Concepts and References for Flexible Modular Battery Cell Production - Version 2??

This article is based on Discussions and Text by Christoph Siara and Wilhelm Graupner, mainly to invite discussion and learn jointly in a wider community.

Why ?

Once a battery cell production site is operational the industry will have seen changes in cell requirements and production technologies will have progressed. A living factory is needed. That means flexibility over time and modularity to facilitate change. Not changes on a daily base but the ability to modify the product and production process to stay most competitive.

Modular flexible production will mean to deal with (1) product-driven changes as well as (2) production process change that will happen to improve cost and environmental impact. The first Element is mainly due to chemistry as well as architecture (mechanical mainly)

(1) Examples for Product-Driven Flexibility in Architecture and Chemistry

• Modular Design and Automation: Modern battery production lines are increasingly adopting modular approaches. This flexibility allows for rapid adaptation to new technologies and changes in battery chemistry. For instance, Manz AG offers modular production equipment that covers the entire battery production value chain, enabling efficient scaling from prototype to large-scale production? (Manz High-Tech) . Italvolt's gigafactory in Italy exemplifies this approach, focusing on modular designs to cater to various battery formats and chemistries, ensuring the facility can quickly adapt to market and technological changes (Italvolt) .
• Integration of Advanced Technologies: Volkswagen's PowerCo is developing a unified cell design that can accommodate different cell chemistries within the same production line. This design reduces complexity and maximizes cost benefits through scaling while maintaining flexibility in terms of cell chemistry and performance classes? (electrive.com) .

(2) Example for Production Process Changes adding requirements to Modularity: Wet to Dry

• Dry Coating Technology: Dry coating eliminates the need for the traditional wet slurry method, significantly reducing energy consumption and factory footprint. This method uses a powder mixed with a binder, applied to the metal foil without the need for solvents. Companies like Tesla, Volkswagen, and several other major players are actively developing and scaling this technology? (EV Tech Intl)? (CleanTechnica)? (electrive.com) . Tesla's implementation of dry coating at its Gigafactory in Austin, Texas, aims to reduce production costs and energy usage. Despite challenges in scaling the process, particularly with the cathode, the potential benefits include a smaller factory footprint and lower energy requirements? (CleanTechnica) . Volkswagen's PowerCo has also invested in dry coating processes, aiming to apply this method in large-scale production by 2027, which could cut energy consumption in production by 30%? (electrive.com) . Dry coating not only lowers production costs but also enhances sustainability by eliminating hazardous solvents used in wet processes. The process simplifies production, reduces energy requirements, and lessens the environmental impact of battery manufacturing? (EV Tech Intl)? (electrive.com) .

(3) Ramping to low waste or high yield and keeping it there

(4) Impact on Recycling

For recycling a modular approach is required too. There are several "bifurcations" in the "EU System" which make the topic a bit "intricate".

• 1. the current system is designed to accommodate the lead-acid and A, AA, AAA battery cells business model, and functions as a closed loop.
• 2. the new battery regulation incorporates this system and seeks to enlarge it to li-ion battery manufacturing.
• 3. EU recycling norms if in place, have not (yet) been implemented on national level.
• 4. Metal Recycling Economy, Waste management is a "dirty" business, with some virtuous exceptions, governed by a regulatory jungle.

What is there to recycle ? Battery Packs, Battery Modules, Battery Cells. Connectors, Electronic Management Components, Tapes, Glues, Shields....

Whatever the form-factor, down to the battery cell is all quite straight-forward, technically - it gets dis-assembled and "recycled". For Battery cells, depending on chemistry, the last resort (safety) - is pyrolysis, otherwise hydro-met., recovering Cathode and Anode components - so called black mass, to be recycled and re-used. Closed-loop recycling - re-use within the same value chain - is a major research field for all applications.

(5) References and Implementations

• Manz AG: Offers comprehensive solutions for modular battery production, emphasizing flexibility from prototype to large-scale production. Manz AG
• Italvolt: Building a flexible, modular gigafactory in Italy for diverse battery formats and chemistries. Italvolt
• Volkswagen PowerCo: Investing in dry coating technologies and unified cell designs to streamline and future-proof battery production. Volkswagen PowerCo
• Tesla: Implementing dry coating processes at its Gigafactory in Austin, targeting cost reductions and energy efficiency improvements. Tesla

For the this and the next version we will mainly aim to include more known best practices in the current chapters rather than expand the current article.

This is still a start and claims by no way to be complete - please let us know what you might miss here.