Advanced Manufacturing Processes

for Low Cost Greener Li-ion Batteries

Joint EC / European Green Cars Initiative

Clustering Event 2012
Fondation Universitaire, Rue d'Egmont 11, 1000 Bruxelles

11/12 July 2012

GC.NMP.2011-1
Project financially supported by
7th Framework Program of the
European Commission under
Grant Agreement no. 285268

GREENLION
Advanced Manufacturing Processes for
Low Cost GREENer Li-ION Batteries
Call: FP7-2011-GC-ELECTROCHEMICAL-STORAGE
Topic: Advanced eco-design and manufacturing processes for batteries
and electrical components
Grant Agreement #285268
Total budget: 8.6 M
EC contribution: 5.6 M
Starting date: 1/11/11
Duration: 4 years

GREENLION CONCEPT
From green materials to greener batteries
Actions at 3 key levels of the battery value chain:

Electrode

Cell

Module
with integrated
BMS

i) more environmentally
friendly production of
the battery components

ii) substantial shortening

of the battery assembly
procedure

Battery
pack

iii) easier and more effective

disassembly and end-of-life
recycling

i.Electrode Processing
- Aqueous Processing of Natural Binders
(independent of active materials chemistry starting selection: C/LFP)

GREENLION
Improvements
Aqueous slurries WASTE/ ECO
Non-fluorinated polymers RECYC
COST
Non-thermoplastic polymers COST
Laser cutting COST

Cell Assembly

- Slot-die coating process adjustment on pilot line

ii. Cell Assembly

GREENLION
Improvements
Laser cutting instead of die
notching COST

Stack-Winding process COST

Eco-friendly bonding process

ECO

Pre-drying for lower dry room

requirements COST

More efficient and long-life cell

sealing ECO
Adjusted formation step time
COST

iii. Module Design & Assembly

Pouch cells

Module
Testing

Battery Pack

Module
Assembly
Packaging &
Management
System

GREENLION
Improvements
Automation of module assembly process
COST
Easy disassembling for maintenance
and recycling at their end of life ECO
Lighter battery module design through
air cooled solutions ECO/ COST

- Lighter module design through air cooled solutions:

Electrical and thermal simulation of GREENLION cells to develop a module including BMS (SOC, SOH algorithms,
equalization) and Thermal Management System.

- Eco-designed bonding techniques to improve sealing and disassembly:

Degreasing and activation/primering of surfaces for structural bonding. Adhesives/glues with additives to activate
easier disassembly for maintenance/reuse/recycling.

- 3D design of automatic battery module/pack assembly line:

Pilot line in 3D (validation of a prototype for Key-Processes) as a turn-key production line for Li-ion module
manufacturing (Cycle time: 3 sec/cell production capacity 880MWh/year)

...through an step by step approach:

Electrode

GEN1

Cell

Module

GEN2

GEN3

Electrodes (0.5 m2, s.s.)

Laboratory coater

Electrodes (m2, d.s)

Industrial pilot plant coater

Cells (ca. 5 Ah)

Cells (ca. 20 Ah)

Modules

GREENLION Consortium
16 partners from 7 member states:

10 Industries
(8 Large, 2 SME)
3 Research Institutes
3 Universities

GREENLION Partnership and Roles

CELL

MODULE
Electrodes

Manufacturing

Design /
Assembly

Specs. /
Validation

IND

RES

Materials

Recycling / LCA

NOTE: atribution of roles to partners not exhaustive; here limited to only one mention per partner for clarity

WorkPackage structure
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

2.1 Battery materials for

aqueous coating
UL, POLIMI, SOLVAY, TIMCAL, WWU

WP2
Advanced
electrode
development
& testing

2.2 Formulations and processes for aqueous coatings

WWU, ENEA, UL, SOLVAY, TIMCAL

2.3 Characterization and testing of electrodes

ENEA, WWU, POLIMI, VW

MAIN
ACHIEVEMENTS

SO FAR

Selection of components
for GEN1 cells ( 5Ah):
Graphite / NMC

0.5 m2 negative and

positive electrodes for
GEN1 cell:

CMC binder

DELIVERED

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

WP3
Cell design,
development
& testing

3.2 Cell assembly process optimization

3.1 Cell specs &
design
CEGASA, KEMET, WWU,
ENEA, RESCOLL

KEMET, CEGASA, RESCOLL, CIDETEC, WWU

3.3 - Cell testing procedure

3.5 Cell simulation &

modelling

AIT, CIDETEC, ENEA, WWU, VW, SEAT

AIT, CIDETEC

3.4 - Testing and evaluation of Cells

ENEA, AIT, CIDETEC, WWU

MAIN

Design of the final

GREENLION cell ( 20Ah)

ACHIEVEMENTS

UNDERWAY

SO FAR

Manufacture of GEN1 cells

from fluorine-free binders,
small area electrodes
ABOUT TO START

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

WP4
Battery module
eco-design,
assembly &
testing

4.1- Battery module design

4.3 - Testing procedure

CIDETEC, CEGASA, AIT, RESCOLL, SEAT, VW

AIT, ENEA, CIDETEC, SEAT

4.2 - Assembly processes development

4.4 - Battery module testing

CEGASA , CIDETEC, AIT, MASS

AIT, ENEA

MAIN
ACHIEVEMENTS

SO FAR

Design of the GREENLION battery modules

UNDER DISCUSSION
COUPLED WITH CELL DESIGN & ECODESIGN

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

5.1: Electrode manufacturing

process on pilot line
PCF, CEGASA, SOLVAY, TIMCAL, WWU

WP5 Manufacturing of electrodes,

cells & modules in pilot-line

5.2: Cell manufacturing

process on pilot line
KEMET, CEGASA

5.3: Design battery module

assembling processes/equipments
MASS, CEGASA

MAIN
ACHIEVEMENTS

SO FAR

Electrode manufacturing :
transference from lab-coater
to industrial pilot line :
ALREADY STARTED

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (LCA & Reuse/

Recycling Strategies)

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

6.1: Regulatory assessment

concerning REACH- CLP (GHS).

Task 6.2: Eco-design

Task 6.3: LCA
RESCOLL, TR, CEGASA, SEAT

Task 6.4: Recycling/Reuse

TR, RESCOLL, CEGASA, WWU, TIMCAL

RESCOLL, TR, TIMCAL

Benchmarking on recycling
processes done

MAIN
ACHIEVEMENTS

SO FAR

LCA& ecodesign ;
gathering of inputs from partners
reference cell
Greenlion cell

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

Task 7.1: Specs. of

demonstrator and
validation test plan
SEAT, CEGASA, VW

WP7
Demonstration
of battery
module
& validation

Task 7.2: Battery-pack

production process
validation

Task 7.3: Testing and

Validation of battery module
SEAT, VW

CEGASA , KEMET, MASS

MAIN
ACHIEVEMENTS

SO FAR

SCHEDULED FOR 4TH YEAR

WP7 parners already
contributing in other related
WPs, esp. in 4.1 Battery
module design

WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP2
Advanced
electrode
development &
testing

WP3
Cell design,
development &
testing

WP4
Battery module
eco-design,
assembly &
testing

WP7
Demonstration of
battery module &
validation

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

WP8 Dissemination, Exploitation

& Training

8.1: Training activities

RESCOLL, All partners

8.3: Exploitation of results

8.2: Dissemination
RESCOLL, All partners

MAIN
ACHIEVEMENTS

SO FAR
www.greenlionproject.eu

CEGASA, All partners

Exploitation Potential
The key objective of GREENLION is to improve lithium ion battery cells & modules at
cell and module components processing, assembly and manufacturing
lowering production costs
energy and environmentally friendly processes

...specifically aiming at electric vehicle applications.

Ten out of sixteen partners (62%) in GREENLION are industries including:
materials suppliers (SOLVAY, TIMCAL),
machinery developers (POLYTYPE , KEMET, MONDRAGON ASSEMBLY),
battery manufacturer (CEGASA),
(recycling) process developer (TECNICAS REUNIDAS)
automotive end-users (SEAT, VW).

...covering the whole battery manufacturing value chain

Also, GREENLION will provide advances to a number of scientific and engineering challenges
for battery cell and module manufacturing.
The successful resolution of these challenges will lead to breakthroughs in Li Ion batteries to
be directly exploitable by industry and scientific contributions to benefit the tech. community

Topics for cooperation within the cluster

in contact with ELIBAMA similar

project running in parallel:

ANYWAY:
Several clusters of projects with related scope

i.e. GREENLION partners in:

HELIOS, AMELIE, CORE, SOMABAT, DELIVER, E3CAR,
EDASH, ELVA, MOTORBRAIN, SMART-LIC.....

Technical topics

i.e. see program!!

Cross-participation of individual partners in

complementary projects

Participation in ELCAR
project workshop on LCA:

Cross-cutting issues

materials, processing
recycling, LCA
BMS, module development
benchmarking
standards

Dissemination & Training

Thank you !!

[email protected]