Clampable, water-cooled workpiece carriers for the forming process of prismatic cells

In the production of prismatic lithium-ion cells, the forming process is a critical quality driver: during the initial electrochemical charging (forming) and subsequent storage (aging), the cell chemistry is stabilized, the SEI film is formed and the subsequent cell performance is defined. At the same time, high thermal and mechanical loads are placed on the cell.
To avoid cell deformation, overheating or loss of performance, controlled, stress-free fixation with active thermal management is crucial.

The ZELL Battery workpiece carrier system provides cell manufacturers with a clampable, water-cooled platform that has been developed for all process-relevant steps relating to forming - and at the same time significantly improves cell quality, process control and automation capability.

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⚙️ Process steps - where ZELL Battery can be used

ZELL Battery carrier systems can support the following manufacturing steps:

1. Electrolyte filling (Filling)
   - Stable holder prevents tipping and leaks; optional drip tray integration
2. Pressure application (pre-press)
   - plane-parallel pre-tensioning against swelling by electrochemical reaction
3. Forming (Charge/Discharge)
   - Thermally stable hold with heat development; active water cooling or thermal oil connection
4. Aging (maturing phase)
   - storage for hours to days in the same tray - constant temperature and dimensionally stable
5. Final inspection (OCV, IR, sorting)
   - Contacting & measurement possible directly in the carrier
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 combines mechanically tensionable fixings with active temperature control and process-oriented design:

• 🔧 Clamping elements with defined pressure force prevent cell inflation during charging
• 💧 Integrated water cooling channels or thermal oil guides - homogeneous heat dissipation at increased forming temperature
• 🔒 Cell holder for prismatic formats 80-300 mm high, configurable for multiple cells per tray
• 🧱 Robust construction made of stainless steel & insulating components (electrically non-conductive)
• 🧠 Industry 4.0-capable: Optional DMC, RFID or QR tracking for batch traceability & 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 cell quality and process control:

• Uniform 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 recharging between processes necessary
• Process time savings thanks to continuous material flow
• Less waste and rework thanks to controlled handling
• Long service life: >1,000 uses per carrier in industrial applications

For integration and traceability:

• Seamless batch allocation via serial engraving or DMC
• Compatible with MES/ERP systems
• Easy integration into existing forming and test systems

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Conclusion: ZELL Battery - stable cell, stable process

The forming process determines the quality of each individual prismatic battery cell. The ZELL Battery workpiece carrier system provides cell manufacturers with 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 cell value.