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Development of R2R direct Gravure coater and Laminating system
for Pouch battery of Electric vehicle applications
[CEO. Dong Soo, Kim]
CONTENTS
1 Market
2 Problem
3 Product
4 Technology
5 Process
6 Properties
※ APPENDIX
Electric vehicle Explosion
1
• Explosion of Tesla electric car with Panasonic’s Cylindrical lithium battery
• Fire & Personal injury, “Driver death”
2018. 03 Car crash occurred in California, USA → The driver died due to Explosion & Fire
I. Market
Ref. 모터 그래프
Vehicle Model Battery Manufacturer Cause
Tesla electric vehicle Model X Panasonic (Cylindrical battery) Battery Overheating & Distortion
Pouch type battery Predominance
2
• Pouch type battery advantage due to “High energy efficiency & Light & Design freedom etc.”
• Polymer electrolyte → No electrolyte leakage & No explosion, Improved Safety
• LG Chem, a maker of pouch-type battery, forecasts Electric car battery Sales to be at least “8 trillion won” in 2020
I. Market
Ref. 모터 그래프
Capacity : 35GWh in 2018 → 90GWh projected in 2020
Ref. 전자신문 2018.07.24
※ Battery types and Models for electric vehicle
Battery
typeCharacteristic
Battery
manufacturer
Car
maker
Pouch
High energy
efficiency
Light weight
Safety
Design freedom
LG Chem.
SK Innovation
AESC etc.
HYUNDAI/KIA
Volkswagen
GM, Ford, Volvo,
NISSAN etc.
Prismatic
Affordable cost
Durability
Massive production
Samsung SDI
TOSHIBA
SANYO
PEVE etc.
BMW
Audi
TOYOTA
Volkswagen etc.
Cylindrical
Panasonic
SANYO
LG Chem.
Samsung SDI
etc.
Tesla
* Includes Small/Medium and Large battery Ref. Industry gathering
Li-battery Industry Market
3
• Expanded from Mobile/IT devices to Electric vehicles and ESS, Increased Demand
• Expanded Supply of electric vehicles : Promote electric car Support policy and Production around the world
I. Market
Ref. 모터 그래프
Secondary Battery Market for Electric vehicles [Amout]
$15.7 billion in 2016 ▶ $67.6 billion in 2020 (331% ↑)
Lithium Battery Global Market Outlook
Li-Polymer Battery Industry Market
4
• Li-Polymer Battery Growth with High energy density & Low explosion hazard
(15 trillion won in 2020 → 32 trillion won in 2030)
• Increased demand for Exterior material of Li-polymer battery, “Growing together”
• Pouch film (※ Exterior material) – Monopoly of Japanese companies & High dependence on imports
(Occupy more than 80% of the industry market → “Localization Essential”)
I. Market
Ref. 모터 그래프
Pouch Film Market Outlook Cost per Pouch type battery material Market Share by Manufacturer
*Ref: 당사자료, SNE리서치 *Ref: 당사자료*Ref: SNE리서치(2013)
Risk & Low efficiency of lithium battery
5
• Risk – Cylindrical and Prismatic batteries, Possibility of Explosion due to Electrolyte leakage
• High efficiency – Electric vehicle, Require High efficiency & High capacity Battery
Pouch Battery, Improved Safety & High Energy Density (※ Polymer electrolyte and Light & Thin)
II.Problem
Ref. 모터 그래프
Battery type
Cylindrical & Prismatic Pouch
Advantages · Easy of Supply, Durability· Safety, High efficiency· High Design Freedom & Space utilization
Problems· Explosion, Secondary damage such as Fire· Product weight· Low space utilization “Reduced efficiency”
· High Production unit Price
* Ref. Google Image
Limitations of Extrusion lamination
6
• Manufacturing Method of Pouch film – Extrusion lamination & Dry lamination
• Limits of Extrusion lamination – Thin film coating Difficulty & Materials/Time Loss
• Impossible of coating thickness Less than 10㎛, Operation yield approx. 80%
II.Problem
Extrusion lamination Dry lamination
장 점· Mass Production (Processing speed Max. 600m/min)
· Excellent Chemical resistance
단 점
· Materials/Time Loss → Increased manufacturing cost
· Coating thickness Limit (>10㎛)
· Low yield (Loss by Edge Bead)
· Thin film coating (<10㎛)
· Continuous Production, Uniform Operation→ Improve yield (approx. 90%)
· Simple Process → Reduced manufacturing cost
· Need to Aging Process (Temp.50℃, 3days)→ Adhesion formation
· Low Chemical resistance→ Edge Bead : Melt resin Clustering
Pouch film for Li-Polymer battery
7
• Development of Exterior material for pouch type battery
• Pouch Film – Exterior material of Li-Polymer battery & Composite film composed of Metal and Polymer films
• Function – Battery cell Protection & Battery safety & Reliability
III.Product
Nylon
Al foil
CPP
Cross section of Pouch film (x500)
Li-Polymer Battery and Pouch film Structure
Product Specifications
8
III.Product
[Structure of Pouch film]
Application Field
9
III.Product
Small Battery(Mobile IT device)
Medium & Large Battery
(EV, ESS)
Li-polymer Battery
Electric vehicleMobile / IT devices
Roll-to-Roll Dry lamination
10
• Development of Roll to Roll Dry lamination
Direct Gravure Coater with Excellent Repeatability
Continuous Production method → Increased Productivity & Reduced manufacturing Costs
Thin film Coating of 2~5㎛ & Yield over 90%
Ⅳ.Technology
Roll to Roll Dry lamination Equipment and Schematic
START
Process technology using Gravure Coater
11
• Direct Gravure Coater
Concave Printing method
∙ After filling the Concave part of Gravure cylinder with ink, Printing with pressure by Back-up Roller
Excellent Coating Uniformity
∙ Not influenced by external variables such as Pressure change applied to the roll
Thin film Coating – from Nanometer(㎚) to Micrometer(㎛)
“Coating + Speed/Tension + Dry/Lamination Control = Stable Production“
Ⅳ.Technology
Partial Control System of Dry lamination
12
Ⅳ.Technology
Dry lamination Parts and Systems
Dancer & Web guide Gravure coater Hot Air Dryer Laminater
• Torque : 0 ~ 300N
• Speed : ~ 600m/min
• Control : CPC[Center Line Guide]
• Tension control &Film centering & Anti-shake
• Speed : 300mm/s
• Pressure : 0 ~ 50kg
• Coating Thickness :Control as Roll dyne [㎚~㎛]
• Dryer Length : 6m
Total 6zones – Stable drying
• Temperature : ~ 150℃
• Speed : 300mm/s
• Pressure : 0 ~ 200kgRoller Height & Pressurecontrol
• Temperature : ~ 200℃
• Joint R&D of “Adhesive and Surface treatment agent” → Improved Durability & Reliability
Material technology
13
Collaboration with manufacturers
“Polyolefin Adhesive & Cr3+/Polymer Surface treatment agent”
Ⅳ.Technology
Surface treatment
agent
Al foil : Polarity , Adhesive : Non-polar
Different properties, Low bond strengthApplication of Surface treatment agent
Increases adhesion between Film and AdhesiveImproved Adhesive strength
Aluminum foil
Adhesive
CPP film CPP film
Adhesive
Aluminum foil
Optimization of Materials
14
• Low Chemical resistance compared to Extrusion lamination
→ Joint R&D with manufacturer (※ Surface treatment agent & Adhesive)
• Optimization of Materials → “Ensure Product Reliability” (※ Adhesive strength & Electrolyte resistance etc.)
Ⅳ.Technology
Value Chain
Materials Manufacturer
Nylon film
Al foil
CPP film
Surface treatment
1st Adhesive
2nd Adhesive
Manufacture Process
15
V.Process
Adhesive
1st Adhesive (NY/Al) 2nd Adhesive (Al/CPP)
Polyurethane Polyolefin
Aging condition
1st Aging (NY/Al) 2nd Aging (Al/CPP)
50℃ × 4days [5days]
Properties Test
16
• Properties test for Reliability & Quality of the Pouch film
• Ensure Product Quality → Adhesive Strength, Electrolyte resistance, Formability and Heat seal strength etc.
VI.Property
Test equipment and method Adhesive Strength Electrolyte resistance
Adhesive strength by Dry tem. Of Surface treatment agent
Adhesive strength by Process conditions of Adhesive
Electrolyte resistance by Process conditions of Adhesive
• Dry temperature at 100℃ :
Excellent Adhesive strength
• Less than 80℃ :
Insufficient drying, Poor bonding
• Adhesive Dry temperature at 80℃ : Excellent Adhesive strength & Electrolyte resistance
• Above 100℃ dry temp. : Adhesive strength Decreases due to adhesive hardening
• Good Property in the best working Speed : 18m/min
Properties Test
17
VI.Property
Formability Heat seal strength
Seal bar
Formability by Adhesive coating thickness Heat seal strength by conditions
CoatingThick. 5㎛ Forming depth6mm CoatingThick. 7㎛ Forming depth6mm
• Adhesive Coating Thickness : Affects Formability
• Increased coating thickness,
Reduced flexibility of adhesive & Reduced formability
• Heat sealing Temperature 180℃ & Time 3sec
Excellent Heat seal strength
• Excessive temp. & time : CPP film thermal deformation
Optimization of Process & Properties
18
• Process Optimization
• Comparison of Properties with Competitors Self-assessed measurement
VI.Property
Properties Unit TOPnC Competitor (日)
Thickness ㎛ 153 153
Adhesive Strength N/15mm 23.5 18.5
(1) Electrolyte Resistance N/15mm 10.3 11.3
(2) Forming Depth mm 6.0 5.5
(3) Heat Sealing Strength N/15mm 156.0 128.8
⦁ (1) Electrolyte resistance : immerse it into electrolyte (EC:DEC:DMC=1:1:1, LiPF6 1M) at 85℃ , after 24hr⦁ (2) Forming size : 4 cm x 5 cm / Pouch size : 14 cm x 17 cm⦁ (3) Heat Sealing strength : Sealing temp. 180℃ / Pressure 40kgf / Time 3sec
CoatingLaminating
Surface treatment agent Adhesive
Thickness Speed Dry temp. Thickness Speed Dry temp. Pressure Speed Temp.
< 1㎛ 6m/min 100℃ 3~6㎛ 18m/min 80℃ 130kg 18m/minAl/NY 60℃
Al/CPP 100℃
Customer Verification Test
19
• Tested by the Customer for Product & Technical verification → All Passed
Test report
No Properties Spec Result
3 Thickness 153±3 ㎛ 154
5 Formability ≥ 4.7mm 4.7
7Heat seal strength
≥ 50N 135.6
10Electrolyteresistance
> 34.5N 94.8
11Adhesivestrength
≥ 3N 6.6
Domestic Car Maker Test report [2018.09]
VI.Property
Customer Verification Test History
CustomerChina (Battery, Automobile, Energy companies) Domestic car
makerA R K Q G C J
Model No. TCMP 153 TCMP 113 TCMP 153 TCMP 113 TCMP 113 TCMP 113 TCMP 113 TCMP 153
Date 2017. 08 2017. 08 2018. 07 2018. 08 2018. 08 2018. 08 2019. 01 2018. 09
Result PASS PASS PASS PASS PASS PASS PASS PASS
China Battery Company(K) Test report [2018.07]
※ TCMP113 for Mobile/IT , TCMP153 for Electric vehicle
APPENDIX
Company Overview
20
VII. Team
Shareholders Number of shares Equity ratio(%)
Technical holding of Hanbat Univ. 33,600 21.5
CEO. Kim 122,572 78.5
Total 156,172 100.0
Company
CEO
Establishment
Product
Capital
Address
TOPnC Co.,LTD.
Dong Soo, Kim
2014. 08. 07
Secondary battery Pouch, Functional film, R2R equipment, 3D Printing
8.62 billion won
125, Dongseo-daero, Yuseong-gu, Daejeon, Republic of Korea
Shareholders
URL www.topnc.co.kr
Intellectual Properties
21
• Patents and Technology for Pouch film & Equipment
VII. Team
Company CertificationPatents
Application Registration
• Recognition of Company affiliated research institute
• SME Certification (※ SME : Small and Medium Enterprises)
• Venture Business Certification
• Industry-University Cooperation Agreement
17 27
• Patent Application & Registration for “Product & Manufacturing
technology & Equipment & Evaluation equipment”
THANK YOU