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Project Overview

IK4 CIDETEC GreenLion Electrode Processing

IK4 CIDETEC GreenLion Cell Assembly

IK4 CIDETEC GreenLion Module Design & Assembly

IK4 CIDETEC GreenLion WorkPackage structure

The only way Europe might become competitive against Asian countries in the battery production is through the development of new chemistry/technologies based on innovative materials and processes in this manufacturing value chain, allowing for:

  1. the more environmentally friendly production of the battery components;
  2. the substantial shortening of the battery assembly procedure, and
  3. the easier and more effective disassembly and end-of-life recycling.

 

Altogether, these improvements will allow higher energy efficiency and substantial production cost reductions thus ensuring a real competitiveness based on new technological IP rather than only mass production optimization.

 

In the GREENLION project, we address the above issues by the industrial development of eco-designed processes at the electrode, cell and battery module level. At the electrode processing stage (that will be otherwise independent of the active materials chemistry), developing and making use of:

  1. aqueous slurries rather than toxic organic volatile compounds (25% cost reduction);
  2. non-thermoplastic polymers that allow for high temperature drying, which results in shorter and less expensive assembly procedure (10% efficiency); and
  3. easily disposable non-fluorinated polymers (at expected 10 times less materials cost).

 

At the cell assembly level, further improvements to the existing procedures as well as changes at some steps of the assembly process will be developed to increase energy efficiency and shorten times (and hence lower costs) during the manufacturing process, by implementing:

  1. laser cutting instead of mechanical notching of the electrodes (15% cost),
  2. adjusted stack winding of components from aqueous-based electrodes and their drying process before electrolyte filling and sealing, to lower dry room requirements,
  3. environmentally friendly bonding process for more effective and long-life cell sealing, and
  4. Adjusted formation step time (ideally for electrodes with reduced formation cycle) in cell manufacturing line (5% time reduction).

 

Finally, developing a modular battery allows an easier handling of cells within a complete battery pack. At this battery module level, GREENLION project will design an autonomous unit including its own electrical and thermal management as a simple and reliable building block that will allow the manufacturing and maintenance of the whole battery packs easier and more inexpensively, with the lowest possible environmental impact. This will be achieved by:

  1. Lighter battery module designs (including electronics) by implementing air cooled solutions instead of liquid cooling systems (expected 20% less weight),
  2. bonding process of module housing for safe operation but easy disassembling for maintenance and reuse/recycling at their end-of-life, and
  3. automation of module assembly process (3 seconds per cell vs. manual assembly).

 

These developments will be scaled-up and realized in pilot lines during the project, following a continuous environmental assessment of materials and processes. A validation of the finally assembled battery module will be carried out leaded by the automotive end-user who will also provide the targets and specifications for EV application.