Winding Vs Stacking, Which Technology Works Best For Lithium-Ion Batteries?

In the lithium-ion battery cell assembly process, there are two main technologies: winding and stacking.

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These two technologies are always related to key technical points such as battery cell space utilization, battery cell cycle life, cell manufacturing efficiency, and manufacturing investment.

Overview

1. What is Winding Technology?

2. What is Stacking Technology?

3. What technology is used in the lithium-ion battery cells on the market?

4. What are the benefits of lithium-ion battery cells formed by the stacking process?

5. What is the development direction of cylindrical cells, prismatic cells, and pouch cells from the current scene?

6. How do you comment on these two technical routes in terms of manufacturing efficiency and yield efficiency?

1. What is Winding Technology?

After slitting the cathode roll, separator, and anode roll, the winding process involves winding them by a fixed winding needle in sequence, extruding them into a cylindrical or square shape, and then placing them inside a square or cylindrical metal shell. The size of the slitted rolls, the number of coils, and other parameters are determined according to the design capacity of the battery cell.

2. What is Stacking Technology?

The stacking process involves cutting the cathode and anode sheets into the required size, then stacking the cathode sheets, separator, and anode sheets into small cell units, and finally stacking these small units to form the final single cell.

3. What technology is used in the lithium-ion battery cells on the market?

Pouch cell: Both technologies are used, depending on the manufacturer.
Blade cell: Designed and produced by the stacking process.
Prismatic cell: Both stacking and winding processes can be used. In China, the main technology is currently winding but transitioning to stacking.
Cylindrical cell: As a mature product, it always uses the winding process.

4. What are the benefits of lithium-ion battery cells formed by the stacking process?

Lithium-ion cells formed by stacking have higher energy density, a more stable internal structure, higher safety, and a longer lifespan.

Higher energy density: Compared to winding, stacking maximizes battery space utilization, resulting in higher energy density within the same cell volume design.

More stable internal structure: During battery use, lithium-ion insertion causes expansion of the cathode and anode plates. In winding, this expansion leads to inconsistent internal stress and possible deformations. The stacking process, however, maintains similar expansion forces across layers, keeping the interface flat.

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Higher level of safety: In winding, the bending plates at the ends experience uneven tension, potentially causing deformation. Stacking evenly distributes stress, thus enhancing safety.

Longer lifespan: Stacked battery cells have more tabs, resulting in shorter electron transmission distances and smaller resistance. Reduced internal resistance lowers the heat generated, whereas winding is prone to deformations affecting battery performance.

5. What is the development direction of cylindrical cells, prismatic cells, and pouch cells from the current scene?

Cylindrical: Large cylindrical designs are increasingly popular, with standardized winding processes. Single cell manufacturing speed needs improvement to broaden use scenarios.

Pouch cell: Adopting the stacking process is becoming overwhelmingly popular.

Prismatic cell: Maintaining existing sizes favors winding (coiling); however, evolving into square shell stacking for short and long blade designs will lead to adopting the stacking process.

For consumer batteries, efficiency improvements are prioritized over capacity and performance, leading to a high demand for winding technology. However, for power batteries, large modules and cells are the future trend. Stacking technology better showcases the advantages of large-scale batteries in terms of safety, energy density, and process control over winding.

6. How do you comment on these two technical routes in terms of manufacturing efficiency and yield efficiency?

Winding large cylindrical cells: The introduction of dry electrodes around mature processes shows great future potential.

Stacking: Tier-1 cell manufacturers continually innovate, and power battery companies follow suit, shifting towards the super stacking + blade battery solution design.

Winding: The stable development of square shell winding maintains current trends, with the largest capacity construction in terms of original production.

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