Advanced Low Cost Automated Manufacturing Technology for Prismatic Lithium Battery Cells (Discrete-Parts)

LithChem has designed an innovative low cost continuous automated manufacturing process for making prismatic lithium battery cells, the main cost (discrete-part) for lithium batteries. The process consists of three key pieces of innovative equipment: 1) a novel coater for continuously coating the electrodes which has been built; 2) a continuous automated assembly machine for combined cutting, welding and stacking the cells which has been designed and the unit steps demonstrated at the bench scale; and 3) semi-automated hard packaging, filling, and sealing of cells which has also been demonstrated at the bench scale. This versatile process will produce either rechargeable (lithium-ion) or non-rechargeable (primary) lithium battery prismatic cells in a wide range of sizes and capacities by minor equipment adjustments. The prototype prismatic cells made by this process have the maximum energy density and cycle life for lithium cells/batteries. Labor has been reduced and the capital cost is dramatically lower than current Japanese equipment for making cylindrical cells. In Phase I, LithChem will perform the cost analysis for make/buy decisions on the remaining equipment, and verify the expected low manufacturing costs (<$0.40/Wh) for DLA and DOD customers. This all-American automated manufacturing line will be built and demonstrated in Phase II.