rau - cov kab loj loj.

Cov ntaub ntawv kawm no muab cov qauv tsim qauv tsim qauv nruj heev rau kev tsim, kev yuav khoom, thiab txhim kho 100Ah Pouch Cell Pilot Line nyob rau hauv ib lub tsev kawm ntawv infrastructure. Peb yuav tshuaj xyuas cov ntsiab lus hloov pauv tseem ceeb, los ntawm slurry rheology ntawm nplai mus rau qhov kev xav tau ntawm ntau- txheej ultrasonic vuam.

Keeb Kwm Evolution: Los ntawm Kev Taw Qhia Casting rau Automated Precision

Txhawm rau kom nkag siab qhov twg peb yuav mus hauv 2026, peb yuav tsum nkag siab txog txoj hauv kev ntawm txheej txheej txheej txheem. Kev tshawb fawb roj teeb thaum ntxov tau tso siab rau "Tape Casting," ib txheej txheem qiv los ntawm kev lag luam ceramics. Tus Kws Kho Mob Hniav yog qhov kev hloov pauv ntawm qhov no -ib qho yooj yim, nruj bar uas theem ib lub pas dej ntawm slurry. Nws ua haujlwm zoo rau cov roj teeb thaum ntxov LCO (Lithium Cobalt Oxide) uas yuav tsum muaj lub zog ntom ntom.

Txawm li cas los xij, raws li kev lag luam tau txav mus rau siab - lub zog thiab siab - cov hlwb muaj peev xwm, cov kev txwv ntawm "tus kheej- ntsuas" tau tshwm sim. Kev taw qhia ntawm Slot Die txheej, thev naus laus zis thev naus laus zis hauv cov duab thaij duab thiab qib siab -kawg daim ntawv kev lag luam, tau hloov pauv lub chaw tsim khoom roj teeb. Nws txav kev lag luam los ntawm cov txheej txheem "passive", qhov twg cov ntawv ci rub cov kua dej, mus rau "active" txheej txheem, qhov twg cov cuab yeej dictates cov kua tus cwj pwm. NtawmTOB NEW ENERGY, peb tau sau tseg tias qhov kev hloov pauv no ib leeg tuaj yeem txhim kho cell - mus rau - xov tooj ntawm tes sib xws li 40% hauv ib puag ncig kev sim.

I. Facility Infrastructure: Yam yuavtsum tau kawm uantej rau High-Cells Peev Xwm

Ua ntej ib qho ntawm cov khoom siv roj teeb raug txiav txim, lub tsev kawm ntawv yuav tsum hais txog qhov chaw. Lub 100Ah ntawm tes muaj qhov ntim loj ntawm cov ntaub ntawv muaj zog heev. Kev tsim kho vaj tse tsis yog tsuas yog kev xav tau vaj tse xwb; Nws yog ib qho kev sib txawv ntawm cov xovtooj ntawm tes electrochemical kev ua haujlwm.

1. The Ultra-Dry Room Engineering

Cov khoom kim tshaj plaws thiab tseem ceeb tshaj plaws rau kev tsav tsheb roj teeb yog Chav Qhuav. Hauv ib lub npib cell lab, ib qho argon-cov hnab looj tes puv nkaus txaus. Rau 100Ah hnab cell kab uas muaj yob-rau- yob txheej, automated stacking, thiab kua electrolyte filling, taug kev- hauv chav qhuav yog qhov yuav tsum tau ua.

Rau tus qauv Lithium-ion chemistry (NMC/Graphite), chav qhuav yuav tsum muaj dej ntws ntawm -40 degrees Celsius (kwv yees li 127 ppm dej). Txawm li cas los xij, yog lub tsev kawm ntawv npaj siab los tshawb fawb tom ntej no - tiam Sulfide Solid -State Electrolytes lossis Lithium-Hlau anodes, qhov yuav tsum tau poob mus rau -60 degrees Celsius (tsawg dua 10 ppm). Ua kom tiav qhov no yuav tsum tau loj Rotary Desiccant Dehumidifiers. HVAC engineering yuav tsum suav rau cov cua sov uas tsim los ntawm lub tshuab nqus tsev kom qhuav thiab cov dej noo tawm los ntawm cov kws tshawb fawb lawv tus kheej (feem ntau yog 100 txog 150 grams dej rau ib tus neeg, ib teev).

2. Pem teb Loading thiab Vibration Isolation

Cov tsev kawm ntawv qib siab, tshwj xeeb tshaj yog cov kev tshawb fawb qub, feem ntau tsis raug ntsuas rau kev lag luam hauv pem teb. Ib lub yob-rau- yob qhov tuag coater ua ke nrog lub siab- siab nruam calendering tshuab tuaj yeem hnyav ob peb tons thiab siv qhov taw tes loj heev-loads. Tsis tas li ntawd, calendering machines thiab planetary mixers tsim tsawg- zaus vibrations uas tuaj yeem cuam tshuam nrog siab nyob ib sab- daws teeb meem electron microscopes (TEM/SEM). NtawmTOB NEW ENERGY, peb pab neeg npaj chaw ua hauj lwm nrog tsev kawm ntawv architects los tsim kev cai vibrations - cais pads thiab xam dynamic pem teb kev nyuaj siab ua ntej khoom xa tuaj.

3. NMP Solvent Recovery thiab Exhaust Management

Cov txheej txheem txheej siv N-Methyl-2-pyrrolidone (NMP) ua cov kuab tshuaj rau cathode slurry. NMP yog tshuaj lom thiab nruj tswj hwm los ntawm ib puag ncig kev noj qab haus huv thiab kev nyab xeeb (EHS) cov qauv. 100Ah pilot kab yuav tsum muaj kev sib koom ua ke NMP Recovery System txuas nrog lub coater lub tso pa tawm. Cov txheej txheem no siv cov dej txias txias los yog zeolite rotor adsorption los ntes NMP vapor ua ntej nws mus txog lub tsev kawm ntawv lub hauv paus tso pa tawm, xyuas kom ua raws li cov cai hauv zej zog.

II. Pem hauv ntej-Kev Ua Haujlwm Kawg: Scaling Slurry thiab Electrode

Txhawm rau tsim ib qho 100Ah hnab ntawm tes, koj xav tau kwv yees li 3 mus rau 4 square metres ntawm ob -sided coated electrode. Ib pawg txheej txheem ntawm 10 lub hlwb xav tau 40 square meters. Koj tsis tuaj yeem sib tov rau hauv lub beaker lossis lub tsho tiv no nrog ib rab riam.

1. Siab -Shear Mixingntawm 50-liter Scale

Kev hloov pauv los ntawm 1-liter lab tov khoom mus rau 50-liter dual planetary lub tshuab nqus tsev tov khoom hloov cov dej dynamics hauv paus. Hauv cov khoom loj, kev tswj qhov kub thiab txias yog qhov nyuaj. Lub zog shear siab ua kom muaj cua sov hauv cheeb tsam, uas tuaj yeem ua rau PVDF binder crystallize lossis cov kuab tshuaj kom evaporate ntxov ntxov.

Lub 50L mixers peb muab rau cov kab hauv tsev kawm qib siab tau nruab nrog dual-txheej dej txias tsho thiab ntau-point PT100 kub sensors. Tsis tas li ntawd, lub tshuab nqus tsev degassing thaum lub sij hawm sib tov kawg yog qhov tseem ceeb. Txhua lub micro- npuas ntim hauv 50-liter batch yuav txhais rau hauv pinholes thaum txheej txheej txheej, ua rau muaj kev puas tsuaj loj lithium dendrite loj hlob hauv 100Ah cell.

2. TxheejthiabCalenderingrau Energy Density

Raws li tau tham hauv peb qhov kev txheeb xyuas yav dhau los ntawm qhov kev siv thev naus laus zis, cov txheej txheem ua ntej - ntsuas ntsuas tsis yog- sib tham ntawm qhov ntsuas no. Rau 100Ah hlwb, qhov chaw thauj khoom loj yog thawb mus rau nws qhov txwv (feem ntau tshaj 20 milligrams ib square centimeter rau siab - daim ntawv thov hluav taws xob).

Thaum coated thiab qhuav, lub electrode yuav tsum tau densified siv hydraulic yob xovxwm. Calendering ib 300mm dav electrode yuav tsum tau ntau pua tons ntawm linear siab. Yog hais tias lub siab tsis zoo tag nrho ntawm cov chais, cov ntawv ci yuav wrinkle los yog "camber." Peb muab peb cov pilot calendering tshuab nrog "Roll Bending" technology thiab induction cua sov kom soften lub binder, tso cai rau siab compaction ceev (xws li, 3.6 g / cm3 rau NMC cathodes) tsis crushing lub active khoom hais.

III. Nruab nrab -End Processing: Lub Tsev Kawm Ntawv ntawm Lub Hnab

Kev sib dhos ntawm lub hnab ntawm tes yog ib qho kev tawm dag zog hauv kev ua haujlwm siab heev. Ib 100Ah cell tsis yog ib chav tsev electrochemical; Nws yog ib qho kev sib txuas mus txog 80 lossis 100 tus neeg txheej ntawm cathode, cais, thiab anode.

1. Z-Kev sib twvs.Cua

Thaum lub cylindrical hlwb siv winding, loj- cov ntaub ntawv lub hnab ntim cia siab rau Z-Stacking. Nyob rau hauv Z-stacking tshuab, ib tug nruam sawb ntawm separator yog folded rov qab mus rau hauv ib tug "Z" qauv, nrog discrete nplooj ntawv ntawm txiav cathode thiab anode tso rau hauv lub folds.

Engineering kam rau ua ntawm no yog unforgiving. Lub anode yuav tsum yog me ntsis loj dua lub cathode ("Overhang") kom tiv thaiv lithium plating ntawm cov npoo thaum them nyiaj ceev. Yog tias cov txheej txheem stacking misaligns ib daim ntawv cathode los ntawm 0.5 millimeters kom nws txuas mus dhau lub anode, tag nrho 100Ah cell yog qhov phom sij. Peb cov tshuab pilot stacking tshuab tau siv ntau lub koob yees duab CCD lub zeem muag los ua qhov kaw - txoj hlua khi txoj hlua khi ntawm ya, kom ntseeg tau zoo tshaj plaws overhang geometry rau txhua txheej.

2. Lub Physics ntawm Multi- TxheejUltrasonic Vuam

Thaum lub cell yog stacked, tag nrho 80 txheej ntawm txhuas ntawv nyiaj (los ntawm cathodes) yuav tsum tau welded mus rau ib tug txhuas tab, thiab tag nrho 80 txheej ntawm tooj liab ntawv ci (los ntawm lub anodes) yuav tsum tau welded rau ib tug npib tsib xee los yog tooj liab tab.

Qhov no tsis tuaj yeem ua nrog laser vuam vim tias cov ntawv nyias nyias yuav tsuas vaporize. Hloov chaw, peb siv cov khoom siv ultrasonic vuam. Cov txheej txheem no siv siab - zaus acoustic vibrations (feem ntau 20 kHz txog 40 kHz) siv nyob rau hauv siab los tsim ib qho khoom siv hauv lub xeev weld.

Vuam 80 txheej rau 100Ah ntawm tes yuav tsum muaj lub zog loj heev -feem ntau 3000 txog 4500 Watts. Qhov kev sib tw yog "weld penetration." Yog tias lub zog qis dhau, cov khaubncaws sab nraud povtseg yuav tsis sib raug zoo (ua rau muaj kev tiv thaiv sab hauv siab). Yog tias lub zog siab dhau lawm, lub sonotrode (cov cuab yeej vibrating) yuav rhuav tshem cov txheej saum toj kawg nkaus. NtawmTOB NEW ENERGY, peb muab customized sonotrode horn tsim thiab dynamic siab tswj systems tshwj xeeb engineered rau lub hnyav tab-rau-foil ratios pom nyob rau hauv EV- qib hlwb.

3. Hnab tsim thiab sib sib zog nqus kos duab

Lub casing ntawm lub hnab ntawm tes yog ua los ntawm Aluminium Laminated Film (ALF) -ib qho kev sib xyaw ntawm nylon, aluminium foil, thiab polypropylene. Txhawm rau tuav cov pawg loj 100Ah, qhov sib sib zog nqus "khob" yuav tsum txias- ua rau ALF siv lub hnab ntim tshuab.

Rau siab - hlwb muaj peev xwm, qhov tob ntawm lub khob no tuaj yeem tshaj 10 millimeters. Thaum sib sib zog nqus nqus, ALF muaj kev ntxhov siab heev. Yog hais tias lub punch thiab tuag tsis zoo polished, los yog yog hais tias lub clamping siab tsis raug, lub txhuas txheej nyob rau hauv zaj duab xis yuav micro- puas. Cov pob txha tsis pom no yuav tso cai rau cov dej noo nkag mus rau hauv lub cell hla nws txoj sia, ua rau muaj kev puas tsuaj loj. Peb tus kws tsav dav hlau- nplai tsim tshuab siv servo- tsav punches nrog programmable ceev nkhaus kom maj mam ncab zaj duab xis yam tsis ua txhaum nws lub zog tawm los.

IV. Rov qab-End Processing: Chemistry of Activation

Thaum cov pawg raug kaw hauv peb sab ntawm lub hnab, cov txheej txheem hloov pauv ntawm kev siv tshuab ua haujlwm rov qab mus rau chemical engineering.

1. Nqus Electrolyte Fillingthiab Wetting Dynamics

Kev txhaj tshuaj electrolyte rau hauv CR2032 npib ntawm tes siv sijhawm vib nas this. Txhaj 100 mus rau 150 grams ntawm electrolyte rau hauv nruj nreem compressed 100Ah hnab cell stack yog ib qho kev sib tw loj heev hydrodynamic. Lub porosity ntawm compressed electrodes thiab nanopores ntawm lub separator tsim loj capillary kuj.

Yog tias koj tsuas yog nchuav cov kua dej rau hauv, nws yuav tso dej rau saum toj, tawm hauv nruab nrab ntawm tes kom qhuav. Thaum lub xov tooj raug them, cov chaw qhuav no yuav dhau los ua qhov chaw tuag, yuam cov chaw ntub dej ua haujlwm ntawm ob npaug ntawm lawv tus qauv C- tus nqi, rhuav tshem lub cell tam sim ntawd.

Nyob rau hauv peb cov roj teeb pilot kab, peb siv lub tshuab nqus tsev electrolyte filling tshuab. Lub hnab ntim tsis tau muab tso rau hauv lub chamber, thiab lub tshuab nqus tsev nqus tau nqus, tshem tawm tag nrho cov huab cua los ntawm cov electrode pores. Tom qab ntawd cov electrolyte yog txhaj. Thaum atmospheric siab reintroduced, nws lub cev quab yuam cov kua tob rau hauv nruab nrab ntawm pawg. Rau 100Ah hlwb, lub tshuab nqus tsev no- lub voj voog siab yuav tsum tau rov ua dua ntau zaus, ua raws li qhov siab -kub kub so lub sij hawm kom ntseeg tau tias tag nrho cov homogeneity ntawm ntub dej.

2. Tsim, Gas Generation, thiab Secondary Sealing

Cov kauj ruam kawg ntawm kev tsim khoom yog "Tsim"- thawj zaug ua tib zoo them lub roj teeb los tsim cov khoom Electrolyte Interphase (SEI) txheej ntawm lub anode.

Thaum lub sij hawm SEI tsim nyob rau hauv cov kua electrolyte system, ib tug loj npaum li cas ntawm cov pa roj (feem ntau ethylene, hydrogen, thiab carbon monoxide) yog generated. Hauv 100Ah cell, cov pa roj no loj heev. Qhov no yog vim li cas lub hnab ntim tau tsim nrog "Gas Bag"- ib qho ntxiv, tsis muaj qhov ntev ntawm lub hnab ALF qhov twg cov roj tuaj yeem khaws tau.

Tom qab kev tsim ua tiav ntawm peb qhov siab -cov roj teeb ntsuas qhov tseeb, lub xov tooj ntawm tes tau hloov mus rau lub tshuab nqus tsev zaum kawg sealing tshuab. Lub tshuab no pierces lub hnab roj hauv lub tshuab nqus tsev ib puag ncig, tshem tawm tag nrho cov pa roj, thiab siv qhov kawg thermal foob ncaj qha saum lub cev ntawm tes. Lub hnab ntim roj ntau dhau ces txiav tawm thiab muab pov tseg. Cov txheej txheem no yuav tsum muaj qhov tseeb tshwj xeeb los xyuas kom meej tias tsis muaj electrolyte raug nqus nrog rau cov roj, uas yuav hloov pauv cov cell ua tib zoo suav cov kua dej- rau - muaj peev xwm piv.

V. Kev Tswj Xyuas Zoo thiab Kev Nyab Xeeb hauv Tsev Kawm Qib Siab

Ib qho kev lag luam Gigafactory muaj kev ruaj ntseg bunkers rau kev kuaj cell. Lub tsev kawm ntawv kuaj mob feem ntau nyob hauv ib lub tsev uas muaj cov tub ntxhais kawm thiab lwm lub chaw tshawb fawb. Yog li, Kev Tswj Xyuas Zoo (QC) thiab Kev Nyab Xeeb Kev Nyab Xeeb rau 100Ah kab yuav tsum tsis muaj qhov tsis zoo.

1. Tsis yog-Kev kuaj kev puas tsuaj

Ua ntej 100Ah cell puas tau them, nws yuav tsum tau kuaj xyuas. Peb koom ua ke siab -voltage Hi-Lub lauj kaub ntsuas tshuab txhawm rau kuaj xyuas micro- luv ua ntej electrolyte filling. Qhov tseem ceeb tshaj, peb pom zoo kom X-Ray tshuaj ntsuam xyuas cov kab ke los txheeb xyuas qhov sib txawv ntawm Z- pawg. Yog tias qhov anode overhang anomaly raug kuaj pom los ntawm X-ray, lub xovtooj ntawm tes raug muab pov tseg ua ntej nws yuav ua rau muaj kev pheej hmoo thermal.

2. Thermal Management thiab EHS raws tu qauv

Thaum lub sij hawm lub voj voog - kuaj lub neej ntawm 100Ah ntawm tes, ib qho kev tshwm sim thermal khiav tawm ib qho tsis txaus ntseeg ntawm lub zog, tshuaj lom hydrofluoric acid (HF) roj, thiab hluav taws. Cov khoom siv kuaj roj teeb uas muab rau cov kab hauv tsev kawm qib siab yuav tsum tau nyob hauv qhov tawg - cov ntaub ntawv pov thawj ib puag ncig cov chav nruab nrog cov hluav taws kub tua hluav taws thiab mob siab rau sai - pa tawm cua.

VI. Economic Blueprint: Tsim 100Ah Pilot Line

Txhawm rau muab cov tsev kawm ntawv Tus Thawj Saib Xyuas Kev Tshawb Fawb (PIs) thiab cov thawj coj hauv chav haujlwm nrog lub luag haujlwm tiag tiag rau daim ntawv thov nyiaj pab, ntawm no yog lub tswv yim kev teeb tsa rau tus qauv 100Ah NMC / Graphite pilot kab tsim los ntawmTOB NEW ENERGY:

VII. Xaus: Lub Hub ntawm Tom ntej-Tsim Kev Tsim Kho Tshiab

Tsim kom muaj 100Ah hnab ntawm tes tsav kab hauv ib lub tsev kawm ntawv yog qhov tseem ceeb tshaj plaws. Nws hloov lub tuam tsev chemistry rau hauv qhov chaw tsim khoom siab heev. Nws tso cai rau cov kws tshawb fawb los ua pov thawj tias lawv cov ntaub ntawv tshiab tuaj yeem tiv taus lub cev compression ntawm calendering, thermal stress ntawm high -shear mixing, thiab complex fluid dynamics ntawm nqus wetting.

Thaum lub tsev kawm ntawv tuaj yeem nthuav tawm lub voj voog -cov ntaub ntawv lub neej tsim los ntawm qhov zoo tshaj plaws, tsim hauv 100Ah hnab cell, lawv tsis yog luam tawm cov ntaub ntawv ntxiv lawm -lawv tab tom txiav txim rau lub neej yav tom ntej ntawm cov khoom siv tsheb.

NtawmTOB NEW ENERGY, peb nkag siab tias cov kws tshawb fawb kev kawm tsis tas yuav yog kws kho tshuab. Tias yog vim li cas peb txoj hauv kev mus rau hauv tsev kawm ntawv lub chaw kuaj roj teeb yog holistic. Peb tsis tso cov khoom pallets ntawm qhov chaw thau khoom; peb tsim cov chaw, koom ua ke cov cav tov, cob qhia cov tub ntxhais kawm ntawv qib siab -cov kws kho mob ntawm cov txheej txheem kev lag luam, thiab muab cov khoom siv txuas ntxiv uas tsim nyog los ua kom txoj kab khiav haujlwm. Peb tsim tus choj hla Valley of Death, tso cai rau koj cov kev tsim kho tshiab kom ncav cuag lub ntiaj teb kev lag luam.

Hais txog TOB NEW ENERGY

TOB NEW ENERGYyog lub ntiaj teb no lees paub ib qho - nres kev daws teeb meem rau kev lag luam roj teeb, mob siab rau kom nrawm rau kev lag luam ntawm cov khoom siv hluav taws xob siab heev. Peb cov kws tshaj lij suav nrog tag nrho cov roj teeb lub neej, muab cov kev daws teeb meem zoo rau kev tshawb fawb txog roj teeb, kev sim- teev cov kab ntau lawm, thiab cov chaw tsim khoom loj loj. Peb ua haujlwm rau txhua qhov tseem ceeb thiab cov chemistry, suav nrog Lithium-ion, Solid-State, Sodium-ion, thiab Lithium-sulfur systems.

Los ntawm kev sib koom ua ke ntawm kev txiav- ntug cov khoom siv roj teeb hloov kho, kuaj cov khoom siv roj teeb nruj, thiab kev sib tham tsis sib xws,TOB NEW ENERGYtxhawb nqa cov tsev kawm ntawv qib siab, cov koom haum tshawb fawb, thiab cov tuam txhab lag luam thoob ntiaj teb kom hloov pauv tsis tu ncua los ntawm cov tswv yim electrochemistry mus rau kev ua lag luam- cov khoom lag luam. Peb yog koj tus kws tshaj lij engineering koom tes hauv kev nrhiav lub roj teeb qhov kawg.