Periodic Reporting for period 1 - Reliefed (3D tab cooled Battery pack solution based on an innovative 3D extrusion manufacturing process to better manage thermal regulation of EV batteries)
Période du rapport: 2023-01-01 au 2023-12-31
Thermal regulation is central in an efficient battery pack. Especially if you want to combine a long service life with fast rechargeability and high power outtake.
Reliefed’s proprietary z.trusion® technology is a disruptive manufacturing technology that allows to produce tab cooled battery packs in mass production at low cost with minimal environmental impact. Z.trusion® integrates rotating die(s) in the pressurized zone of the extrusion tool.
This is an enabler to create 3D structural optimised topology on the aluminium profile with an extrusion speed of ~0.4 m/s. The aluminium profiles are, in the initial design, 90mm wide and 8mm thick, and provide grooves for fixation of cells, and heat transfer with integrated cooling channels.
The technology allows for different cell formats (e.g. cylindrical cells, prismatic and pouch).
A 95+% lower production costs and less environmental impact can be achieved compared to traditional manufacturing alternatives.
A manufacturer for the aluminum extrusion line has been chosen (Prizma engineering) as they could deliver on technical requirements, cost and time.
Battery pack building and testing: Reliefed has signed a statement of cooperation with Polestar. The objective is to within the EIC project, adapt the z.trusion® technology to fit with Polestar research activities within battery pack development.
Reliefed has evaluated different cooling channel concepts suitable for Polestar battery architecture and suitable for the Reliefed z.trusion® technology. Reliefed has received system technical requirements for CFD simulations and CAD dimension requirements. A cooling design has been presented to Polestar which will be the base for the next step in the project, which is to order a mockup for physical test evaluation at Polestar test center.
The next steps are to:
• Order physical aluminium profile mockup to be evaluated at Polestar in a complete battery module setup
• Order test equipment for thermal evaluation at Reliefed test center
• Perfom thermal evaluation at Polestar and subsequently at Reliefed
• Evaluate results
• Update profile design with regards to test results and z.trusion® manufacturing tooling requirements.
• Develop z.trusion® tool with CAD and extrusion simulations