Fraunhofer Research Institution for Battery Cell Production FFB 
ECO-iL-DRY
ECO-iL-DRY – »Systementwicklung für einen intelligenten Laser-Hybridprozess zur Effizienzsteigerung beim Trocknen von Batteriefolien«
The ECO-iL-DRY project aims to significantly improve the drying process for battery films in terms of energy efficiency and quality in order to meet the requirements of sustainable energy storage and rising energy costs. The drying process step is central to battery production in terms of energy and quality. Challenges include increasing throughput, improving quality, enhancing energy efficiency, and avoiding critical materials such as organic solvents.
To achieve this overall goal, the project has three sub-goals: the development of an innovative laser matrix module to increase energy efficiency and reduce the required drying area, the implementation of an adaptively controlled hybrid drying process using thermography and residual moisture measurement to improve electrode quality, and the realization of an energy-optimized dryer prototype by combining laser and convection drying in a scalable system, including the use of laser waste heat to preheat the dryer air.
Work plan
The project is divided into seven work packages:
WP 1 covers the definition of target values and battery formulations. Target values for system technology and dry processes are specified, and cathode and anode formulations are defined.
In WP 2, the matrix laser module is developed in parallel. This includes the development of the optical system, the construction of a test bench for module and optical characterization, the development of diode drivers with fieldbus control, and suitable cooling concepts for laser modules and power electronics.
WP 3 involves the development and construction of the hybrid dryer. This includes the construction of a pilot plant for the integration of laser and measurement technology, the integration of a heat pump for energy recovery, and commissioning at the Fraunhofer IPT.
WP 4 covers recipe and process development on a laboratory scale with iterative optimization of the coating recipe and drying process, as well as characterization of the influence of the drying parameters.
In WP 5, drying experiments and process optimization of hybrid drying are carried out. The hybrid dryer is integrated into the FFB PreFab for further processing of the electrodes.
WP 6 addresses process sensor technology, process modeling, and data evaluation. This includes thermography, inline residual moisture measurement, process modeling, data analysis, and quality prediction.
WP 7 includes LCA analysis and performance and economic evaluation, including assessment of the scalability of the hybrid drying technology.
Utilization of results
The interdisciplinary consortium aims to improve the energy efficiency and quality of the battery film drying process. The hybrid drying technology is being further developed with the goal of achieving its transferability to industrial applications. At the end of the project, a prototype will be operated in the FFB PreFab, enabling scaling to industrial plant size. Within one year of project completion, the aim is to have a commercialized version, including the sale of hybrid dryers or the retrofitting of existing plants.
Scientific exploitation
The project results increase the scientific excellence of the partners involved. Findings on convection- and laser-based drying technologies and new electrode formulations will be disseminated through specialist publications, conference and trade fair participation, and other formats.
In addition, the results will form the basis for further research projects on drying, for example for battery electrodes or MEA coatings for fuel cells in the context of the energy transition.
Economic exploitation
The project strengthens industrial battery cell production through the further development of energy- and space-saving hybrid drying technologies. The results can be exploited economically through new products, retrofit solutions, licensing models, or spin-offs, and contribute to the development of new markets and the strengthening of competitiveness.