Manufacturing Process of Lithium-ion Batteries for Home Energy Storage

Home energy storage batteries are produced through a carefully controlled multi-stage process involving electrode preparation, cell assembly, and final processing. The technology shares similarities with electric vehicle batteries but is optimized for stationary storage applications.

1. Electrode Manufacturing:

• Slurry Preparation: Active materials (lithium iron phosphate for cathode, graphite for anode) are mixed with polymeric binders, conductive additives, and solvents to form homogeneous slurries.
• Coating Process: Using precision coating machines, the anode slurry is applied to copper foil and cathode slurry to aluminum foil current collectors.
• Drying Phase: Coated electrodes pass through multi-zone ovens where solvents are evaporated under controlled temperature profiles.
• Calendering: Heavy rollers compress the dried electrodes to precise thicknesses (typically 100-200μm) to ensure optimal energy density.
• Slitting Operation: Large electrode sheets are cut into required widths using laser or mechanical slitters.

  

2. Cell Assembly:

• Separator Placement: A microporous polymer separator (20-25μm thick) is positioned between electrodes to prevent short circuits while enabling ion transport.
• Stacking Configuration: For prismatic home storage cells, electrodes and separators are stacked in alternating layers rather than wound.
• Tab Connection: Aluminum tabs are ultrasonically welded to current collectors for efficient power transfer.
• Housing Assembly: Cells are enclosed in robust aluminum cases with integrated pressure relief mechanisms.
• Electrolyte Filling: Lithium salt electrolyte (1M LiPF6 in EC/DMC) is vacuum-injected to ensure complete saturation.
• Final Sealing: Laser welding creates hermetic seals after moisture-sensitive electrolyte introduction.

3. Formation & Testing:

• Initial Formation: Cells undergo controlled charge/discharge cycles (typically 0.02C-0.2C) to form stable SEI layers.
• Aging Process: 7-14 days of temperature-controlled storage identifies potential performance drift.
• Quality Verification: Each cell is tested for capacity (5-20kWh typical), internal resistance (<1mΩ), and cycle life (≥6,000 cycles @80% DoD).

4. System Integration:

• Module Assembly: 12-24 cells are connected in series/parallel within steel enclosures with integrated cooling plates.
• BMS Installation: Battery Management Systems monitor voltage, temperature, and state-of-charge for each cell group.
• Pack Finalization: Multiple modules (4-8 typically) combine into complete 10-100kWh storage solutions with safety disconnects and communication interfaces.

Key adaptations for home storage:

• Enhanced cycle life prioritization over energy density
• Passive cooling systems instead of liquid cooling
• Stacked prismatic cell designs for space efficiency
• MSDS and UN38.3 safety standard compliance

The complete process from raw materials to tested home storage unit typically requires 15-25 days in modern automated facilities.

Security You Can Trust
JM's lithium-ion battery security features:
• Military-grade casing
• Self-heating electrolyte (prevents freezing)
• 10-year warranty with performance guarantee