Production Process-深圳市达尔酷新能源有限公司

PRODUCTION PROCESS

In a Class 10,000 clean workshop, positive active materials (ternary / lithium iron phosphate), negative active materials (graphite), conductive agents, binders and solvents are precisely metered via a fully automatic closed feeding system. The materials are then mixed in a vacuum planetary mixer to form stable slurry with uniform consistency, zero particles and low air bubbles.

Electrode Coating

Adopting high-precision slot-die coating machine, the slurry is evenly coated on positive aluminum foil and negative copper foil. It undergoes continuous drying in an ultra-long zoned temperature-controlled oven. The online β-ray and laser thickness measurement system conducts real-time monitoring to ensure highly consistent areal density and thickness of electrodes.

Electrode Calendering

Wide-width electrodes are slit into narrow strips by a high-speed slitter, then precisely punched into single electrodes of designed size by a fully automatic laser die-cutting machine, with tab positions formed simultaneously. CCD visual inspection eliminates defective products to ensure accurate dimension, burr-free edge and no powder falling off.

Electrode Slitting & Die Cutting

Wide-width electrodes are slit into narrow strips by a high-speed slitter, then precisely punched into single electrodes of designed size by a fully automatic laser die-cutting machine, with tab positions formed simultaneously. CCD visual inspection eliminates defective products to ensure accurate dimension, burr-free edge and no powder falling off.

Electrode Baking

The die-cut electrodes are sent into a fully automatic vacuum drying oven and baked cyclically in a high-temperature and high-vacuum environment to completely remove trace moisture. This prevents electrolyte decomposition and battery gas production after liquid injection, ensuring the moisture content of the cells meets the standard.

Lamination Process

In a Class 10,000 clean room, high-speed Z-type lamination machine technology is adopted to accurately stack layers alternately in the order of "separator → negative electrode → separator → positive electrode". The CCD system monitors the alignment accuracy in real time (within ±0.1mm) to form a bare cell with a regular structure.

Tab Welding

A laser welding machine is used to firmly weld the positive aluminum tabs, negative nickel tabs and electrode collector. AI vision is used to real-time detect the weld quality, ensuring welding strength, electrical conductivity and yield rate.

Vacuum Liquid Injection

In a dry environment with ultra-low dew point (≤-50℃), electrolyte is quantitatively injected by a high-precision vacuum liquid injection machine. Through multi-stage vacuum standing circulation, the electrolyte fully and evenly soaks the electrodes and separators.

Secondary Packaging (Sealing)

After the completion of liquid injection and infiltration, a vacuum sealing machine is used to remove air and residual gas inside the cell, heat-seal the liquid injection port to form the final seal. In some processes, edge cutting and folding are performed simultaneously to optimize the cell shape.

Formation (Activation)

The cells are placed in a high-temperature and high-pressure formation cabinet for the first small-current charge-discharge to activate the electrode materials, forming a stable SEI film on the surface of the negative electrode. The voltage, current and temperature are monitored throughout the process to ensure the formation quality and safety.

Capacity Sorting (Grading)

In a constant temperature environment, batteries are subjected to standard charge-discharge tests by fully automatic capacity grading cabinets. Key parameters including capacity, voltage, internal resistance and DCIR are accurately measured. Products are automatically grouped by performance grade to ensure excellent battery consistency.

Appearance & Performance Inspection

Adopting AI machine vision, X-ray inspection, air tightness tester, OCV/IR tester and other testing equipment, we comprehensively inspect the cell appearance, dimensions, internal structure, electrical performance and airtightness, and eliminate all defective products.

Finished Product Packaging

Qualified cells undergo automatic labeling, film wrapping, anti-static bag packaging, inner box placement and carton packing. The entire process adopts full data traceability, and the finished products are finally stored in the warehouse.

Shenzhen Dorcool New Energy Co., Ltd.

powerbattery@dorcool.com

Address: Room 1011, Building 1, Ruifeng Optoelectronics Mansion, Yutang Community, Yutang Subdistrict, Guangming District, Shenzhen, China

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