Electromobility and the increasing demand for high-performance energy storage are continuously driving innovations in battery cell production. One of the central processes in manufacturing is the formation of battery cells, in which the performance parameters of the cell are determined by controlled charging and discharging. The mechanical stability of the cells is of decisive importance here in order to guarantee a consistently high quality and service life of the batteries. With the newly developed formation trays from ZELL®, this process is now more efficient, safer and space-saving.
ZELL® Formation Trays were specially developed for prismatic battery cells and offer double-sided clamping by means of torque. This innovative design enables even pressure distribution on the cells, preventing uncontrolled expansion during formation. The design ensures optimum contacting, which increases process stability and protects the batteries from mechanical damage.
In addition, the tray is designed to minimize space requirements in production and logistics. Its compact design allows more battery cells to be transported and stored on the same surface area, significantly reducing logistics and handling costs. This is particularly advantageous for large-scale manufacturers who need to continuously optimize their production processes.
ZELL® Formation Trays are an ideal solution for companies in various areas of energy storage. In particular, automotive manufacturers who produce battery cells for electric vehicles benefit from stable formation. The mechanical fixation of the cells ensures that the chemical structure of the batteries does not change negatively during the formation process. This not only improves the cycle stability, but also increases the range of the vehicles, as the batteries retain higher energy efficiency.
In addition, the trays are also suitable for the production of stationary energy storage systems. Companies that manufacture energy storage for households, industrial plants or grid services can use ZELL® Formation Trays to ensure consistently high quality of their batteries. The space-saving design also enables more efficient use of production capacities.
A significant advantage of the new formation trays is the reduction in production costs. The improved process stability reduces waste and ensures that fewer defective battery cells are produced. This not only saves material costs but also reduces energy consumption in production.
In addition to the economic advantages, formation trays also contribute to sustainability. The more stable formation of the battery cells leads to a longer service life of the energy storage devices, which reduces the number of batteries that need to be replaced. This has a direct positive impact on the CO2 balance of the entire supply chain.
ZELL®, together with Bosch and Schuler, has developed the first prototypes. The close collaboration with leading companies in the industry underscores the quality and innovative strength of the formation trays. The first major inquiries are already coming from Korea, which illustrates the technology's potential on an international level, despite its head start in Asia.
The company's goal is to further optimize battery cell production through intelligent solutions and to establish itself as a leading European supplier of formation trays. Through continuous development and close cooperation with industry partners, ZELL® will continue to improve its products and adapt them to the needs of the growing electromobility and energy storage markets. In addition, manufacturing costs can be further reduced with each successfully implemented project and the knowledge gained from it.
ZELL® Formation Trays are a forward-looking solution for battery cell production. They offer manufacturers of batteries for electric vehicles and stationary energy storage systems a more efficient, stable and economical way to form their cells. The sophisticated design not only increases process reliability, but also contributes to sustainability. With its innovative strength and strong partners, ZELL® is setting new standards in battery cell production and establishing itself as a leading company in this field.
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