In WP2, the cell requirements were identified and the cells fitting these, purchased. The cells were tested (TR), successfully developing a TR model.
The design of BB1 has been proposed (CFD simulations and CAD designs), 3D printed onto dummy cells. The micro channels showed no leakage when circulating water. The same process with real cells is ongoing to be tested and assembled into cell units to test the efficiency of BB1. The results at cell level are in D2.5 and will be shown at cell unit level in D3.2.
Temperature sensors (BB2) are being developed with bio-based and recycled contents. A design and a formulation have been proposed, showing good resistivity properties. Work still has to be done due to the unforeseen effect of humidity. Hydrogen sensors (BB2) are also being developed. Their resistance proportionally increases with the increase of concentration of hydrogen, even at low levels. However, the response time is still too slow (20 s), more work is needed to reach the objectives.
In WP3, cell units will be assembled using the CAD from D3.1 to demonstrate the scalability of BB1. The tests on cell units will start in Dec 2024. Innovative busbars were successfully developed. BB3 was designed, 3D printed and tested. It combines heat dissipation, ease of assembly by welding and ease of disassembly using a first and a second life busbar. It contributes to the objectives of an increased safety during operating steps. Two different designs of BB4 "easy-to-dismantle" have been developed. The decrease of time needed for disassembly as has been assessed to >90% compared to welded busbars and the risks of electrisation almost disappears.
In WP4, a generic module was designed. SRP material formulation was developed with PA and PET incorporating FR to reach V0 classification. Their recyclability was studied. The thermoplastic was recovered at >85% and the FR at >50%. Their mechanical properties being too weak, PC was chosen to 3D print the casing. BB7 was designed using simulations of TR, the tests to confirm its efficiency have started and show promising results.
In WP5, the decision tool is designed. It allows the study of 2 cells (LFP and NMC) and will include all the BBs. It implements a multi-criteria decision analysis approach to evaluate and rank different combinations of BBs.
To ensure sustainable lifecycle at module level, few technical developments were assessed using LCA tools. For now, BB1 has a lower environmental impact (decrease of 20%) compared to classic thermal management solutions due to the reduced weight. VERSAPRINTs inks from BB2 have a lower environmental impact than commercial inks (carbon footprint reduction of 40%). The study of BB3, BB4, BB5, BB6 and BB7 will be shown at M21.
