Papers by Francesco Maltoni
Springer eBooks, Sep 19, 2023
Springer eBooks, Sep 19, 2023
Journal of remanufacturing, Jun 19, 2020
Traditional remanufacturing is characterized by disassembly of a core up to an optimal depth of d... more Traditional remanufacturing is characterized by disassembly of a core up to an optimal depth of disassembly and by the replacement of some parts in order to achieve the specifications and reliability of the original product. Because of the product architecture and the reliability characteristics of electric vehicle batteries, such an approach does not recover the full residual value of battery cells. For batteries, a depth of disassembly up to cell level is necessary, but problematic because of inconvenient battery design features. Hence, an alternative framework will be presented, where each of the battery cells and the battery system key components are considered a core in itself, and the value of a remanufactured battery module depends on the combination of its cells. The product architecture and component requirements will be explained for batteries made of the three most common cell types used in the automotive industry. In addition, three solutions will be presented for the implementation of the proposed framework for remanufacturing regarding both product design and key aspects of the process chain, such as laser cutting and laser welding of battery cells. Keywords Remanufacturing of battery packs. Remanufacturing of battery modules. Sorting and repurposing of battery cells. Electric vehicles batteries lifecycle. Battery cells. Laser welding. Laser cutting
2019 18th IEEE Intersociety Conference on Thermal and Thermomechanical Phenomena in Electronic Systems (ITherm), 2019
Recent work by Hunt et al. has shown that pouch cell tab cooling can prolong the cells lifetime b... more Recent work by Hunt et al. has shown that pouch cell tab cooling can prolong the cells lifetime by up to a factor of three, compared to surface cooling, because of more uniform temperature distribution. Nevertheless, tab cooling has not found widespread application yet, mainly because of the engineering problem of electrically isolating the tabs, while conducting heat away from them at the same time. Hence this work demonstrates the viability of a novel fluid tab cooling method for battery modules with pouch cells optimized for series production. The design was simulated at system level with a 1D electrical-thermal-hydraulic model in Amesim and the critical geometries were simulated in 3D in Ansys. The performance of this system is sufficient for fast charging at a current of 1C continuously. Sensitivity analyses of the design parameters have shown heat transfer bottlenecks, on the module side the thermal contact resistance between components and thermal conductivity of the cold pla...
Journal of Remanufacturing
Traditional remanufacturing is characterized by disassembly of a core up to an optimal depth of d... more Traditional remanufacturing is characterized by disassembly of a core up to an optimal depth of disassembly and by the replacement of some parts in order to achieve the specifications and reliability of the original product. Because of the product architecture and the reliability characteristics of electric vehicle batteries, such an approach does not recover the full residual value of battery cells. For batteries, a depth of disassembly up to cell level is necessary, but problematic because of inconvenient battery design features. Hence, an alternative framework will be presented, where each of the battery cells and the battery system key components are considered a core in itself, and the value of a remanufactured battery module depends on the combination of its cells. The product architecture and component requirements will be explained for batteries made of the three most common cell types used in the automotive industry. In addition, three solutions will be presented for the implementation of the proposed framework for remanufacturing regarding both product design and key aspects of the process chain, such as laser cutting and laser welding of battery cells. Keywords Remanufacturing of battery packs. Remanufacturing of battery modules. Sorting and repurposing of battery cells. Electric vehicles batteries lifecycle. Battery cells. Laser welding. Laser cutting
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Papers by Francesco Maltoni