The Aragón Automotive Cluster is leading a national project to manufacture electric vehicle batteries using more efficient and sustainable materials, in which the La Rioja Automotive Cluster is participating.
Viloria explained “the aim of promoting a more digital, sustainable and competitive national battery value chain through collaboration between the AEI Rioja, AVIA, CAAR, CIAC, CEAGA, FACYL and GIRA clusters, together with SERNAUTO and one member company from each of the clusters (Nasika Products, Alcántara, Converzar. LK Mobility, +Millor, Aenium and Lis Data Solutions) and a member of SERNAUTO (Birziplastik). As specific objectives, Viloria spoke of ‘complete traceability through a digital battery passport, prediction of useful life with digital twin and AI; more sustainable, lightweight and safer materials and components, improved thermal safety and fire performance: design optimisation for a second life and recycling (circular economy) and validation in a pilot environment with integrated solutions’.
The results of the project have been broken down into nine sub-projects: the design of a digital passport that allows complete traceability of raw materials, manufacturing processes, use, maintenance and recycling, ensuring interoperability with other project systems.
On the other hand, the implementation of a digital twin with artificial intelligence for predictive maintenance, capable of anticipating battery degradation, optimising guarantees and facilitating their safe reuse in a second life. In addition, the development of lightweight, circular encapsulators using post-consumer fibre-reinforced plastics, contributing to weight reduction and the use of recycled materials.
Three other results achieved are the innovation of lightweight, fire-retardant, multi-layer thermal insulation materials that improve heat dissipation and the safety of energy storage systems; the application of additive manufacturing for metal components such as foams that improve thermal management, recyclability and structural strength of the battery pack; and the design of advanced elastomers with electromagnetic shielding and fire resistance properties that protect the battery from thermal and electrical hazards.
The third set of achievements is reflected in the optimisation of cell connection systems through the development of efficient, safe and easily removable busbars, facilitating recycling and repair; the establishment of industrial protocols for the recovery, repair and recycling of modules and cells, defining standards for the second life of batteries and their integration into circular processes; and finally, the functional validation of the solutions developed through integration into a pilot battery, evaluating improvements in weight, autonomy, safety and recyclability compared to conventional solutions.