From anodes to smart sensors: the latest COBRA developments
On Tuesday September 8th, the COBRA project hosted its first General Assembly, nine months after the project launch. The actions taken during this first year have centred around the physical and chemical characterisation of battery components and their materials, with a special focus on cathodes and anodes. Following the first characterisation results, the cell specifications and production line for GEN0 have been defined.
In parallel to ongoing activities, the COBRA partners have started to develop a Life Cycle Inventory (LCI), which enables the preliminary cradle-to-gate analysis of GEN1 candidates. This LCI will enable COBRA to understand the different materials, processes and energy needed to produce the battery and to compare the different GEN1 candidates.
Component composition
For the anodes, silicon was secured from several Si waste sources, such as silicon pot scrap from photovoltaics (PV). The silicon powders obtained from different sources were analysed and characterised and the first electrode samples were developed. The production process of silicon powder will be improved over the next months, as well as the further characterisation of both powders and electrodes.
Similarly, for the cobalt-free cathodes, multiple samples were developed and characterised, including SEM material screening, electrochemical testing and advanced structural analysis using spectroscopy, which had promising results. This process will continue over the next few months.
Cell production
In order to test and validate the technology developments, COBRA counts on partner Liacon to adapt and upgrade its production line to produce different battery generations.
In total, 4 different generations of pouch cells are going to be manufactured and tested. The GEN0 large pouch cells (NMC 622) will be produced mainly to test their safety, design and manufacturing methodology, and establish a benchmark for electrochemical performance, environmental impact, and cost. The large pouch cells of GENX, intend to combine the components exhibiting the best overall results from GEN1 and GEN2 into a complete battery pack combining BMS, wireless sensors, as well as the new manufacturing processes and their consequent environmental and economic impact. The GEN0 cells are expected to be delivered by the end of December.
Smart sensors
For the development of new battery modules (hardware and software), special attention will be given to the development of smart sensors. After defining the software and hardware requirements over the last few months, COBRA aims to define the smart sensor testing by December, as well as finalise the concept for the BMS.
The decisions taken on the requirements include the implementation of 2 MCUs that will work in parallel within each smart battery module. Also, within the development of the aforementioned GENX battery pack, it is estimated that there will be at least 3 smart battery modules with various smart sensors to compare. These include a pressure sensor, an Electrochemical Impedance Spectroscopy sensor, a Strain Gauge sensor and a gas sensor.
Moreover, in order to acquire current information (needed to estimate the state-of-charge, state-of-health, and state-of-function) a current sensor will also be included in these smart modules. Nonetheless, the quantities and correlation among these different types of sensors require testing before their implementation in the GENX battery.
Partners are satisfied with the work performed and results so far, and are working to deliver the GEN0 cells by the end of this year!
If you’d like further details on the latest developments in COBRA, or want to reach out to one of the partners, contact cobra@baxcompany.com or visit our Twitter and LinkedIn channels.
