Purpose
The formation process for secondary batteries is a critical step that induces electrochemical reactions inside the cells to stabilize their initial performance. This process is typically carried out by repeating charge–discharge cycles while the cells are under applied pressure, and the equipment used for this purpose is the PPC (Press Plate Chamber).
A PPC is composed of multiple channels, each of which holds an individual cell. Because of this multi-channel configuration, the degree to which pressure is applied uniformly across channels is a key performance parameter for the equipment.
If pressure is not uniform, performance variability can occur between cells, which may compromise product reliability and safety. Consequently, customers are considering the adoption of PressureScan II to quantitatively verify the PPC’s pressure uniformity and to enable continuous management of this parameter.
Results
Background & Key Considerations
Clients prioritized the following factors when evaluating the adoption of PressureScan II:
1.Data output format: How the pressure distribution is visualized and whether the output supports quantitative analysis.
2.Data storage scheme: Storage format for repeated measurements and equipment history management.
3.Sensor repeatability & reliability: Consistency and reproducibility of measurements under identical conditions.
Solution Deployment & Testing
1. Repeatability verification
To support the customer’s feasibility assessment, we conducted preliminary tests using an off-the-shelf sensor (SFC4300CX). The PressureScan II sensor is an FSR-type (force sensing resistor) implemented as a thin film. Because the sensing element is exposed in this form factor, measured outputs can vary depending on the material of the pressed object.
To mitigate this variability, applying a force spreader improves measurement stability and repeatability; software calibration can be used in conjunction with the spreader if needed.
Accordingly, repeatability tests were performed with and without spreaders and across different spreader materials, including the spreader material Kitronyx typically recommends for high-rigidity loads.
Test outcome (repeatability):
•Sensor only: approximately ±3% error.
•With force spreader: improved to approximately ±1% error.
•These results demonstrate that PressureScan II enables intuitive and reliable quantitative analysis of the PPC’s pressure uniformity on actual customer equipment.
2. Comparison by spreader material & advantages
Differences in pressure distribution patterns and values depending on spreader configuration are primarily due to local stress concentration that occurs when the sensor contacts a high-stiffness surface (e.g., stainless steel) directly.
Without a spreader, micro-irregularities on the pressed surface are directly reflected in the sensor output, so applied force is not sufficiently distributed; this can degrade repeatability.
A properly selected force spreader reduces local stress concentration, promotes more even load distribution, and therefore improves measurement stability and reproducibility.
When the sensor was used alone, pressure was heavily concentrated at the edges; with a force spreader applied, the load is visually distributed much more evenly across the surface.
Among the tested configurations, Kitronyx recommends the Teflon + Rubber combination. Teflon (PTFE) reduces the influence of macroscopic surface irregularities on the plate, while a compliant material such as rubber compensates for fine-scale surface asperities that occur within the sensor. This pairing reduces excessive localized loading on the sensor — lowering the risk of damage — and improves the stability and repeatability of measurement data.
In summary, a force spreader is a device that evens the contact between the sensor and the pressed object. Although using a spreader may introduce some systematic difference in measured values, it significantly reduces structural error and enables stable, reliable measurement of pressure distribution, yielding more precise data.
To obtain more accurate absolute force and pressure values, there are two recommended approaches:
① Perform calibration with the spreader in place and apply the same hardware configuration during measurement, or
② Use ForceLAB2’s Scale Factor function to correct systematic error.
🎓 Related Materials
[Technical Contents] Characteristics of Sensor Output Variations Based on Applied Material and Solutions
Expected Benefits and Applications
1. On-site implementation approach
By integrating the sensor, force spreader, and jig into a single, ready-to-use module, operators can deploy the system immediately without separate setup.
➡️Related solution: PressureScan II J/F
— an integrated solution tailored for the formation process.
- Improved operability: reduced setup time and simplified operator workflow.
- Measurement reliability: consistent measurements under fixed hardware conditions.
- Efficient equipment management: data-driven management of pressure uniformity.
2. Expected benefits
By measuring and visualizing actual contact pressure distribution in real time (rather than using non-contact methods), the solution contributes to improved equipment reliability and product quality during the formation stage — a critical step in secondary battery manufacturing.
- Optimize equipment maintenance intervals.
- Predict and mitigate process defects before they occur.
- Strengthen quality control through equipment- and process-data-driven management.
※ The features and contents described in this document are subject to change without notice for performance improvement.
The images included are for illustrative purposes and may differ from actual results.
If you have any other inquiries, please leave a message through the URLs below, and we will respond promptly.
For product inquiries: https://www.kitronyx.com/contact
For technical support inquiries: https://www.kitronyx.com/support_request
Purpose
The formation process for secondary batteries is a critical step that induces electrochemical reactions inside the cells to stabilize their initial performance. This process is typically carried out by repeating charge–discharge cycles while the cells are under applied pressure, and the equipment used for this purpose is the PPC (Press Plate Chamber).
A PPC is composed of multiple channels, each of which holds an individual cell. Because of this multi-channel configuration, the degree to which pressure is applied uniformly across channels is a key performance parameter for the equipment.
If pressure is not uniform, performance variability can occur between cells, which may compromise product reliability and safety. Consequently, customers are considering the adoption of PressureScan II to quantitatively verify the PPC’s pressure uniformity and to enable continuous management of this parameter.
Results
Background & Key Considerations
Clients prioritized the following factors when evaluating the adoption of PressureScan II:
1.Data output format: How the pressure distribution is visualized and whether the output supports quantitative analysis.
2.Data storage scheme: Storage format for repeated measurements and equipment history management.
3.Sensor repeatability & reliability: Consistency and reproducibility of measurements under identical conditions.
Solution Deployment & Testing
1. Repeatability verification
To support the customer’s feasibility assessment, we conducted preliminary tests using an off-the-shelf sensor (SFC4300CX). The PressureScan II sensor is an FSR-type (force sensing resistor) implemented as a thin film. Because the sensing element is exposed in this form factor, measured outputs can vary depending on the material of the pressed object.
To mitigate this variability, applying a force spreader improves measurement stability and repeatability; software calibration can be used in conjunction with the spreader if needed.
Accordingly, repeatability tests were performed with and without spreaders and across different spreader materials, including the spreader material Kitronyx typically recommends for high-rigidity loads.
Test outcome (repeatability):
•Sensor only: approximately ±3% error.
•With force spreader: improved to approximately ±1% error.
•These results demonstrate that PressureScan II enables intuitive and reliable quantitative analysis of the PPC’s pressure uniformity on actual customer equipment.
2. Comparison by spreader material & advantages
Differences in pressure distribution patterns and values depending on spreader configuration are primarily due to local stress concentration that occurs when the sensor contacts a high-stiffness surface (e.g., stainless steel) directly.
Without a spreader, micro-irregularities on the pressed surface are directly reflected in the sensor output, so applied force is not sufficiently distributed; this can degrade repeatability.
A properly selected force spreader reduces local stress concentration, promotes more even load distribution, and therefore improves measurement stability and reproducibility.
When the sensor was used alone, pressure was heavily concentrated at the edges; with a force spreader applied, the load is visually distributed much more evenly across the surface.
Among the tested configurations, Kitronyx recommends the Teflon + Rubber combination. Teflon (PTFE) reduces the influence of macroscopic surface irregularities on the plate, while a compliant material such as rubber compensates for fine-scale surface asperities that occur within the sensor. This pairing reduces excessive localized loading on the sensor — lowering the risk of damage — and improves the stability and repeatability of measurement data.
In summary, a force spreader is a device that evens the contact between the sensor and the pressed object. Although using a spreader may introduce some systematic difference in measured values, it significantly reduces structural error and enables stable, reliable measurement of pressure distribution, yielding more precise data.
To obtain more accurate absolute force and pressure values, there are two recommended approaches:
① Perform calibration with the spreader in place and apply the same hardware configuration during measurement, or
② Use ForceLAB2’s Scale Factor function to correct systematic error.
🎓 Related Materials
[Technical Contents] Characteristics of Sensor Output Variations Based on Applied Material and Solutions
Expected Benefits and Applications
1. On-site implementation approach
By integrating the sensor, force spreader, and jig into a single, ready-to-use module, operators can deploy the system immediately without separate setup.
➡️Related solution: PressureScan II J/F
— an integrated solution tailored for the formation process.
2. Expected benefits
By measuring and visualizing actual contact pressure distribution in real time (rather than using non-contact methods), the solution contributes to improved equipment reliability and product quality during the formation stage — a critical step in secondary battery manufacturing.
※ The features and contents described in this document are subject to change without notice for performance improvement.
The images included are for illustrative purposes and may differ from actual results.
If you have any other inquiries, please leave a message through the URLs below, and we will respond promptly.
For product inquiries: https://www.kitronyx.com/contact
For technical support inquiries: https://www.kitronyx.com/support_request