A Better Life with Batteries – How to Make a Battery Step.4 Pack Process

When electrode manufacturing, assembly, and formation processes are finished, batteries are connected to form a module to fit the models they will be applied to. Now, we will learn about the last step of battery manufacturing, the pack process.

What is Pack Process?

The pack process is to produce a modular battery with the manufactured battery cells and to put them into a pack before final delivery. The battery now has electrical properties after formation. It is either supplied to clients in a unit of cell or in the form of a dedicated module for each EV model.

Cell to Cell

Production of a module is mostly about attachment and connection. First, the surfaces of battery cells are cleaned. Adhesive is applied to the module case and the cells are put into the case side by side. The attached cells are then connected with a wiring harness or a busbar. And when the cover is put in place, a module is complete.

Module to Module

Lastly, a pack is produced when the modules are placed in a battery pack and connected to each other. The numbers of cells and modules vary depending on the models of the battery cells and application. For example, if a pack that accommodates 96 battery cells requires modules that contain 6 cells each, a total of 16 modules are necessary to make one pack.

BMS, Managing Multiple Cells

Since a pack has numerous cells, balancing and managing the cells is essential. And the Battery Management System (BMS) monitors and regulates the battery’s state.

We have covered the entire steps of battery manufacturing: The electrode manufacturing process where cathode and anode are made; the assembly process where battery ingredients are assembled; the formation process where batteries are activated to play their roles; and the pack process where batteries are connected in a module. Note that technologies employed in each process enhance battery safety and performance!

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