How high end curved, tiny and thin lipo batteries are made

如何用105人每月生产200万支高端聚合物特种电池?

How do we produce 2M pieces of high-end special lipo batteries per month with only 105 employees?

 

聚合物电池已经有十几年的历史, 技术很成熟了; 六年前, 基安比的工程师别人在做熟的时候,在广州开始特种(超小, 弯曲及超薄)电池, 同时完善一些电池高性能。到现在，他们掌握了如何105人每月生产200万高端特种聚合物电池的技术要求, 公司于是在2013年, 东莞一江之隔的园洲建起的自己的工业园, 成为中国专门生产弯曲电池, 特小聚合物电池, 超薄电池等最大的生产基地.

Lithium ion batteries have been in development for over ten years. Six years ago, an engineer at GMB began to make special (tiny, curved and thin) batteries. Now, we have mastered the technical requirements of how to produce 2M pieces of high-end special lipo batteries per month with only 105 employees. Our company established its own industrial park in Yuanzhou across the river from Dongguan in 2013 becoming the largest production base of specialized curved batteries, tiny lipo batteries and ultra-thin batteries in China.

他们是做了那些事？ How do we do it?

 

不管你生产什么大小的聚合物电池, 如果你要生产质量好的, 四大生产要素是你得首先考虑的, 即车间的生产温度湿度, 化学品搅拌, 极片上的化学物质涂布和极片的滚压。

No matter what size of lipo battery you produce, if you want high quality you must  first consider four factors in production: the production temperature and humidity in the workshop, the material mixing process, proper coating, and an accurate pressing machine.

生产车间的温度及湿度。

The production temperature and humidity in the workshop

 

生产车间的温度及湿度， 尤其是在温湿度高的南方,必需严格控制的，尤其要生产性能稳定，并具备满足高端电池要求条件。 高端电池有各种要求，如较普通电池长30%的续航能力，高低温性能， 快充电功能, 微小电池能大功率工作等, 绝不能有普通聚合物气胀等。 生产一般的聚合物电池， 设置一些普通空调和一些民用除湿机放在车间，然后加长极片的烘烤除去微量水份, 而只在注液工序增加小功率的工业除温机, 因此五千平米的车间花个十几万足矣, 生产出的电池也能满足普通用户的要求.

基安比要生产高端电池，配备大型的除湿机， 整个一楼的车间五千平米的工作区， 配备了三台机芯为端士产的大型工业除湿机， 每个车间作100%密封处理， 温湿中央控制， 保证所有车间的温湿度一致。 仅第一层，就耗资是普通聚合物电池生产车间的10倍， 达180万元, 放眼看去, 很是亮丽。

 

The production temperature and humidity in the workshop, especially the high temperature and humidity in Southern China, is strictly controlled. This ensures the manufacture of stable products that set the standard for high-end performance batteries. There are a few requirements for high-end batteries such as: a 30% (or more) longer life span than a common battery, the capacity to handle high and low temperatures, a faster charge function, a high discharge rate for smaller batteries, no swelling like common batteries have etc. First we produce a common lipo battery using common air-conditioners and civilian dehumidifiers in the workshop. We then extend the pole piece bake time to remove any trace of moisture. Next we increase the low-power industrial dehumidifier in the workshop for the process of injecting electrolytes. We spared no expense in making a five thousand square meter workshop capable of producing  batteries that meet the requirements of our customers.

Each workshop makes the sealing process perfect. The whole first floor is a five thousand square meter working area equipped with three large industrial dehumidifiers from Switzerland. They are the central control on the temperature and humidity, making sure all the workshops are the same temperature. The first floor alone cost 10 times as much as a common lipo battery workshop a grand total of 1.8 million RMB. The results look beautiful.

  

搅拌机

Mixing machine

 

想要电池好， 首先得把材料搅拌均匀，无气泡。 如果要做高端的电池，在高速搅拌中还得保持材料的干温度及温(湿)度，那就得用这台真空双模恒温全自动搅拌机了。

Want a good battery? You must first mix the ingredients evenly, with no bubbles. If you want a high-end battery, you must maintain a dry temperature and humidity of the material during the high speed stirring process. This is accomplished in the vacuum dual mode constant temperature automatic mixer. (Pictured below)

 

涂布机

Coating machine

聚合物电池高端电池，第一就要续航能力要强，容量均一， 这就得看搅拌好的极性材料能非常均匀的涂在正负级的两面，然后要非常均匀地将它们烘干， 上(下)图的设备就是干这个的。

The high-end lipo batteries must receive an even coating of the polarity material mixture on both the positive and negative sides. This gives it a longer battery life and uniform capacity. The equipment shown below coats and evenly dries the sheets.

 滚压机

Pressing machine
为进一步确保电池续航能力及容量的一致性，需要进一步的提高片的能量密度， 这台机器就是做这的，两对大滚轮重达12吨，控制盘设好了， 在电脑的控制下，随时调节两轮之间的间隙度，压出的片厚度误差厚度在0.0001毫米, 确保每个电池具有一样的高容量密度。

The machine with the two large 12 tonne idler wheels pictured above is improving the energy density of the sheet. This process further ensures the consistency of increased battery life and capacity. The control board that can be directed via computer can adjust the gap between the two wheels at any time. The tolerance for the thickness of the sheet is 0.0001mm. This ensures that each cell has the same high capacity density.

 

到此应该大功告成，远远还没有！！ 基安彼要做的是高端物种电池,        即弯曲电池, 超薄电池及超小聚合物电池.小到什么程度?　比你的指甲还小！！ 人工操作这种小电池的级片的极耳焊接，　极片卷绕困难，速度慢; 加之人是有情绪的，大批量生产时, 电池的稳定性不能保证, 导致合格率下降, 最疑义。对于电池生产前段工序，我们可以购买最好的设备，而生产这种微小的，或超薄的，或微小弯曲的电池，市场上没有现在的设备。　而这些生产瓶颈就是我们现在的优势。一个工人一天只能卷绕只能卷出500只电池, 一天十万只的产量需要200个工人, 而我们只要十台特种卷绕机,而且从不闹情绪. 其它的生产工序在过去六年中, 使我们一百位工人用二班, 每月生产出二百万高端特种电池.

这些电池生产出来后, 不仅要进行高温老化, 同时要在高温中经受相对湿度为95%的考验. 然后QC工程师要对这批电池进行针刺, 挤压,碰撞, 跌落等安全试验后进行包装, 送到您的手上.

 

But we are not done yet!! GMB produces high quality curved, ultra-thin and small lipo batteries. How small? Smaller than your nails! Manual operation on this little battery’s sheet and tabs is very difficult and slow. A great deal of patience is required to roll the positive and negative sheet. Emotions can run high at work,   especially in mass production, and if we cannot guarantee the stability of the battery, it could result in a declining passing rate. This scenario is very unrealistic however. We can buy the best equipment for the process of battery production, but there is no single device on the market now that can produce these tiny, ultra-thin, or tiny curved batteries alone. Our production method is our advantage. A worker can only roll out 500pcs of batteries per day, so 100,000pcs battery per day will need 200 workers. GMB only needs 10 sets of special rolling machines, and no one gets disgruntled. In the past six years, we only needed 100 worker operating in two shifts in order to produce 2000000pcs of special high-end batteries.

 

After the battery production, they undergo tests without aging them in a relative humidity of 95% at high temperature. The QC engineer will then perform safety tests such as acupuncture, extrusion, impact, and drop tests before we send our batteries straight to your hands.

 

知道了我们的设备， 您不一定知道我们的技术沉淀， 你得试一下我们85度高温电池， 看它能储藏多少天； 试一下-40度低温电池， 看它能放出百分之多少容量；试一下世上最轻的电池，看看有没有比它更轻的；试一下快充聚合物电池， 看三分钟能充到95%电量 …

You do not yet know the advanced technology batteries that this equipment can produce. You have to try our 85℃ high temperature battery and see how many days it can be stored; Try our -40 ℃ low temperature battery, it can discharge any percentage capacity; Try the lightest battery in the world, see if there are any lighter than it; Try the fast charge lithium polymer battery and test them for three minutes to see if they can be charged to 95% capacity...

 

 

想试一下这些电池吗?　下表是我们有模具的型号表， 我们提供免费样品：

Want to try out these batteries? We provide free samples of many mold models listed in the table below:

 

 

Item(型号)	Voltage (V)	Capacity (mAh)	High Energy Density(高容量)	REMARKS备注
GMB201030R	3.7	43	47.3	有模电芯模，弯折模 Cell mold, curved mold
GMB201021R	3.7	22	24.2	有模电芯模，弯折模 Cell mold, curved mold
GMB200830R	3.7	32	35.2	有模电芯模，弯折模 Cell mold, curved mold
GMB251341R	3.7	95	104.5	有模电芯模，弯折模 Cell mold, curved mold
GMB 501215	3.7	50	55	有模电芯模 Cell mold
GMB 361215R	3.7	40	44	无磁性电池 有电芯模 Non-magnetic battery, Cell mold
GMB 622238	3.7	450	504	有模电芯模 Cell mold
GMB 451937	3.7	250	280	有模电芯模 Cell mold
GMB 502030	3.7	240	264	有模电芯模 Cell mold
GMB 302547	3.7	320	352	有模电芯模 Cell mold
GMB 302436R	3.7	220	242	有模电芯模 Cell mold
GMB 382030	3.7	190	209	有模电芯模 Cell mold
GMB 301009	3.7	12	13.2	有模电芯模 Cell mold
GMB 502025	3.7	180	198	有模电芯模 Cell mold
GMB 301240	3.7	110	121	有模电芯模 Cell mold
GMB 241240R	3.7	80	88	有模电芯模 Cell mold
GMB 250816R	3.7	13	14.3	无模具 No mold
GMB 501320	3.7	75	84	有模电芯模 Cell mold
GMB 251215R	3.7	20	22	有模电芯模 Cell mold
GMB 251515R	3.7	28	30.8	有模电芯模 Cell mold

 

 

Item(型号)	Voltage (V)	Capacity (mAh)	High Energy Density(高容量)	REMARKS备注
GMB153030R	3.7	85	93.5	无模具   No mold
GMB142828R	3.7	65	71.5	无模具   No mold
GMB233080R	3.7	560	627.2	无模具  No mold
GMB253030	3.7	180	198	无模具  No mold
GMB 255050	3.7	500	560	有电芯模  Cell mold
GMB 301013	3.7	14	15.4	无模具  No mold
GMB 301017	3.7	16	17.6	无模具  No mold
GMB 301025	3.7	43	47.3	无模具  No mold
GMB 301030	3.7	62	68.2	有电芯模  Cell mold
GMB 303030	3.7	230	253	无模具  No mold
GMB 303040	3.7	320	352	无模具  No mold
GMB 303048	3.7	420	470.4	无模具  No mold
GMB 303540	3.7	430	473	无模具  No mold
GMB 305050	3.7	750	825	有电芯模  No mold
GMB 323540	3.7	400	440	无模具  No mold
GMB 402528	3.7	230	253	无模具  No mold
GMB 451124	3.7	65	71.5	无模具  No mold
GMB 501320	3.7	75	82.5	有电芯模  Cell mold
GMB 541835	3.7	280	308	无模具  No mold
GMB 571322	3.7	140	154	无模具  No mold
GMB 601524	3.7	150	165	无模具  No mold

 

 

Item(型号)	Voltage (V)	Capacity (mAh)	High Energy Density(高容量)	REMARKS备注
GMB701437	3.7	310	341	无
GMB065438	3.7	65	71.5	无（超薄） ultra-thin
GMB063022	3.7	12	13.2	无（超薄）
GMB055050	3.7	85	93.5	无（超薄）
GMB 064245	3.7	60	66	无（超薄）
GMB 042541	3.7	12	13.2	无（超薄）
GMB 0452550	3.7	16	17.6	无（超薄）
GMB 0455050	3.7	40	44	无（超薄）
GMB 104050	3.7	65	71.5	无（超薄）
GMB 104856	3.7	85	93.5	无（超薄）
GMB 102040	3.7	18	19.8	无（超薄）

                                                                                                            

通过下面的方式， 拿到免费样品：

Email:

info@gmbattery.com

info@gmbattery.com.cn

ceo@gmbattery.com

ceo@gmbattery.com.cn

call: 0752-6688061/6688062

Shenzhen office:0755-36950220