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

Informations projet

Reliefed

N° de convention de subvention: 190176840

DOI

10.3030/190176840

Date de signature de la CE 19 Decembre 2022

Date de début 1 Janvier 2023

Date de fin 30 Septembre 2026

Financé au titre de

• The European Innovation Council (EIC)

Coût total

€ 3 572 004,78

Contribution de l’UE

€ 2 500 000,00

Coordonné par

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)

Période du rapport: 2023-01-01 au 2023-12-31

Résumé du contexte et des objectifs généraux du projet

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.

Travail effectué depuis le début du projet jusqu’à la fin de la période considérée dans le rapport et principaux résultats atteints jusqu’à présent

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

Progrès au-delà de l’état des connaissances et impact potentiel prévu (y compris l’impact socio-économique et les conséquences sociétales plus larges du projet jusqu’à présent)

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.