The Challenge
Build prototype 1Ah+ lithium metal pouch cells to client specification. Due to the moisture sensitivity of lithium foil, the challenge was to develop a process for lithium foil handling and pouch cell assembly entirely in an inert atmosphere. Cell assembly challenges included electrode handling and trimming, tab welding, and electrode stacking or winding– all of which are typically done in open air.
The Solution
Thanks to our close partnership with Felix Machines, and our team of in-house engineers, we were able to devise a cost-effective solution for a prototype assembly line fully enclosed in a glovebox. The design process included developing a method to wind electrodes in a jelly roll (rather than the more standard z-fold method). This made it easier to accommodate lithium foil rolls purchased from suppliers, enabled higher precision with lerger capacity designs, and accelerated the manufacturing process in a restrictive glovebox environment.
The Results
The combined experience of our process engineering and cell building teams enabled us to successfully develop a new cell assembly technique for the customer and provide them with a plan for building their own prototyping capabilities. The cells that came out of this project provided the customer with their first-ever working lithium metal pouch cells to demonstrate their technology, and allowed them to go on to raise significant capital for their own vertically integrated facility.