For EV makers, the battery pack is both the largest and most costly element in the vehicle. Conventional manufacturing relies on multiple assembly steps that increase both production time and overhead costs, but by combining multiple-step processes into a one-stop lamination process, manufacturers can streamline production.
There is a critical need for thinner, robust structures for high-volume production, and as CCS designs move from bulky plastic trays to using advanced lamination approaches, battery makers can reduce costs, create thinner CCS, and maintain close tolerances for accommodating larger battery packs.
How Does Advanced Lamination Technology Streamline the Assembly Process?
Moving away from conventional CCS designs that use bulky plastic trays, ENNOVI-CellConnect-Pouch utilizes advanced lamination technology to create thin and lightweight solutions that enhance electrical and thermal performance at a lower manufacturing cost. The combining of multiple processes into a single patent-pending one-stop lamination step reduces battery assembly time and costs.
This streamlined assembly process enables the cell contacting system to get rid of inefficiencies and speed up battery pack production, all the while cutting costs and improving usage of materials. By combining multiple-step processes into a one-stop lamination process, our ENNOVI-CellConnect-Prism eliminates multiple processes to reduce cell contacting system costs by up to 15% for prismatic cells.
What is the Impact of Low-Profile Insulation on Cell Density?
PET is used for the dielectric layers on low-voltage circuits, high-voltage current collectors, and terminal busbars, removing the need for other insulation materials. By replacing bulkier traditional insulation with these thin layers, EV makers can create space to accommodate more cells within the same battery pack volume. Furthermore, these low-profile materials support stable operation across high-voltage platforms, seamlessly handling a battery module voltage of 12 – 800V and higher.
How Does Streamlined Assembly Support Advanced Battery Architectures?
ENNOVI-CellConnect-Prism allows for the smooth integration of individual prismatic cells to form larger battery modules or advanced cell-to-pack (CTP) and cell-to-chassis (CTC) configurations. As CCS designs move from bulky plastic trays to using advanced lamination approaches, battery makers can reduce costs, create thinner CCS, and maintain close tolerances for accommodating larger battery packs.
More importantly, streamlining assembly for prismatic cells gives EV makers a wider range of choices to leverage gigafactories producing high volumes of prismatic cells on the global market.
Driving Down Costs: Why Advanced Lamination is the Key to Prismatic CCS Efficiency
Implementing a one-stop lamination process reduces production time and can cut costs by up to 15%. Utilizing low-profile dielectric materials maximizes energy density and provides the flexibility to create designs for battery modules or new advanced cell-to-pack and cell-to-chassis configurations.
To request a technical review of your battery architecture and discover how our advanced lamination processes can accelerate your path to market, contact our engineering team today.