Toyota is set to receive $4.5 million in federal funding for research on automating the dismantling and rebuilding of used electric vehicle battery packs for eventual reuse.
The funding is part of the Energy Department’s Advanced Research Projects Agency-Energy (ARPA-E) program, specifically under the Catalyzing Innovative Research for Circular Use of Long-lived Advanced Rechargeables (CIRCULAR) initiative. Toyota aims to establish a domestic circular supply chain for EV batteries through this project.
Circular supply chains focus on maximizing the reuse and recycling of materials. Toyota identifies the slow disassembly process and material sorting as the main challenges in reusing EV batteries, including categorizing battery cells based on degradation levels.
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Through this research project overseen by Toyota Research Institute of North America (TRINA), Toyota aims to develop an automated pack disassembly process, diagnostic tools for cell classification, and a re-fabrication process for creating new energy systems from recovered components.
Toyota is among the 13 recipients of CIRCULAR funding, with several participants focusing on automation. The University of Colorado received $1.8 million to explore the use of humanoid robots and robot arms for disassembling battery packs, while BMW secured $4.4 million for developing a battery pack designed for rapid robotic disassembly without compromising structural integrity or energy density.
Reusing batteries for second-life applications before recycling for materials can reduce the CO2 footprint and overall environmental impact. Batteries from various electric vehicles are already being repurposed for secondary uses.
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Toyota’s collaboration with Redwood Materials is also contributing to the recycling efforts, particularly focusing on repurposing Prius batteries through automotive recyclers nationwide.
Redwood Materials recently secured a substantial $2 billion Energy Department loan, highlighting the importance of streamlining the disassembly process for future EV battery packs to enhance both reuse and recycling efforts.