2.5 Electrolyte Filling

Electrolyte filling is the process of introducing a precise amount of liquid electrolyte into the assembled dry cell—whether pouch, cylindrical, or prismatic. A dosing lance is positioned at the cell opening, and electrolyte is dispensed under vacuum or controlled pressure to ensure uniform wetting of the electrodes and separator. Dynamic pressure profiles activate capillary action to fully saturate porous components and eliminate air pockets. In some cases, multiple filling and wetting cycles are used to optimize distribution. After filling, the cell is sealed to prevent leakage and moisture ingress.