Ansmann AG Designs Second Generation ‘GreenPack' Supported By Sustainable Borealis Polypropylene Compounds

New Plastic-Compounds Boosting Mobile Energy with second generation exchangeable battery system “GreenPack”

The more renewable energy and mobility concepts are implemented, the more important it gets to pay thorough attention to the ecological footprint of the materials and processes in order to lower CO₂ -emissions. This is why the German battery experts of Ansmann AG and Borealis, one of the world’s leading providers of advanced and circular polyolefin solutions, are cooperating in the development and production of the second generation of Ansmann’s exchangeable battery system called “GreenPack“.

The aim of this collaboration is to design the lithium-ion battery of the next generation, Ansmann’s “GreenPack”, enabling the advantages of polypropylene usage. The new generation of GreenPack battery systems will be equipped with a polypropylene housing and cell holder. Different to usual materials, the Borealis polypropylene (PP) offers better eco-efficiency. One key reason for this is the lower material density and therefore a weight advantage of PP versus typically used plastics, which contributes to a larger driving range of the e-vehicle. Other advantages are the excellent insulation properties of polypropylene and energy savings in production due to the lower melting point of the PP material. In addition, CO2-emissions in the production of PP are generally just less than half of the footprint of the conventionally used plastic alternatives. Based on existing requirements for the battery, Borealis supports Ansmann with choosing the right material, ensuring functionality by making simulations (like battery drop tests) and securing processability and quality by optimizing the converting process.

The GreenPack exchangeable battery was taken over for further development by the mobile energy experts of Ansmann AG in August 2020. Generation one of the one-grip interchangeable energy storage device for green power currently offers 48 V nominal voltage, 1400 Wh capacity and a high max. continuous current load of 25 A. The GreenPack system is equipped with intelligent communication and standardized interfaces to allow the usage of exchangeable batteries in different devices of different producers. They can be equipped with cells of different cell chemistries and are unlimitedly scalable within the application.

GreenPack succeeds as a universal “green” batterypack solution
The GreenPack is used in e-fleets of sharing and delivery services as well as in commercial transport. It can be found in lawn mowers, snow blowers and weed trimmers used in gardening and landscaping. In associated exchange/charging stations, empty GreenPack battery modules can be swapped for full ones quickly and on demand.

Thilo Hack, as board member responsible for R&D at Ansmann AG, says: "In comparison to conventional materials, the new material developed by Borealis for our upcoming GreenPack generation will come without plasticizers. It will be lighter and more flexible than other typically used plastics; yet it will meet all chemical and mechanical safety criteria and will have a significantly lower CO₂
footprint. We are very pleased, we can make our GreenPack even greener supported by Borealis as a strong and experienced development partner!"

Borealis has a vast wealth of expertise and experience in the development of advanced and circular polyolefin solutions for the entire value chain of lithium-ion battery systems, as well as in the simulation and modelling of different components, such as cell holders or housings of the battery packs. Martyna Matelska-Jucha, Head of Borealis New Business Development: “We are excited about this opportunity to jointly develop a novel, swappable battery GreenPack with our partner Ansmann. This is another proof point for how Borealis re-invents products for new and technical challenging applications like mobile battery solutions for a more sustainable lifestyle. Those we can only achieve by working together as partners throughout the whole value chain.”