PARTMODPACK: Impact of particles during battery pack module assembly

Particulate contaminants are specified within Technical Cleanliness Analysis (TCA). In industrial processes, particles are constantly present; they are generated during material handling, transportation, and even through natural movements within the production environment. Even particles that are normally harmless can pose a serious risk to sensitive components such as battery modules, high-voltage systems, and seals by causing short circuits and impaired functionality. To prevent these issues, it is crucial to understand the properties, quantity, and effects of particles, as well as to develop methods for their control and analysis.

This project primarily addresses manufacturing, which must be cost-effective, sustainable, and safe in order to produce batteries with high quality and long service life. For these aspects, technical cleanliness is important. This means maintaining a production environment free from contaminants and particles to ensure the high quality and reliability of manufactured components.

At present, there is a lack of knowledge regarding the electrical properties of particles, critical particle types, and tolerance levels.

Particles are present in all shapes and sizes, ranging from the submicrometre scale to a few millimetres. They are continuously generated and introduced during normal industrial processes, or when doors are opened and closed, people walk, objects are moved, and so forth. Particles are present, and will always be present, in greater or lesser quantities, but the most important task is to determine:

• Where do particles pose a risk to components or systems?
• Which types of particles are critical for normal operation?
• When (during which process) are harmful particles generated?
• What contamination level (number of particles) is hazardous?
• How can particles be removed from sensitive components?
• How are particles analysed and measured?

The objective is to contribute new knowledge that strengthens existing guidelines and standards, thereby enabling cost-effective, sustainable, and safe battery manufacturing with high quality and long service life through the avoidance of harmful particles.