Toyota receives $4.5M to support a circular domestic supply chain for EV batteries

Plano, Texas-based Toyota Engineering & Manufacturing North America Inc. (TEMA), inclusive of Toyota Motor North America (TMNA) R&D, has been selected to receive $4.5 million in funding from the U.S. Department of Energy's (DOE's) Advanced Research Projects Agency-Energy (ARPA-E) to support the development of a domestic supply chain for electric vehicle (EV) batteries.

The funding is part of the Catalyzing Innovative Research for Circular Use of Long-lived Advanced Rechargeables (CIRCULAR) Program.

TEMA’s Toyota Research Institute of North America (TRINA) division will administer the project – Development of an Autonomous Robotic Disassembly Process for Applications in Battery Pack Circularity – in collaboration with Oak Ridge National Laboratory (ORNL), Oak Ridge, Tennessee; National Renewable Energy Laboratory (NREL), Golden, Colorado; and Houston-based Baker Hughes’ inspection technology product line, Waygate Technologies.

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This project aims to develop an industry-relevant template for a “3R” (reduce, reuse, recycle) facility, Toyota says. The goal is to help resolve the primary bottlenecks in current battery supply chain circularity, including automation of battery pack disassembly, data-driven battery classification and addressing cell degradation.

In support of this goal, the teams working on the project will develop tools and procedures, which include an automated pack disassembly process, advanced diagnostic tools and protocols for module and cell 3R classifications and a refabrication method for 3R cells into new energy systems.

According to Toyota, these innovations envision a scenario where end-of-life lithium-ion batteries are systematically evaluated, classified and reused prior to being considered for recycling.

“As it stands, this project and program will highlight avenues for everyone to rethink their approach to battery circularity and help prioritize the extension of battery life, facilitate battery reuse and reduce battery waste while unveiling the appropriate pathways to achieve such priorities,” says Nik Singh, principal scientist at TRINA. “This is only made possible by the collaboration between the exceptional teams comprised within this project group.”

The concepts developed within this project will also be applied in industrial settings led by TMNA’s Battery Lifecycle Solutions (BLS) business development team.

“This collaboration represents a significant step forward in developing sustainable solutions for the battery lifecycle,” says Sarah Kennedy, manager at BLS. “By applying the innovations established from this project, we aim to create a framework that not only reduces battery waste but also enhances the circularity of our battery supply chain, supporting Toyota’s commitment to sustainability and mobility.”