Let’s take a look at what’s involved in lithium-ion battery manufacturing. After all, these are what powers everything from our cell phones to electric vehicles to energy storage systems. Why? They pack more punch and are the most durable batteries. That makes them the best batteries for many applications.
And more and more of them are selling every year. Just two years ago, 53.6 billion dollars worth of lithium-ion batteries were sold. And that number is going up 15% a year!
Let’s explore the chemistry and engineering that goes into making these critical components of our untethered world.
Lithium-Ion Battery Manufacturing
Lithium-ion batteries are electrochemical storage devices that generate voltage for those who don’t know. How does that happen? Lithium ions move electrons around in electrolytes, creating voltage that we can tap. Now let’s go through the actual manufacturing process, starting with the cells:
Individual Battery Cells
Most lithium batteries are made using many smaller cells. Each cell, in turn, has an anode, a cathode, and an electrolyte solution. The anodes are oxidizing metals like zinc. Cathodes are a form of lithium oxide. The electrolyte is a lithium salt solution.
You were paying attention in chemistry, weren’t you! So you know these things can be dangerous. It is vital to handle them properly (see: dot lithium batteries training online), including recycling batteries.
Keeping the anodes and cathodes separate in manufacturing is critical. First, both are mixed in a conductive slurry. The next step is baking on a foil – aluminum for the cathodes and copper for the anodes.
Next comes winding the cell together and installing vents and terminals. The last step is putting the electrolyte in the cell under vacuum – exposing the electrolyte to air causes oxidation. Then, after testing the cells it’s on to the next step.
Wiring and BMS
Wiring the individual cells together – positives to negatives – using copper wire and aluminum terminals allows building larger batteries. Most lithium-ion batteries also have a Battery Management System (BMS). The BMS tracks things like charging, discharging, and temperature.
Depending on how big a battery you’re making, the correct number of cells are combined by welding the anodes and cathodes to separate plates. Assembling the individual cells into a battery pack comes next.
Make a Case
Now that you’ve got battery cells, wiring, and a BMS, you need to put it all in something tough enough to protect it from the elements and occasional abuse. Battery cases are made using plastic, silicone, or rubber, depending on the end-use.
After putting the battery packs into the case, connecting the BMS, and testing everything, voila! You’ve got a lithium-ion battery!
From Cells to Phone Battery
As you can see, there’s a lot of chemistry involved in lithium-ion battery manufacturing. It starts with the individual cells’ anodes, cathodes, and electrolytes – then combines the individual cells into larger battery packs. Finally, it’s all packed into a tough, protective case, ready for use.
So the next time you use your cell phone, remember to thank all the people who figured it out!
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