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Lithium ion batteries are mainly composed of four parts: positive electrode, negative electrode, non-aqueous electrolyte, and separator. At present, the most commonly used lithium batteries in the market are lithium iron phosphate batteries and ternary lithium batteries. The difference in positive electrode raw materials between the two is significant, and the production process flow is relatively similar, but the process parameters need to change significantly. If lithium iron phosphate is completely replaced with ternary materials, the rectification effect of the old production line will be poor. For battery manufacturers, it is necessary to replace the equipment on the production line on a large scale.

Lithium battery manufacturing process: the first, middle, and last three processes, accounting for nearly 35%/30%/35%

The production process of lithium batteries is relatively complex, and the main production process mainly includes the stirring coating stage (front stage) of electrode production, the winding and liquid injection stage (middle stage) of cell synthesis, and the packaging inspection stage (rear stage) of formation packaging. The value (purchase amount) accounts for about (35-40%): (30-35)%: (30-35)%. The differences mainly come from differences in equipment suppliers, import/domestic proportion differences, etc. The process flow is basically the same, and there is a deviation in the value to quantity ratio, but overall it conforms to this proportion.

The lithium battery equipment corresponding to the pre production process of lithium batteries mainly includes vacuum mixers, coating machines, roller presses, etc; The intermediate process mainly includes die-cutting machine, winding machine, laminating machine, injection machine, etc; The later stages of the process include chemical forming machines, volumetric testing equipment, process warehousing and logistics automation, etc. In addition, the production of battery packs also requires Pack automation equipment.

Lithium battery front-end production process: relationship between electrode manufacturing and battery core performance

The result of the front-end process of lithium batteries is the completion of the preparation of the positive and negative electrode plates. The first step is stirring, which means that the positive and negative electrode solid-state battery materials are mixed evenly and solvent is added, and stirred into a slurry through a vacuum mixer. The mixing of ingredients is the foundation of the subsequent lithium battery process, and high-quality mixing is the basis for the high-quality completion of subsequent coating and rolling processes.

After the coating and rolling process, it is divided, that is, the coating is subjected to a cutting process. If burrs are generated during the cutting process, safety hazards may arise during subsequent assembly, electrolyte injection, and even battery use. Therefore, the front-end equipment in the lithium battery production process, such as mixers, coating machines, roller presses, slitting machines, etc., are the core machines of battery manufacturing and are related to the quality of the entire production line. Therefore, the value (amount) of front-end equipment accounts for the highest proportion of the entire lithium battery automation production line, about 35%.

Lithium battery mid stage process flow: efficiency first, winding before stacking

In the manufacturing process of lithium batteries, the intermediate process mainly involves completing the formation of the battery. The main process flow includes slicing, pole winding, die-cutting, cell winding and lamination forming, etc. It is currently a highly competitive field among domestic equipment manufacturers, accounting for about 30% of the value of lithium battery production lines.

At present, there are two main manufacturing processes for power lithium batteries: winding and stacking. The corresponding battery structures are mainly cylindrical and square, and soft pack. Cylindrical and square batteries are mainly produced using winding technology, while soft pack batteries are mainly produced using stacking technology. Cylinders are mainly represented by 18650 and 26650 (Tesla has independently developed 21700 batteries and is promoting them throughout the industry). The difference between square and soft packaging lies in the use of hard aluminum shell and aluminum-plastic film for the outer shell, with soft packaging mainly using lamination technology and aluminum shell mainly using winding technology.

The soft pack structure is mainly aimed at the mid to high end digital market, with a high profit margin per unit product. Under the same production capacity conditions, the relative profit is higher than that of aluminum shell batteries. Due to the tendency of aluminum shell batteries to form economies of scale, product qualification rates, and cost control, both currently have considerable profits in their respective market areas. In the foreseeable future, it will be difficult for both to be completely replaced.

Due to the fact that the winding process can achieve high-speed production of battery cells through rotational speed, while the speed that can be improved by lamination technology is limited, currently the winding process is mainly used for power lithium batteries in China. Therefore, the shipment volume of winding machines is currently greater than that of lamination machines.

The preceding steps for winding and lamination production are the production of polar films and die-cutting. Production includes welding of cut electrode pieces/ears, dust removal of electrode pieces, application of protective tape, encapsulation of electrode ears, and winding or fixed length cutting. The winding electrode pieces are used for subsequent fully automatic winding, and the fixed length cutting electrode pieces are used for subsequent semi-automatic winding; Punching and cutting of electrode plates is the process of winding and punching the cut electrode plates into shape for subsequent lamination processes.

In terms of lithium battery packaging and welding, mainstream laser technology integration and application manufacturers such as Lianying, Dazu, and Guangda are all involved, which can meet the demand without the need for imports.

Process flow of lithium battery in the later stage: Capacity separation is the core link

The production process of lithium-ion batteries in the later stage mainly includes four processes: volumetric separation, formation, testing, and packaging, accounting for about 35% of the production line value. Formation and capacitance are the most important stages in the later stage of the process, which activate and detect the formed battery. Due to the long charging and discharging testing cycle of the battery, the value of the equipment is the highest. The main function of the formation process is to activate the battery cells after liquid injection packaging, while the volumetric process tests the battery capacity and other electrical performance parameters and grades them after battery activation. Formation and separation are usually completed by automated separation and separation systems, respectively.

Lithium battery pack process: seemingly simple but requires integration with systematic design

The power battery pack system is a battery pack that connects numerous individual battery cells in series or parallel, integrating power and thermal management hardware systems. Pack is the key to the production, design, and application of power battery systems, and is the core link connecting upstream battery cell production and downstream vehicle application. Usually, design requirements are proposed by battery cell factories or automobile factories, and are usually completed by battery factories, automobile factories, or third-party Pack factories.

The lithium battery pack production line is relatively simple, with core processes including loading, bracket pasting, welding, testing, and other processes. The core equipment includes laser welding machines and various pasting testing equipment. At present, major lithium battery equipment manufacturers have limited automation integration layouts in this field, while laser equipment manufacturers such as Daizu Laser and Lianying Laser have a higher market share in the Pack equipment field due to their absolute advantages in the laser field.

At present, the automation rate of Pack production is relatively low because the sales of single new energy vehicles are not large enough, and the cost of using automated production lines is relatively high.

Lithium iron phosphate and ternary: topics that cannot be avoided in terms of energy density, different materials require full equipment investment

At present, the mainstream positive electrode materials for power lithium batteries in China are divided into two categories: lithium iron phosphate and ternary. Among them, lithium iron phosphate is currently the safest positive electrode material for lithium-ion batteries, with a cycle life of usually over 2000 times. In addition, due to the mature industry and the decrease in price and technical threshold, many manufacturers consider using lithium iron phosphate batteries due to various factors. However, lithium iron phosphate batteries have obvious shortcomings in terms of energy density. Currently, BYD, the leader in lithium iron phosphate batteries, has a single cell energy density of 150Wh. By the end of 2017, BYD is expected to increase the energy density to 160Wh. In theory, it is difficult for the energy density of lithium iron phosphate to exceed 200GWh.

Ternary polymer lithium batteries refer to lithium batteries with nickel cobalt manganese oxide as the positive electrode material, and the actual proportion of nickel cobalt manganese can be adjusted according to specific needs. Due to the higher energy density of ternary lithium batteries (currently, the energy density of ternary lithium batteries in leading power battery manufacturers such as CATL can generally reach 200Wh/kg-220Wh/kg, and the industry predicts that the energy density of individual ternary battery cells will reach 300Wh/kg by 2020), the passenger car market is turning to ternary lithium batteries, and in buses with higher safety requirements, lithium iron phosphate is more favored. With the development of all electric passenger cars, ternary lithium batteries are occupying an increasingly important position.

There are differences in energy density and cost between the two materials, and different cars and car companies have different choices. The two are roughly the same in terms of production process flow, with differences mainly reflected in the use and proportion of materials, significant differences in specific process parameters, equipment cannot be produced on the same line, and the cost of simply transforming and switching production capacity is relatively high (ternary materials have strict requirements for vacuum dehumidification, while previous lithium iron phosphate production lines did not have dehumidification requirements). Therefore, multiple home appliance chip factories will simultaneously layout and purchase equipment separately in production capacity planning.

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