Production of next generation battery cells in Europe for transport applications

The scope of the topic covers production processes for future variants of lithium cells such as advanced lithium-ion not excluding the so-called post-lithium-ion technologies. Developing manufacturing processes specific to a given technology that has not yet reached the necessary level of maturity would be premature and risky. Therefore the topic focusses on the two following areas which could be applied to broader transport modes and even for stationary energy storage applications:

―To evaluate the most promising next generation of Li-ion or post-Li-ion-systems (in comparison with the best-in-class Li-ion-System) that could reach the market in the very near future and clearly identify potential challenges in the manufacturing process that would give Europe a competitive advantage when mastering the most promising improved Li-ion or post-Li-ion chemistry. The project partnership should form a forum of the different players: transport vehicles and vessels manufacturers, Tier 1 suppliers, equipment suppliers and research institutes.

―Develop new production technologies within the different manufacturing stages provided that they are generic enough to show reduced dependency on a specific chemistry to support industrial partners in the area of manufacturing and to increase the knowledge base of production technologies.

Examples of generic technologies might be:

―Battery technologies with Li-anode, bipolar batteries, all-solid-state battery technologies (e.g. ceramics, polymers, post graphite technologies …)

―Electrode coating independent of solvents or solvent free

―New processing techniques (mixing, milling of powders, new dyeing techniques, DryCoating, etc.)

―Technologies that allow integration of in-situ quality monitoring

―Methods of ultrafast handling and monitoring of electrodes (e.g. assessment of electrode quality to minimize scrap)

―Data processing, standardised interfaces according to industry 4.0

―Flexible assembly lines that can accommodate to different cell formats.

―Improvement of coating width and speed, double sided simultaneous coating (of electrode sheets)

―Coatings not needing clean rooms

The Commission considers that proposals requesting a contribution from the EU of between EUR 3 and 5 million each would allow this specific challenge to be addressed appropriately. Nonetheless, this does not preclude submission and selection of proposals requesting other amounts.

The objective of the topic is to support the future development of a production base for next generation Lithium battery cells or post-lithium battery cells in Europe that would be able to compete with present world leaders of the sector. World leaders have started producing batteries and cells of the lithium-ion family since the nineties for mass consumer electronics such as personal computers and mobile phones, giving them the opportunity to acquire experience in mass production, optimize their technologies and create product diversification. Europe is strong in providing the raw electrochemical materials and the production equipment, however experience and knowledge on production at mass scale is missing. Small scale production of lithium cells is taking place for niche applications, but lack of mass markets such as consumer electronics makes mass production for automotive applications unlikely due to high entry barriers but also to less performing electrochemical formulations.

To develop its production base, Europe should develop more competitive chemistries and start-up-scaling production lines and progressively acquire the necessary knowledge and experience to further optimise battery technology.

At the same time, Li-ion technology is evolving rapidly. Several lithium cell variants exist (Lithium Nickel Cobalt Manganese, Lithium Nickel Cobalt Aluminium, Lithium Iron Phosphate, etc.) or are under intensive investigation (e. g. Lithium Sulphur, Lithium Silicon, Lithium Polymer and also a combination of several variants). For the time being none of the variants under investigation that would have a significant impact on batteries energy density (and electric vehicles range) and cost is clearly emerging as the most promising one. In addition, none of these variants reached sufficient maturity to envisage any large scale industrial exploitation. Significant investment in R&D in this area is still required.

Developing mass production of cells based on today's conventional Li-ion technologies would not give Europe an advantage to compete with world leaders in the field because Europe would lag behind in chemistries and manufacturing processes. Asian manufacturers benefit from high economies of scale because of existing mass production infrastructure and thus have the possibilities to commercially hinder new competitors from entering the market. However, Europe is strong in packaging and electronics for batteries.

It is now time to integrate battery cell production technologies into research activities. This initiative is intended to coordinate running national initiatives and prepare for stronger European research and innovation activities to be launched in the coming years. Such activities would support the objectives of the Strategic Transport Research and Innovation Agenda within the Energy Union policy.

―To allow Europe to recover competitiveness without targeting a specific technology in the production of future battery cells for transport and energy applications

―Increase production related knowledge and develop technologies for modular battery cell production lines in order to improve quality and decrease cost of battery cells that are ready to be deployed

―Contribute to sustainable production by either reducing scrap directly or recycling measures

―The results of the research could also benefit battery cell manufacture in Europe for other sectors such as stationary storage and storage for long-distance transport

―The battery concepts should improve energy, power and safety in comparison to current technical standard.