3D tab cooled Battery pack solution based on an innovative 3D extrusion manufacturing process to better manage thermal regulation of EV batteries

Project Information

Reliefed

Grant agreement ID: 190176840

DOI

10.3030/190176840

EC signature date 19 December 2022

Start date 1 January 2023

End date 30 September 2026

Funded under

• The European Innovation Council (EIC)

Total cost

€ 3 572 004,78

EU contribution

€ 2 500 000,00

Coordinated by

RELIEFED AB
Sweden

Periodic Reporting for period 1 - Reliefed (3D tab cooled Battery pack solution based on an innovative 3D extrusion manufacturing process to better manage thermal regulation of EV batteries)

Reporting period: 2023-01-01 to 2023-12-31

Summary of the context and overall objectives of the project

The energy transition in general, and the EV trend in particular, require efficient battery packs. These must be light, strong, thermally regulated, recyclable and cheap.
Thermal regulation is central in an efficient battery pack. Especially if you want to combine a long service life with fast rechargeability and high power outtake.
Reliefed’s proprietary z.trusion® technology is a disruptive manufacturing technology that allows to produce tab cooled battery packs in mass production at low cost with minimal environmental impact. Z.trusion® integrates rotating die(s) in the pressurized zone of the extrusion tool.
This is an enabler to create 3D structural optimised topology on the aluminium profile with an extrusion speed of ~0.4 m/s. The aluminium profiles are, in the initial design, 90mm wide and 8mm thick, and provide grooves for fixation of cells, and heat transfer with integrated cooling channels.
The technology allows for different cell formats (e.g. cylindrical cells, prismatic and pouch).
A 95+% lower production costs and less environmental impact can be achieved compared to traditional manufacturing alternatives.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Establish extrusion and battery test center: A location has been chosen for a test center, which is in Mölndal, southern part of Gothenburg. It is 2000m2 in total divided into an office space and lab area. A structure layout is prepared for commissioning of an aluminum extrusion press which will produce battery cooling aluminum profiles. Plan for key recruitments have been initialized for the commissioning and execution of the test lab. Reliefed is currently going through cv:s and the interviewing process is initiated.

A manufacturer for the aluminum extrusion line has been chosen (Prizma engineering) as they could deliver on technical requirements, cost and time.

Battery pack building and testing: Reliefed has signed a statement of cooperation with Polestar. The objective is to within the EIC project, adapt the z.trusion® technology to fit with Polestar research activities within battery pack development.

Reliefed has evaluated different cooling channel concepts suitable for Polestar battery architecture and suitable for the Reliefed z.trusion® technology. Reliefed has received system technical requirements for CFD simulations and CAD dimension requirements. A cooling design has been presented to Polestar which will be the base for the next step in the project, which is to order a mockup for physical test evaluation at Polestar test center.

The next steps are to:

• Order physical aluminium profile mockup to be evaluated at Polestar in a complete battery module setup
• Order test equipment for thermal evaluation at Reliefed test center
• Perfom thermal evaluation at Polestar and subsequently at Reliefed
• Evaluate results
• Update profile design with regards to test results and z.trusion® manufacturing tooling requirements.
• Develop z.trusion® tool with CAD and extrusion simulations

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

So far, only virtual, so called CFD simulations have been conducted to evaluate the cooling performance using the z.trusion® technology, applied to simplified battery modules. Results indicate very good cooling performance but physical validation needs to be performed before the impact from the results can be evaluated.