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Technological breakthrough of square shell battery stacking extruder: boosting power battery efficiency and safety
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2025-10-23
This paper focuses on the technological breakthroughs of the square shell battery stacking extruder, and analyzes its innovative points such as high-precision positioning and adaptive pressure control, as well as its key
With the explosive growth of the global new energy vehicle industry, the performance and quality of the power battery, as a core component, directly determine the cruising range and safety performance of the vehicle. At present, square shell lithium-ion batteries have become one of the mainstream choices in the field of passenger cars and commercial vehicles due to their stable structure and high energy density. However, in the production process of square shell batteries, pole stacking and extrusion molding have long faced pain points such as poor consistency, high pole damage rate, and inaccurate pressure control, which restrict the further improvement of battery energy density and safety. Recently, Zhilian New Energy Equipment Co., Ltd., a leading enterprise in the field of new energy equipment in China, announced that its self-developed new generation of square shell battery stacking extruder has achieved key technological breakthroughs, providing an efficient solution to the pain points of the industry.
It is reported that this new square shell battery stacking extruder integrates a number of cutting-edge technologies, first achieving a qualitative leap in positioning accuracy. The device is equipped with a high-precision positioning system based on machine vision. Through multi-camera collaboration and AI algorithm analysis, it can achieve real-time accurate alignment of the pole piece and the diaphragm. The positioning error is controlled within 0.01 mm - this accuracy is more than 50% higher than that of traditional equipment. Precise positioning not only reduces the misalignment of the edge of the pole piece, but also effectively avoids the risk of internal short circuit caused by alignment deviation, and improves battery safety from the source.
Secondly, the equipment innovatively adopts an adaptive pressure control system. The traditional extruder mostly uses a fixed pressure mode, which is prone to excessive or insufficient local pressure due to fluctuations in the thickness of the pole pieces, resulting in deformation of the pole pieces or residual gaps between layers. The new generation of equipment, through the built-in pressure sensor and dynamic adjustment module, can automatically adjust the extrusion pressure (range 0.5-5 MPa) according to the actual thickness and material characteristics of each group of pole pieces to ensure that each layer of pole pieces is evenly stressed. This technology not only reduces the pole piece damage rate (the trial data shows a decrease of 18%), but also improves the volumetric energy density of the battery by about 5%, which further extends the cruising range of new energy vehicles.
In addition, the intelligence level of the equipment has also been significantly improved. It is equipped with a full-process data monitoring system, which can collect key parameters such as stacking speed, pressure value, positioning error in real time, and analyze and warn through the cloud platform. Once an abnormality is found, the system will automatically shut down and issue an alarm to prevent defective products from flowing into the next link. At the same time, the equipment supports docking with the factory MES system to achieve seamless integration of production data, helping enterprises optimize production processes and improve overall operational efficiency.
At present, this square shell battery stacking extruder has been piloted in a number of domestic head power battery companies. A well-known battery manufacturer said: "After the introduction of Zhilian's new generation of stacking extruder, our battery production efficiency has increased by 22%, the product defect rate has decreased by 16%, and the battery cycle life has also been extended. The application of this equipment provides strong support for us to cope with the market demand for cost-effective batteries."
Industry experts pointed out that the technological breakthrough of the square shell battery stacking extruder not only solved the key pain points in the production process, but also promoted the upgrading of the power battery industry to the direction of "high precision, intelligence and high safety". Driven by the "double carbon" goal, the new energy vehicle and energy storage industry will continue to expand, and the demand for high-performance battery production equipment will further grow. The relevant person in charge of Zhilian New Energy Equipment Co., Ltd. revealed that in the future, the equipment will also combine 5G, AI and big data technologies to develop predictive maintenance functions, further reduce equipment operation and maintenance costs, and create greater value for customers.
With the continuous iteration of technology, the square shell battery stack extruder is expected to become one of the core equipment of intelligent manufacturing of power batteries, helping our country's new energy industry to occupy a more favorable position in the global competition.
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