Academic year-2022-2026

Department:-Mechanical Engg.
Name of topic:-How Batteries are Made and How it
Works
Name:- Ephraim Halam Sec:- A
Enrollment no.:-22UME011
Sub:-Manufacturing Technology 1
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Introduction to Battery
Manufacturing

Battery manufacturing is a complex and highly-automated process that

involves sourcing raw materials, assembling cells, and rigorously testing the
final product. This presentation will provide an in-depth look at the key steps in
battery production, from start to finish.

by 22UME011
Raw Materials and Components
Anode Cathode Electrolyte

The anode is typically made The cathode is made from The electrolyte, often a lithium
from graphite, silicon, or lithium metal oxides like lithium cobalt salt dissolved in organic
metal, and is responsible for oxide or nickel manganese solvents, facilitates the flow of
storing and releasing electrons cobalt oxide, and plays a crucial ions between the anode and
during the charging and role in the battery's energy cathode during operation.
discharging process. density and lifespan.
Battery Cell Production
Electrode Preparation 1
The anode and cathode materials are
coated onto thin metal foils, then dried
and calendered to achieve the desired 2 Cell Assembly
thickness and density. The electrodes, separator, and
electrolyte are carefully stacked or
wound together to form the battery cell,
Formation Cycling 3 which is then sealed in a metal or
The new battery cells undergo initial polymer case.
charging and discharging cycles to
activate the electrodes and form a stable
solid electrolyte interphase (SEI) layer.
Assembly and Packaging
Module Assembly Thermal Management
Multiple battery cells are combined into Cooling systems, such as liquid or air cooling, are
modules, which are then connected in series and integrated into the battery pack to maintain
parallel to form the complete battery pack. optimal operating temperatures and prevent
thermal runaway.

Battery Management System Enclosure Design

The BMS monitors and balances the individual The battery pack is housed in a rugged,
cells, ensuring safe and efficient operation of the protective enclosure to withstand environmental
entire battery pack. factors and impact during use.
Quality Control and Testing

1 Cell Inspection 2 Performance Validation

Rigorous inspection and testing of individual Comprehensive testing of the assembled
battery cells to ensure they meet strict quality battery pack to verify its energy density,
standards. power output, and cycle life.

3 Safety Verification 4 Environmental Certification

Extensive safety testing, including thermal Obtaining certifications and approvals to
abuse, overcharge, and short-circuit meet regulatory requirements for
scenarios, to ensure the battery pack is safe transportation, storage, and use of the battery
for use. products.
Automation and Robotics

Precise Assembly Efficient Rigorous Intelligent Storage

Production Inspection
Robotic systems ensure
the accurate and Automated material Advanced vision Automated warehouse
consistent assembly of handling and transport systems and sensors systems and inventory
battery cells and systems optimize the enable comprehensive management ensure
modules. flow of materials and quality control and efficient storage and
components through testing throughout the retrieval of raw
the manufacturing manufacturing line. materials and finished
process. products.
Environmental Considerations

Material Recycling Energy Efficiency Waste Management

Recovering and reusing Implementing renewable Proper disposal and treatment
valuable materials from spent energy sources and energy- of hazardous materials used in
batteries to reduce waste and efficient manufacturing battery manufacturing to
environmental impact. processes to minimize the protect the environment and
carbon footprint of battery human health.
production.
Conclusion and Future Trends
Increased Automation Continued advancements in robotics and AI-
driven systems to enhance productivity and
quality.
New Battery Chemistries Exploration of alternative materials, such as solid-
state electrolytes and silicon anodes, to improve
energy density and safety.

Sustainable Manufacturing Adoption of more eco-friendly practices, including

renewable energy, water recycling, and closed-
loop recycling of battery materials.

Battery Gigafactories Construction of large-scale, highly-automated

battery manufacturing facilities to meet the
growing demand for electric vehicles and energy
storage.
How Batteries Work

Batteries are electrochemical devices that store and convert chemical energy into
electrical energy. They consist of one or more electrochemical cells, each
containing a positive electrode, a negative electrode, and an electrolyte solution
that enables the flow of electrical charges between the electrodes.
Electrochemical Principles
Reduction 1
At the positive electrode, a
reduction reaction occurs where
electrons are gained, resulting in 2 Oxidation
the conversion of chemical energy At the negative electrode, an
into electrical energy. oxidation reaction occurs where
electrons are lost, releasing
electrons that flow through an
Ion Exchange 3 external circuit.
The electrolyte solution allows the
flow of ions between the electrodes,
completing the circuit and enabling
the electrochemical process.
Battery Components
Positive Electrode Negative Electrode Electrolyte

Also known as the cathode, Also known as the anode, The electrolyte solution
this electrode is where the this electrode is where the allows the flow of ions
reduction reaction takes oxidation reaction occurs, between the electrodes,
place, accepting electrons releasing electrons and facilitating the
and releasing energy. generating energy. electrochemical process.
Primary vs. Secondary Batteries
1 Primary Batteries 2 Secondary Batteries
These are disposable batteries that Also known as rechargeable batteries,
cannot be recharged, as the chemical these can be recharged by applying an
reactions that produce electricity are external voltage, reversing the chemical
irreversible. reactions.

3 Examples
Primary batteries include alkaline and zinc-carbon batteries, while secondary batteries
include lithium-ion and lead-acid batteries.
Charging and Discharging

Discharging Charging Efficiency

When a battery is in use, By applying an external The efficiency of the
the chemical reactions at voltage, the chemical charging and discharging
the electrodes release reactions can be reversed, process is an important
electrons, generating an allowing the battery to be factor in determining a
electric current that can recharged and used again. battery's performance and
power devices. lifespan.
Battery Capacity and Efficiency
Capacity Efficiency
Battery capacity is the total amount of Battery efficiency is the ratio of the energy
energy a battery can store, and is typically output to the energy input, and is affected
measured in ampere-hours (Ah) or watt- by factors like self-discharge and internal
hours (Wh). resistance.

Optimization Applications
Battery manufacturers aim to maximize Battery capacity and efficiency are crucial
capacity and efficiency to provide longer- considerations for various applications,
lasting and more reliable power sources. from portable electronics to electric
vehicles.
Battery Safety Considerations

Fire Hazard Explosion Risk Toxicity Proper Disposal

Improper handling or Overcharging or Many battery
use of batteries can puncturing batteries chemicals are toxic Batteries should be
lead to thermal can cause them to and can be harmful if recycled responsibly
runaway reactions, vent or even ingested or exposed to prevent
posing a fire hazard. explode, presenting a to the skin or eyes. environmental
serious safety risk. contamination and
ensure the recovery
of valuable
materials.
Emerging Battery Technologies
Lithium-Air Offers high energy density, but challenges
with efficiency and safety remain.

Solid-State Uses a solid electrolyte, promising increased

safety and energy density.

Redox Flow Stores energy in liquid electrolytes, allowing

for scalable and long-lasting storage.

Sodium-Ion Cheaper and more abundant than lithium, but

with lower energy density.

These and other emerging technologies are aimed at addressing the limitations of current battery
systems, such as energy density, safety, and cost, to enable a wide range of applications, from
consumer electronics to renewable energy storage.