Can lithium-ion batteries be stacked?

Lithium-ion battery stacking technologies are primarily categorized into four main types: Z-fold stacking, cut-and-stack integration, thermal composite stacking, and roll-to-stack integration. Z-fold stacking and cut-and-stack integration are widespread in domestic applications, while thermal composite stacking, which offers superior quality and production speed, presents higher technical complexities. Internationally, companies like LG New Energy utilize roll-to-stack integration, recognized for its efficiency but protected by LG’s patents.

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Z-Fold Stacking Technology

Z-fold stacking technology is among the most common methods. It involves moving the separator in a zigzag pattern between stacking platforms, allowing the anode and cathode tabs to cross-stack.

This technique has some drawbacks, including separator deformation and low stacking efficiency. Separator deformation can occur due to the swinging motion of the separator, which causes asymmetry and inconsistent deformation. The varying tension during stacking leads to non-uniform stretching and deformation of the separator, impacting battery quality. Furthermore, the process is time-consuming, requiring the separator to swing and achieving only single-layer stacking, thus limiting efficiency.

Cut-and-Stack Integration Technology

Cut-and-stack integration is an enhancement of the Z-fold stacking method, aiming to improve yield rates and stacking efficiency. By consolidating various steps into one machine, it reduces the risks of cell damage during transportation and handling.

Traditional production methods utilize a stacking machine to retrieve and stack sliced electrodes from a material box. During this retrieval, electrodes might collide, bend, or fold. Conversely, cut-and-stack integration unifies electrode cutting, Z-fold stacking, and adhesive thermal pressing into a single process. This integration eliminates bending and picking issues, minimizes collision risks, and enhances yield rates by reducing the number of steps and transfers.

Thermal Composite Stacking Technology

Thermal composite stacking involves simultaneous cutting and stacking of the positive and negative electrodes and the separator, followed by hot pressing. This technology greatly improves stacking quality and production speed, although it entails higher technical challenges.

In thermal composite stacking, the electrodes and the separator are simultaneously fed into a heating device. After heating, a hot roller presses the composite, cutting the separator to form individual stacking units. These units are then mechanically stacked to create electrode assemblies.

One major advantage of thermal composite stacking is maintaining consistent tension, direction, and speed of the separator and electrodes throughout the process, ensuring uniformity. This results in higher-quality batteries. Though more technically challenging than Z-fold stacking, it is ideal for high-energy-density batteries.

Roll-to-Stack Integration Technology

Roll-to-stack integration technology, exemplified by LG's Stack & Folding patent, offers high efficiency but is not available for external sale. This method involves cutting positive and negative electrodes into units and adhering them separately to a separator. The electrodes are then wrapped around the separator, forming interleaved electrode layers. This method achieves high speed and efficiency.

In conclusion, selecting a lithium-ion battery stacking technology depends on several factors, such as battery size, energy density, and production scale. Each method has its pros and cons, influencing the quality and efficiency of the battery manufacturing process. Continuous innovations in stacking technology play a crucial role in enhancing the performance and safety of lithium-ion batteries.

Re: Are Lithium Batteries Safe to Stack?

Thanks, everyone!

The tubes are shipping containers I get some shop supplies in. They're made of polycarbonate with caps at both ends. The 'top' one has a loop that hooks nicely on the bench wall. There's nothing conductive about them.

I figured these would also work as a way to keep the CR123s from rolling around in the 'junk' drawer of our camper. (The kids would just blast new ones out of the package and let them roll free.) I buy the Titanium ones, and they come in 6-piece packs, so I cut the tubes to fit six cells.

Since there's so much chit-chat about the "dangers" of CR123 batteries on this forum and other websites, I just wanted to ensure my camper, shop, or SUV isn't going to go up in flames while sitting in my yard.

If I can figure out how to post a picture of it, I will.

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