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How are the batteries made?

Many of our customers are curious about how the batteries are made, here below is a brief introduction of the procedure and our facilities.    
1. Hydrogen Storage Alloy melting:Rare earth metal are melted together with Nickel, Cobalt, Manganese and Aluminum etc. in a high vacuum furnace, then pulverize the ingot to make HAS powder.
2. Plate making: Nickel hydroxide are mixed with other materials and inserted into a three dimension substrate called nickel foam to get the positive plate. Hydrogen storage alloy powder and other materials are made to slurry shape and pasted on nickel plated steel ribbon to get the negative plate.  
3. Assembly are generally classified to four stations:
  • Winding Station: Positive plate and negative plate are winded with separator in between and inserted to a steel can.
  • The machine will proceed a short circuit test, then it beads the can, apply sealant at the inner edge and place a gasket on from the feeder bowl.
  • Electrolyte Filling Station: Electrolyte is dispensed into each can, filling amount is very important, overfilling may lead to leakage and less filling will lead to bad performance.
  • 3.4 Crimp Station: Cap assembly installed with pressure release safety vent are fed and welded on the cap. Machine close the can and have a voltage test to finish the assembly process.

4. Formation and sorting: this process is used to activate and classify the battery. Cell characteristics like capacity, impedance, charge/discharge performance and life are systematically tested and monitored at given conditions. We do not only sort the battery by their capacity, but also impedance and charge acceptance characteristics to make sure the battery in the same battery pack behave the same way, which will help a lot in ensuring the longest cycle life.  
UN 38.3 Safety Test

We own a national standard UN38.3 testing lab. We can provide UN38.3 test service to our customer.

If you want to set up your own lab, we also provide UN38.3 & IEC62133 equipments and onsite training. Email us for the quote and lead time.
Thermal Abuse Test for IEC62133
Lithium Battery Shipping Regulation
Show & Conference
Next Generation Batteries Conference, San Diego, CA, April 21-22, Booth#9
32nd International Battery Exhibit, Mar.9-12,2015, Florida, Booth #209
The Battery Show 2014, Sept. 16-18, 2014, Novi, Michigan, Booth# B1544
Energy Mobility 2014, booth#126, Apr 29-30, 2014, San Diego, CA
Lithium Battery Power 2013, Nov 12-15, 2013, San Diego, CA
The Battery Show 2013, Sept. 17-19, 2013, Novi, Michigan
More News...
An article about Nik Wallenda makes history crossing the Grand Canyon. He was carrying BSI 1080i mini POV cameras with LFH4S4R1WR battery build by us.

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