Image: Fraunhofer IPAIn traditional battery pack design, multiple battery cells are first grouped into modules, which are then assembled into a battery pack. However, Cell-to-Pack technology eliminates the module level, integrating the cells directly into the battery housing. This reduces the number of components and weight while creating more space for battery cells, which, in theory, should increase the battery capacity and range of the electric vehicle.Nevertheless, the Cell-to-Pack manufacturing process presents specific challenges for recycling. These challenges are the focus of the research project ‘Difference’, funded by the Federal Ministry for Research, Technology and Space (BMFTR) as part of the B@ts battery research initiative. The biggest challenge lies in the replacement of conventional screw connections with large-scale adhesives and foam fillings between the battery cells in Cell-to-Pack systems.These bonding materials, along with the highly integrated design, significantly complicate disassembly and recycling. Removing them requires labour-intensive manual work or thermomechanical processes. The resulting limited recyclability also contradicts the goals of the European Battery Regulation, as the project leaders emphasise. This regulation aims for high recycling rates for critical raw materials such as lithium, nickel, cobalt, and copper.Another issue with Cell-to-Pack systems is the lack of repair concepts. If individual cells fail, the entire battery system often has to be replaced because exchanging single cells is impossible—a cost amounting to several thousand Euros. This also rules out second-life applications.In light of these recycling challenges, the ‘Difference’ project has identified four key research topics:Research into laser-based disassembly methods for structural elements of the battery packDevelopment of laser-based methods for the selective separation of adhesives, foams, and metallic componentsImplementation of automated, robot-guided disassemblyEcological and economic evaluation of the new processesThe goal is to develop a modular, adaptive, and automated disassembly system with four stations. This system aims to enable a comprehensive disassembly process chain for highly integrated battery packs, whether for subsequent recycling processes or for repair and remanufacturing applications.The Fraunhofer Institute for Manufacturing Engineering and Automation (Fraunhofer IPA) is coordinating the project and contributing its expertise from the Centre for Digitalised Battery Cell Production (ZDB), as well as in the development of robot-assisted automation and disassembly technologies for the circular economy. Other consortium members include Trier University of Applied Sciences with its Environmental Campus Birkenfeld, waste management and recycling provider PreZero, automation company Kautenburger, and TRUMPF Laser and System Technology.fraunhofer.de (Link in German)
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