Professional supercapacitor pilot line solutions from TOBGROUP. We provide customized supercapacitor pilot line equipment, installation, and process optimization support.
TOBGROUP is dedicated to bridging the critical path from laboratory to industrialization for supercapacitor technology, offering a full-stack supercapacitor pilot line solution. It focuses on the validation of high-power density electrode processes, matching of fast-charging electrolytes, design optimization for ultra-long cycle life, and development of low-cost manufacturing processes, providing a bridge to mass production for advanced systems like activated carbon-based, graphene-based, and hybrid types.
The supercapacitor pilot line adopts a dual-core philosophy of "High Flexibility Design + Mass Production Standards". While ensuring data reliability and process stability, it supports rapid iteration of electrode formulations and structural designs, significantly accelerating customers' product commercialization.
Core capabilities cover:
● Capacity Range: 500–5000 cells/day (Supports phased expansion)
● Specification Compatibility:
(1) Coin cells: Φ12–Φ25mm
(2) Cylindrical cells (Wound): Diameter Φ15–Φ60mm, Height 30–150mm
(3) Prismatic cells (Stacked): Single cell capacity 1–5000F
● Core Processes:
High solid-content slurry dispersion → Wide-gap coating (200–400μm) → Multi-stage hot pressing → Winding/Stacking assembly → Dry process vacuum electrolyte filling → Laser welding sealing → Formation & Aging → Power characteristic testing → Full lifecycle data traceability
TOBGROUP Supercapacitor Pilot Line Standard Configuration with Full Customization Support
|
Parameter Item |
Standard Configuration / Range |
Customizable Extension |
|
Standard Capacity |
2000 cells/day |
500–5000 cells/day |
|
Max Capacity Range |
1–5000F |
0.1–10000F |
|
Power Density |
≥15 kW/kg |
>25 kW/kg (Optimized) |
|
IR Control (DCIR) |
≤0.3 mΩ·F |
Supports <0.1 mΩ·F solutions |
|
Key Process Modules |
Slurry Dispersion/Coating/Hot Pressing/Assembly/Filling/Sealing/Testing |
Dry electrode/Full-auto sorting add/remove |
|
Data Collection Points (MES) |
150+ |
Expandable to 400+ |
|
Environmental Control |
Dry Room (≤30% RH) |
Inert atmosphere glove box (Optional) |
|
Typical Delivery Lead Time |
18–26 weeks |
14–32 weeks |
● Power Density-Oriented Process Design
(1) Electrode Process: Specializes in highly conductive slurry formulations (Solid content ≥65%), custom wide-gap coaters (accommodating 200–400μm thick electrodes), multi-stage hot pressing controls electrode density gradient.
(2) Electrolyte Wetting: Vacuum negative pressure filling technology enhances wetting efficiency and reduces bubble retention (Filling accuracy ±0.1g).
(3) Sealing Reliability: Laser welding + metallized packaging process, leakage rate <1×10⁻⁸ mbar·L/s.
● Full Lifecycle Data Chain
(1) Integrated MES + SCADA systems enable real-time tracking of:
Slurry rheological properties → Coating areal density consistency (CV≤3%) → Electrode porosity distribution → DC Internal Resistance (DCIR) → Power decay curve.
(2) Establishes performance degradation models for accurate prediction of capacity retention after 100,000 cycles.
● Mass Production Readiness
(1) Supercapacitor pilot line equipment selection shares origins with mass production lines (e.g., scaled-down coater web width design, same laser welder models).
(2) Process windows can be directly extrapolated to mass production with >90% feasibility (Validated by 20+ projects).
● Advanced Technology Pre-R&D Platform
(1) Supports process validation for new systems like graphene aerogel electrodes, ionic liquid electrolytes, and solid-state hybrid capacitors.
(2) Continuous dry electrode processing equipment (Optional): Reduces solvent use, increases energy density by 15%.
|
Phase |
TOB Core Service Content |
|
Needs Diagnosis |
Analyze target performance (Power density/IR/Life), material system (Activated carbon/Graphene), cost boundaries. |
|
Supercapacitor Pilot Line Design |
Provide Process Flow Diagrams (PFD), equipment 3D layout, dry room (≤30% RH) & explosion-proof environment design. |
|
Equipment Customization |
Supply core equipment: High-shear disperser, wide-gap coater, multi-stage hot press, winding assembly machine, vacuum filling station. |
|
Debugging & Optimization |
TOB engineers on-site complete: Electrode process window locking (Compaction density/Porosity), 100k cycle life validation. |
|
Technology Transfer |
Training content: Dry electrode control points, power testing standards, fault diagnosis tree, MES data mining methods. |
|
Ongoing Support |
Provide mass production line expansion planning, material supply chain resources (High-performance activated carbon/Electrolyte). |
Core enablers of technological implementation
Actionable insights from planning to execution
● Electrode Process: Supercapacitors require ultra-thick electrodes (200–400μm vs. typically <100μm for Li-ion), slurries demand high conductivity and low binder content.
● Assembly: No separator required, wound structure is simpler. Formation: No lithiation needed, but requires high-precision power testing.
Uses a three-level control:
(1) Slurry rheology modification (thixotropy optimization)
(2) Gap coater head + multi-zone drying ovens
(3) Online areal density laser detection + real-time feedback adjustment.
Yes, supports quick changeover: Through modular fixtures (coater winder shafts / winding mandrels) and MES recipe management, changeover can be completed within 4 hours.
(1) Reduce current collector resistance (Ultra-thin foil/Surface etching)
(2) Electrode porosity gradient design
(3) Low viscosity, high conductivity electrolyte
(4) Laser welding to reduce contact resistance.
Organic electrolytes (e.g., ACN) decompose upon contact with water, producing gas. Capacity fade rate increases 3-fold when humidity >40% RH (Based on TOB measured data).
TOB provides a "Process Scale-up Factor Package": Includes coating speed scaling ratio (Pilot:Mass Production = 1:3.2), hot press pressure transfer model, electrolyte volume scaling algorithm.
Utilizes a "High Temperature + High Voltage" dual-stress method (e.g., 2.7V @ 65°C). 1,000 test cycles under these conditions can be equivalent to 100,000 cycles at 25°C standard conditions, with data deviation <5%.
TOBGROUP delivered a 3000F 60138 supercapacitor pilot line with full equipment, materials, and on-site commissioning support.
TOBGROUP designed a Na-ion battery lab line producing 18650S, 32138S, 32140S cells for advanced research and development.
TOBGROUP delivered a full-cycle 5MWh pouch cell production line for Li-ion and Na-ion, enabling European energy storage production.
