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Battery Manufacturing – Energie für Morgen

Der Energiesektor befindet sich im Umbruch. Während die Automobilbranche einen Wandel hin zu CO2-neutraler Fortbewegung erfährt, gewinnen Batteriespeichersysteme für erneuerbare Energien und tragbare Elektronikgeräte ebenfalls immer mehr an Bedeutung.

Unsere Produkte des WAGO I/O Systems Field sind dabei die Lösung, um den Herstellungsprozess der Batteriezelle ganzheitlich zu automatisieren. Die neuesten Stromversorgungen der WAGO Serie Pro 2 haben eine ausgeprägte Kommunikationsschnittstelle, um den Produktionsprozess individuell zu überwachen, auszuwerten und die Herstellung von Batterien so effizient wie möglich zu gestalten und somit Kosten bei der Produktion zu reduzieren.

Prozessschritte Batterieherstellung

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Mischen

Der Herstellungsprozess einer Batterie beginnt mit der sogenannten „Slurry Preparation“. Dabei werden die zwei voneinander getrennten Ausgangsstoffe, bestehend aus Anodenrezeptur und Kathodenrezeptur, zu einer Aufschlämmung verbunden. Für die Herstellung sind leitfähige Zusatzstoffe, Lösungsmittel und Bindemittel erforderlich. Dabei spielt die Temperatur eine entscheidende Rolle. Mittels der Steuerung WAGO I/O System Field und des WAGO PFC200 steuern Sie die Temperaturen der Flüssigkeiten, die zwischen 20 und 40 Grad liegen müssen. Unsere MID-Zähler kommen für das Monitoring des Energieverbrauchs zum Einsatz. Da der gesamte Prozess im Reinraum stattfindet, erfolgt der Weitertransport der Slurry zum darauffolgenden Prozessschritt „Beschichtung“ über Rohrleitungen oder in atmosphärisch abgedichteten Lagertanks.

Beschichten und Trocknen

Im Beschichtungsprozess wird eine Trägerfolie per Auftragswerkzeug mit einem Schlicker beschichtet, um einen Film zu erzeugen. Diese Trägerfolie besteht aus Materialien wie Aluminium- oder Kupferfolie. Die Schichtdicken variieren je nach Zelldesign zwischen 10 μm und 25 μm.

Je nach System erfolgt die Beschichtung von Ober- und Unterseite der Folie entweder sequenziell oder gleichzeitig. Um die hohen Qualitätsstandards bei der Batterieherstellung einzuhalten, sind unsere Systeme WAGO I/O System Field und WAGO I/O System Serie 750 ideal für die Überwachung der Schichtdicken.

Ist der Beschichtungsprozess abgeschlossen, folgt die Trocknung. Hierbei wird die Aluminium- oder Kupferfolie in einen Trockner geführt. Bei gleichzeitiger, beidseitiger Beschichtung kommt ein sogenannter Schwebetrockner zum Einsatz. Die Trocknerlänge ist entscheidend für die realisierbare Durchlaufgeschwindigkeit. Der Trockner ist in verschiedene Temperaturzonen unterteilt, um ein individuelles Temperaturprofil zu realisieren. Für die punktgenaue Temperatureinhaltung und -überwachung stellen das WAGO I/O System Field in Kombination mit dem WAGO PFC200 die perfekte Lösung da.

Kalandern

Beim Kalandrieren oder auch Walzverfahren genannt, wird die beidseitig beschichtete Kupfer- oder Aluminiumfolie durch ein oder mehrere rotierende Walzenpaare verdichtet. Die Verdichtung der Folie erfolgt durch die Ober- und Unterwalze. Der Liniendruck bestimmt die Porosität des beschichteten Substrats. Ein zu hoch eingestellter Liniendruck kann dazu führen, dass ein Quetschvorgang oder die Beschädigung des Substratmaterials verursacht wird. Der Walzvorgang ist dafür da, um geringste Unebenheiten auszugleichen. Durch die Robustheit können für das Monitoring des Walzprozesses ebenfalls das WAGO I/O System Field und das WAGO I/O System Serie 750 ideal eingesetzt werden.

Schlitzen

Das Schlitzen ist ein Trennverfahren, bei dem ein breiter Elektrodenstreifen (genannt Muttercoil) in mehrere, kleinere Elektrodenstreifen (genannt Tochtercoils) geteilt wird. Das Schlitzen kann thermisch (Laserschneiden) oder mechanisch (Messerschneiden mit Rollmesser) erfolgen. Die Sauberkeit der Elektrodenstreifen ist von entscheidender Bedeutung, da Verunreinigungen oder Rückstände die Qualität der Tochtercoils und letztlich die Leistung der Batteriezellen beeinträchtigen können. Die Reinigung der Elektrodenbänder erfolgt durch eine Absaugung und/oder einer Bürste, um einen reibungslosen Betrieb und die Qualitätssicherung im Herstellungsprozess zu gewährleisten. Die Schnittbreiten der Tochtercoils können je nach Zellendesign variieren und liegen bei vielen Anwendungen zwischen 100 mm und 300 mm.

Zellassemblierung

Der Prozessschritt des Trennens ist für die Herstellung der Pouch-Zelle erforderlich und bezieht sich auf die Trennung von Anoden-, Kathoden- und Separatorblechen vom Rollenmaterial – der Tochtercoil. Der Trennvorgang wird entweder mit einem Scherenschnitt (Stanzwerkzeug) oder thermisch (Laserschnitt) durchgeführt. Der unbeschichtete Randbereich des Blechs der Batteriezelle wird in einem späteren Prozessschritt zum Schweißen der Kontaktfahne verwendet.

Elektrolytbefüllung und Formation

Die Elektrolytbefüllung ist der abschließende Prozessschritt der Batterieherstellung und erfolgt, nachdem der Zellstapel in die Verpackung eingelegt wurde. Die Öffnungen werden durch ein Siegelverfahren oder durch einen Dorneinsatz mit angeschweißter Verschlusskappe verschlossen. Bei der runden und prismaförmigen Zelle wird anschließend eine sogenannte Voralterung durchgeführt, um Verformungen durch Gasbildung zu vermeiden.

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