Clampable workpiece carriers for the forming process of prismatic cells

In the manufacturing of prismatic lithium-ion cells, the formation process is a critical factor in quality: During the initial electrochemical charge (formation) and subsequent storage (aging), the cell chemistry is stabilized, the SEI film is formed, and the cell’s future performance is determined. At the same time, the cell is subjected to high thermal and mechanical stresses.
To prevent cell deformation, overheating, or loss of performance, controlled, tension-free fixation is crucial .

The ZELL Battery Part Carrier System provides cell manufacturers with a clamping, water-cooled platform developed for all process-relevant steps involved in formation, while significantly improving cell quality, process control, and automation capabilities.

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Process steps – where ZELL Battery can be used

ZELL Battery carrier systems can support the following production steps:

1. Electrolyte filling (Filling)
   – Stable mounting prevents tilting and leakage; optional drip tray integration
2. Printing application (Pre-Press)
   – Plane-parallel pre-tensioning against swelling through electrochemical reaction
3. Formation (charge/discharge)
   – Thermally stable performance under heat generation
4. Aging (maturation phase)
   – stored for hours to days in the same tray – retains its shape
5. Final testing (OCV, IR, sorting)
   – Contacting & measurement directly in the carrier possible
6. Cleaning, buffering & transfer to module assembly
   – Carrier remains in the system until the next process step – no repacking necessary

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Technical Concept of ZELL Battery

The carrier with adjustable fasteners and a process-oriented design:

• Clamping elements with a defined clamping force prevent cell swelling during charging
• Cell holder for prismatic formats 80–300 mm in height, configurable for multiple cells per tray
• Robust construction made of stainless steel and insulating components (non-conductive)
• Industry 4.0-ready: Optional DMC, RFID, or QR tracking for batch traceability and process documentation
• Can be automated: Compatible with robotics, AGVs, lift systems, and palletizing solutions

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Technical and economic advantages at a glance

For ZELL quality and process control:

• Consistent pressure = less swelling, higher plane parallelism
• Reduzierte Zelltemperaturdrift während Formierung (ΔT < ±1,5 °C)
• Minimization of cell defects (deformation, SEI inhomogeneity, gas formation)
• Reproducible clamping force = more stable cell characteristics

For automation and efficiency:

• No re-batching required between processes
• Process time savings through continuous material flow
• Less scrap and rework due to controlled handling
• Long service life: >1,000 uses per carrier in industrial applications

For integration and traceability:

• Seamless batch assignment via serial engraving or DMC
• Compatible with MES/ERP systems
• Simple integration into existing forming and testing systems

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Conclusion: ZELL Battery – stable cell, stable process

The formation process determines the quality of each individual prismatic battery cell. With the ZELL Battery Part Carrier System, cell manufacturers receive a modular, thermally and mechanically stable solution that reduces sources of error, enables automation, and improves cell performance in the long term.

One carrier – many process steps – maximum ZELL value.