Battery Technology
Battery engineers specialized in development, testing, and consulting.
Development of battery cells for electromobility applications. Design and implementation of realistic test setups for mechanical testing of battery cell components. Expert consulting for industrialization, production, and facility planning of your manufacturing plant.
Battery Technology
Automotive: Planning to Production
With specialists in product development, mechanical engineering, and production, Codronic offers comprehensive development and consulting services for the automotive industry.
We design components and assemblies that uncompromisingly meet the highest standards of durability, safety, performance, efficiency, and cost-effectiveness.
Pressmetrics: Testsystem for Battery Cell Housings
Battery Cell Development
Electrical Contacting
The connection of the active materials forms the electrical bridge into and out of the cell. Its design and dimensioning are critical factors for overall performance. This connection is typically realized through welding processes such as ultrasonic or laser welding.
Corrosion Protection
Certain components within the battery cell are corrosive. Combined with external environmental influences, the cell housing must therefore provide durability and safety. Minimizing air gaps and creepage distances is also essential to ensure electrical reliability.
Geometry Optimization
Modern simulation methods, such as static-mechanical FEM analysis, enable rapid evaluation of new designs. Through topology optimization, material usage can be reduced, resulting in lower weight and cost.
Technical Cleanliness
Particles — especially those that are electrically conductive — pose a risk to cell functionality and safety. Moisture absorption by materials must be prevented through the use of dry rooms or glove boxes.
Safety Systems
In the event of a short circuit or mechanical damage, fire may occur. Measures to prevent thermal propagation and to ensure controlled heat dissipation through the venting channel are essential for system safety.
Battery Cell Test Systems
Component Testing
Helium leak test fixtures are used to determine the leakage rates of assemblies and components. Combined with our fixtures for welding trials and load tests, they enable early evaluation of component reliability and process suitability.
Cell Testing
For electrical tests on finished cells, such as electric-impedance-spectroscopy, low-resistance connections are essential to obtain valid results. Reliable testing of geometric features can be performed semi-automatically and contact-free to minimize external interference factors.
Test and Dummy Cells
Reusable T-piece cells with gold reference electrodes enable the rapid generation of scalable insights into cell chemistry. The design combines an anode half-cell, a cathode half-cell, and a full single cell. This configuration makes the T-piece cell superior to conventional coin cells. Test fixtures with integrated contacting and temperature measurement are available for prismatic, pouch, and cylindrical cells. Long-term stable connections with minimal contact resistance are essential for obtaining meaningful and reproducible results.
Test Laboratory Planning
To ensure efficient contacting of test carriers and samples such as our T-piece cells, we offer systems that allow for quick and ergonomic specimen exchange, increasing your laboratory’s testing capacity. In addition, we provide consulting on the setup and selection of required equipment — including potentiostats, cyclers, measurement instruments, and climate chambers.
Battery Industrialisazion
Production Planning and Control
Networking of machines and automation of processes, for example, loading vacuum drying ovens with autonomously operating transport vehicles. Production data acquisition via OPC UA, analysis, and centralized control of individual machines through higher-level systems. Predictive maintenance intervals and optimized maintenance procedures increase equipment availability and overall efficiency.
Specific Requirements of Battery Production
Particle control and humidity management are critical factors in production planning. Cleanroom conditions according to ISO 14644-1 and ISO 7, as well as dry room environments with humidity levels below 0.05%, are maintained through HEPA filtration systems and air dryers. All machinery must be compatible with cleanroom operation. Particle-generating processes such as slitting require special attention to prevent contamination. Laminar airflow systems ensure controlled particle removal and prevent accumulation within the workspace.
Filling, Formation, and Aging
Electrolyte filling activates the cell, enabling energy storage. During formation, the interfacial layers on the electrodes are established. In the aging process, the chemical structures within the active materials stabilize. Preventive safety measures are essential during these process steps to ensure reliable and safe production.
Traceability, Inline, and End-of-Line Testing
Traceability down to the electrode level requires dedicated marking systems. Critical parameters related to safety and functionality should be verified at every stage of the value chain to enable early intervention. Inline inspection and monitoring using vision systems, X-ray, CT-scan, and eddy current testing detect defective components at an early stage. Final end-of-line testing ensures full compliance with all technical and quality requirements.
