Circular Economy Difference Research Project Aims to Optimize Recycling Rate for Cell-to-Pack Battery Systems

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The aim of the Difference research project is to improve the recycling rate for battery systems whose cells are no longer installed in modules but directly in the battery pack. This has now entered the implementation phase.

The market ramp-up of electromobility is closely linked to the further development of battery systems. Cell-to-pack (C2P) architectures, in which battery cells are installed directly in the battery pack without module aggregation, enable better energy density and more efficient use of space. However, conventional screw connections are replaced by large-area bonding and foaming between the battery cells.

The highly integrated design and the new connection materials and types make disassembly and therefore recycling considerably more difficult, as their removal requires time-consuming manual work or thermomechanical processes. The resulting limited recyclability is also at odds with the objectives of the European Battery Regulation. This requires high recovery rates for critical raw materials such as lithium, nickel, cobalt and copper.

Creating the Basis for Recycling C2P Battery Systems

In addition, another problem needs to be solved, as there are currently no standardized repair concepts. The failure of individual cells often leads to entire battery systems being discarded. This leaves great potential for second-life applications untapped. However, the selective separation and removal of functioning cells is not yet possible because highly integrated systems can hardly be selectively dismantled.

This is where Difference comes in, with the aim of creating a technologically robust basis for the closed-loop management of highly integrated C2P battery systems. The focus is on four research topics:

• Research into laser-based disassembly processes for structural elements of the battery pack
• the development of laser-based processes for the selective separation of adhesives, foams and metallic components
• the implementation of automated, robot-guided disassembly
• the ecological and economic evaluation of the new processes

All aspects of recycling are taken into account, from design optimization and automated separation to ecological and economic evaluation. The aim of the project is to develop a modular, adaptive and automated dismantling system with four stations. These enable a holistic disassembly process chain to dismantle highly integrated battery packs for subsequent recycling processes or for various "ReX" topics such as repair and remanufacturing.

Impulses for Sustainable Design Philosophies

Difference sees itself as a bridging technology between the physical recyclability of new battery architectures and the political objectives of resource efficiency, emissions reduction and technological sovereignty. The project delivers industry-compatible, scalable solutions and provides impetus for sustainable design philosophies and regulatory innovation paths in the European battery ecosystem. The project involves the Fraunhofer Institute for Manufacturing Engineering and Automation IPA as consortium leader, Trier University of Applied Sciences, Umwelt-Campus Birkenfeld, PreZero Service Deutschland, Kautenburger, Trumpf Laser- und Systemtechnik as well as Ford, Arena2036, BASF Polyurethanes and bdtronic.

The Fraunhofer Institute for Manufacturing Engineering and Automation IPA is contributing its expertise from the "Center for Digital Battery Cell Production" (ZDB) and in the development of robot-assisted automation and dismantling technologies for the circular economy to the project. The focus is on the sustainable use and recycling of batteries through automated dismantling processes.

The knowledge gained is transferred directly into industrial applications and contributes to the development of efficient recycling and repair processes. The institute also contributes experience from previous projects, for example in the evaluation of recycling technologies, ecological analyses and the development of automated dismantling processes. (se)

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