High-throughput process for manufacturing an electrode-separator composite (ESV) for battery cells

In the manufacture of high-capacitance cells with stacked or Z-folded ESVs, the stacking process is the rate-limiting stage and thus restricts throughput in battery cell production. Whilst it is possible to increase throughput by raising the speed or introducing parallelisation in existing ESV manufacturing processes, the necessary stoppages in the process flow result in a throughput limitation that is virtually insurmountable. The search for alternative, high-throughput approaches to stacking is therefore a major driver in industry and academia.

Using the proposed technology, it is possible to manufacture the electrode-separator assembly in large quantities with high precision and in a time-saving manner. The process is characterised by the use of a cold, fast-setting (<1 s) bonding process for joining during ESV production, rather than a heat-induced bonding process, as is currently standard, such as that used in lamination. The cold application of the adhesive via variably adjustable dispensers also allows for flexible application formats, enabling the production of various discrete and tape-shaped ESVs without the need for lengthy changeover times. An innovative mounting concept for the rollers required for the process also allows adaptation to other geometries without prolonged shutdowns of the entire production line.