SUSTAINABILITY AWARD

AWARDS

AWARD FOR SUSTAINABILITY

VAULTA - SIMPLY SUPERIOR BATTERY CASING TECHNOLOGY ENGINEERING DESIGN

DESIGNED BY Dominic Spooner Jerome Douven

COMMISSIONED BY Vaulta Dominic Spooner

DESIGNED IN Australia

Meeting at an innovative crossroads of efficient design and superior construction, Vaulta has developed a lighter, cheaper and thermally superior battery case that eliminates the need for complex assembly. With no welding, cells can be reused and reconfigured as needed. Perfect for stationary storage projects, electric vehicles, niche products and more. 53—54

With its easily disassembled design, Vaulta’s battery modules work to eliminate battery waste by simplifying their recycling and reuse.

Challenge

Impact Solution

Battery cell technology has evolved rapidly in recent years, yet battery case technology hasn’t been keeping up. Today’s battery cases are unnecessarily complicated and costly, with many parts that require specific tools and machinery for assembly. This adds superfluous size and weight to the batteries, ultimately affecting performance and increasing the likelihood of ongoing maintenance issues. They also need to be welded to the battery cells, making reuse and recycling extremely difficult. As a result only 2-5% of lithium-ion batteries are recycled each year, making a need for a more sustainable and practical design imperative.

Using advanced composite materials and a smart, streamlined design, Vaulta’s battery casing condenses multiple functions into fewer parts, with no welding required. Its simple design means modules can be easily assembled and disassembled, and cells can be reused and recycled. Waste can be reduced and, crucially, it offers batteries a much-needed second life. Vaulta’s patented materials ensure its casing is thermally superior and 10-15% lighter than current battery cases. The new casing design works for all cell-types, is easier to assemble and maintain and can be easily configured to suit different needs.

Vaulta’s design reduces build and market costs by approximately 10% and minimises design iterations. Its weld-free design allows batteries to be assembled either manually or via automation, meaning scalable local assembly is better enabled. The design not only allows recyclers to more easily disassemble the modules, but also allows them to get down to the cell level, meaning cells are diverted from landfill and recycling and givien a second life, extending the life of lithium-ion batteries by up to three times.