UVPolyZell

The objective of the UVPolyZell project is to establish a polymeric binder system for lithium-ion batteries with NMC cathodes, fully avoiding toxic solvents such as NMP (N-methyl-2-pyrrolidone) and fluorine-based polymers (e.g., PVDF).
Fraunhofer FFB’s objective is to scale this novel material system toward series production. Using alternative solvents the aim is to save up to 80 % of the energy required for electrode drying. UV-induced crosslinking of the binder system is developed and integrated into the overall process. Simultaneously, electrode slurry preparation using the binder system components is advanced using novel mixers and stability-enhancing additives, and brought to application.

The following work will be carried out as part of the project:

• Development of an innovative continuous mixing process for an electrode paste using the components of the polymer binder system.
• Development of additives to stabilize the electrode paste and improve its wetting and coating properties.
• Manufacture of electrodes using environmentally friendly solvents and integration of a UV light source.
• Assembly and investigation of test battery cells.

The project is divided into five work packages, with Fraunhofer FFB primarily involved in WP1: Definition of a process benchmark and battery cell specifications, and WP4: Electrode fabrication and cell assembly.

• In WP1, the comparison parameters are determined using standard materials at Fraunhofer FFB, and the necessary approvals and permits are obtained.
• In the second step, within WP4, electrodes are manufactured using the new material system on Fraunhofer FFB’s equipment, and the binder system is subsequently cross-linked using a UV light source.
• In the final step, cells are assembled and evaluated.

The UVPolyZell project enables Fraunhofer FFB to expand its expertise in the investigated materials and process technologies -building on industrial partners’ existing experience to advance the scale-up of the novel binder system, eco-friendly solvents, and mixing technologies within FFB’s research infrastructure. This dual focus yields both economic and scientific valorisation.
FFB’s valorisation plan entails deepening its scale-up research competence based on project outcomes, while expanding its competence portfolio with new innovative materials and process technologies. Prioritising non-toxic materials and energy-efficient process steps is central to establishing sustainable, economically viable battery cell production in Germany.