CATHODE​

Cathode active materials (NMC reference and LFP) from primary and recycled raw materials will be prepared. As a more innovative approach, the LNMO cathode is also synthesized. The aim is to use raw materials from spent batteries and the metal refining industry from the EU region and thus decrease the supply chain risk. WP3 also aims to produce engineered carbon materials and additives to be used in cathodes for the improvement of cyclability and safety.

 

ANODE

​Our aim to develop an advanced anode material by integrating natural graphite, recycled and healed graphite from ASP cells, synthetic graphite, and nano-dispersed silicon powder. This innovative composite will enhance energy density of anode, improve cycling stability achieving 2 000 cycles at 80% initial capacity, and support sustainability efforts in lithium-ion battery production, providing a competitive solution for high-performance energy storage systems.​​

 

SEPARATOR

SAFELOOP will qualify enhanced safety battery separators coated on the exterior with a layer of nanoscale alumina. SAFELOOP will furnish 25-micron thick separators, manufactured from ultrahigh molecular weight polyethene and polypropylene. Silica-filled separators will be evaluated as well. Later we will qualify 15- and 20-micron thick separators, both coated and uncoated. The coating pigment, based on alumina nanoparticles, will be supplied by CCM and the application of the coating will be done by AETC using atomized mist aerosol spray of a dispersion with RT-curable binders.

 

ELECTROLYTE

SAFELOOP will design and develop optimized non-flammable, non-aqueous liquid electrolyte formulations compatible with the project defined primary and recycled anode, cathode and separator to provide 15% improved long-term galvanostatic cycling stability (2000 cycles, 80% initial reversible capacity, C/3 rate at Room temperature) compared to the 2019 baseline cell chemistry, through the formation of effective solid electrolyte interphase (SEI) on anode and cathode electrolyte interphase (CEI) on cathode combined with improved safety (flame retardancy) achieved through implementation of targeted functional additives/co-solvents.

 

POUCH CELLS

Tubitak will perform 2 Ah capacity pouch cell development studies. To do so, anode and cathode active materials delivered in previous steps are going to be utilized. Technical parameters will be optimised during electrode development studies.

 

SAFETY ASSESSMENT​

The safety concerns involved with the flammable SoA battery electrolytes will be addressed through an in-depth study of identified flame-retardant electrolyte additives and co-solvents[DS10] . The newly developed electrolyte formulations (T5.1) will be characterized in terms of safety properties, both on the electrolyte and lab cell (coin, EL CELL- and 2Ah pouch levels. The characterization of the safety properties will include flash point measurements using a commercial flash point analyzer and self-extinguishing time (SET) measurements​

 

BATTERY PACK

​SAFELOOP will perform a comprehensive assessment of the impacts of changes in the recommended BoM of a Gen 3 EV-grade battery based on the tangible benefit it will bring to the performance of the cells. This includes seeing how changes proposed are going to manifest themselves during the entire life cycle of EV batteries, which include the use of these cells in a battery pack, its testing performance, its performance maintenance, transportation, cell disassembly and recycling, and other important life cycle-related considerations. Importantly, the focus will remain on showcasing safety enhancements primarily around comparing the 3 iterations cells produced by SAFELOOP with the existing SoA Gen. 3 cells, which will be tested at the project's outset, specifically for mobility applications.

 

TESTING IN E-BUS CONDTIONS​

A road test, charge-discharge test and performance test will be applied to the BOZ bus.

 

BMU/BMS​

SAFELOOP will implement safety enhancements at the BMU level, such as the cell-sensing part of the BMS and then to recommend how those changes can be integrated into the EV design at the BMS level. To perform these tasks, Yunasko will be supported by Tubitak. These organizations represent industry representatives skilled in BMU design and optimization. It is understood that batteries consisting of slightly different cells can become imbalanced and that any imbalance will propagate, potentially leading to catastrophic malfunction, if there is no BMU that equalizes and compensates for the differences in the individual cells.