SPINMATE: D2.2 Pilot Line and Eco-Design Regulation Towards Disassembly Requirements

This Deliverable is the final result of WP2 – “Specification Requirements and Standardisation for new SSBs”. It reports the output of the two final Tasks of the WP2, namely Task 2.4 – “Define pilot line requirements”, and Task 2.5 – “Define eco-design regulation towards disassembly”. After a brief introduction (Section 1) reporting the context on which the SPINMATE project is founded, the document is divided in two main sections, one for each task. Section 2 – “Pilot line requirements” represents the output of the analysis performed within Task 2.4. In this section, the different manufacturing processes for the SPINMATE cells are analysed from the point of view of the needs of equipment for their upscaling at pilot level. Overall, the manufacturing process consists of four macroprocesses (electrode manufacturing, separator manufacturing, cell assembly, and cell formation), each consisting of several steps. Being the SPINMATE technology based on Li-metal as anode, the manufacturing processes for the two electrodes are meaningfully different and need different equipment. Moreover, within the project two production routes will be tested for cathode preparation: wet processing and dry processing. This Section shows that most of the equipment already present at the partner facilities is suitable for the purpose of the project, apart from some machines for cell assembly and for roll-to-roll manufacturing of the solid electrolyte (separator)membrane. Regarding cell assembly, some modifications have already been planned and will be developed within WP5 – Equipment development and pilot line assembly: (i) Selection of suitable tools for cutting Li-metal anode and electrolyte membrane; (ii) Definition of the peeling system to remove in a semi-automatic way the protective layers from Li-metal anode and electrolyte membrane surface and implementation within the most proper process (i.e. cutting, stacking); (iii) Design of gripper pads and single sheet stacking systems suitable to handle the innovative materials without damaging their surface, while assuring proper layer alignment; and (iv) Bypass of the electrolyte filling in the cell degassing / filling / sealing unit, to simply apply vacuum and close the fourth side of the pouch: liquid electrolyte is not present in the SPINMATE cells, thus the filling operation is not necessary. Regarding separator membrane manufacturing, the modifications to existing equipment would be intensive and not completely necessary for the preparation of the SPINMATE cell prototypes: it has been decided to upscale the single sheet process and to work within WP5 in the definition of suitable machineries for a further upscaling to production. Section 3 – “Eco-design regulations towards disassembly” provides an overview of the design needs to produce sustainable SSB cells, modules and packs. The Section starts with an analysis of the state-ofthe-art design, highlighting limits and drawbacks: current battery technologies are hard to disassemble in an efficient and safe way. Guidelines for battery pack, module and cell design, as well as for safety, are then provided, also showing how the SPINMATE design is in line with such recommendations. Protocols for disassembly of the different components are then proposed: based on those protocols, a qualitative environmental and cost analysis has been performed. It is shown that disassembling solidstate batteries present a promising approach for achieving a more sustainable and cost-effective battery life cycle, allowing preparing for maintenance, re-use, repair, refurbishment, and remanufacturing operations, so extending its lifespan. Additionally, efficient disassembly can streamline waste management and contribute to a more stable supply chain over time. Technological advancements and infrastructure development are necessary to fully realize these advantages, thus the potential benefits of disassembly require investing in technological advancements to optimize the disassembly process and maximize its long-term benefits. The Section is then completed by a decision tree to select the best disassembly route.