ENAX's contracted business to support R&D and mass production of next-generation batteries for a decarbonized society.
The need for the development of next-generation lithium-ion batteries is increasing due to
the diversification of applications such as electric vehicles (EVs), small devices such as
smartphones and tablet devices, and storage batteries for industrial and home
use.
Since the development requirements for lithium-ion batteries vary depending on
the application, ENAX is developing a battery development contract business that takes
advantage of our specialized knowledge and technology. This page provides a detailed
description of our R&D structure, development process, and processes.
While lithium-ion batteries have increased storage capacity and charging speed due to the
diversification of their applications, they also pose risks that cannot be underestimated,
such as heat generation, smoking, and ignition. Therefore, ensuring safety is an important
issue in both R&D, quality assurance, and quality control.
Since new
applications are being actively sought, the short product cycle also requires rapid
observation, analysis, evaluation, and reporting of safety risks. In many cases, we are
faced with the following problems in fulfilling our customers' requirements
There are two indices for comparing battery performance: gravimetric energy density and
volumetric energy density. Volumetric energy density is important when light weight and
large energy is essential for a product, such as batteries used in smartphones. In the
case of electric vehicles (EVs), where the battery must be contained in a given space and
the weight of the vehicle is closely related to the driving range, the weight energy
density is mainly important.
The required charge-discharge performance, cycle
performance, and safety while storing as much energy as possible in a limited weight and
volume require specialized scientific knowledge, material processing technology, and
optimal facilities.
In order to solve the above issues, ENAX supports customers who wish to develop products
by hearing their applications, sharing the issues, and providing support from electrode
and battery element development to prototyping and mass production.
Specifically,
research and development is conducted according to the following structure and
process.
1. Proof-of-concept of next-generation batteries represented by
all-solid-state batteries.
2. Performance verification and identification of production
issues using battery cells of the same size as those used in products
3. Mass
production process design and verification of processes and quality, establishment of QC
(review of procedures and processes in assembly)
4. Responding to pre-production needs
of several hundred to several tens of thousands of cells
5. Verification of pack
assembly processes, impact of component changes and work safety
We support
development from lab-scale proof-of-concept to pilot-scale testing and development for
product demonstration. The pilot-scale demonstration includes safety and production
process evaluations, as well as validation of the suitability and appropriateness of the
product for transfer to mass production.
1. Requests and development requirements
First, we will ask you about your problems
related to batteries and what you would like to achieve. ENAX will then define the
specific battery development requirements to realize your product.
2. Material
Search
Lithium-ion batteries use various materials such as positive (negative)
electrode materials, conductive materials, electrolyte, and separators. We search for and
select the most suitable materials according to development requirements.
3.
Element Development
Element development is a phase in which the electrode recipe and
electrolyte recipe are examined and then checked to see if they match the characteristics
of the product according to development requirements. This is done in a single layer pouch
cell, which is the smallest unit of a lithium-ion battery.
4. Functional
verification
Verification is carried out in stacked cells that are close to the actual
size for product mounting. For example, this phase evaluates the resistance, heat
generation, durability, reliability, etc. when the input/output current required for the
product is applied.
5. Verification of actual equipment installation
This is the
phase in which we procure the necessary amount of dedicated materials based on the number
of cells required for product mounting, and manufacture prototype cells in facilities and
processes that are close to those used for mass production. In this phase, we verify
whether the performance of the cells is as expected for use in the final product, and
conduct tests to ensure compliance with regulations. This is also the phase to determine
if the performance and quality are confirmed and can be transferred to small-scale
production.
6. Small-scale production of products mounted on actual
equipment
This is the phase that prepares for the transfer to mass production process.
This phase mainly includes adjustment of manufacturing processes and lines using assembly
facilities based on the assumption of mass production volume, adjustment of inspection
contents and inspection processes to ensure mass production quality, and preparation of
procedures, PL, QC, etc. for manufacturing.
7. Mass production transfer
The
final phase is the transfer to mass production. Depending on the volume of mass
production, ENAX not only handles mass production, but can also transfer production to a
customer-designated manufacturing site.
1. Slurry making
Active materials, conductive materials, binders, and diluents
(amphipolar solvents including water) that make up the electrode are made into slurry;
ENAX verifies formulation recipes and fabrication processes, focusing on the
dispersibility of the slurry that contribute to battery performance.
2.
Coating
This is the process of coating the collector foil with slurry. ENAX has
established a coating method that guarantees coating material properties* and minimizes
variation by using comma reverse, comma direct, and slot die coating methods to achieve
high quality coating. Unevenness or variation in slurry properties and coating methods not
only causes defects in battery output and capacity characteristics, but also poses the
risk of ignition. Electrode drying, an element of the coating process, not only directly
affects battery performance, but also greatly affects production speed, and is therefore
an important element of process development.
*Ensuring physical
properties of the slurry = Establishing three elements: suppression of viscosity
fluctuations, suppression of agglomeration, and stability of the coated
surface.
3. Calendaring
This process is used to increase the mechanical
strength of coated electrodes and at the same time adhere the active material to the
current collector to improve electrical conduction. To ensure stable battery input/output,
capacity, and cycle performance, cold and hot presses are used to achieve the designed
electrode density and control in-plane variation.
4. Electrode slitting
ENAX's
shear-cut type equipment enables processing of a wide range of sizes.
5. Battery
cell assembly
A typical battery cell is manufactured under the following flow and
environment
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