MySol 3.5k

Para qué sirve

MySol 3.5k is a modular backup battery tailored for Africa’s energy needs. Designed for manufacturing in Africa, it utilizes 100% repurposed lithium cells, old printed circuit boards, and plastic waste, offering affordability and reducing electronic waste.

Qué te inspiró

The project was done in cooperation with ENGIE Energy Access, a prominent energy company in Africa. Their devices that require repairs are sent back to repair centers. While most of these devices can be fixed, some cannot be repaired and enter their end-of-life cycle. Unfortunately, proper recycling facilities are lacking in many African countries, leading to a significant accumulation of electronic waste, which mainly includes various types of batteries and circuit boards. Until now, the company has discarded some of this end-of-life waste because it was deemed unusable, even though many of the batteries are still in good working condition.

Cómo funciona

Old battery cells are tested carefully to ensure safe operation in a new second-life battery pack. Every battery pack needs an electronic circuit board that provides various safety mechanisms. Typically, this is a purchased component, but the idea was to reuse old safety circuit boards. To make it work, many small protection boards were combined to create one large protection board. By doing so, we reduced electronic waste and saved resources. MySol 3.5k is designed in a modular way, allowing customization with different battery modules in terms of size and quantity. Only basic tools are needed for production, and it mainly utilizes easily accessible off-the-shelf components. The compression-based electrical contact ensures easy repairability, extending its lifespan — no need for spot welding or soldering. The enclosure grows with the battery size and is extruded from recycled ABS plastic sourced from old devices.

Proceso de diseño

The project started in Germany, where ENGIE Energy Access has its headquarters. For the first two months, we researched and developed possible solutions for building a second-life battery pack. We considered important safety aspects and built various prototypes. A significant part of the project was developing a technology that allows us to reuse old protection circuit boards, known as battery management systems (BMS), for battery packs. The challenge was that printed circuit boards are usually designed for one specific purpose. In our solution, a small helper board connects to many old BMSs, enabling us to reuse them for a larger battery pack. Once we had a functional concept, I flew to Zambia, where the company operates. I stayed there for six months to gain in-field knowledge and to further develop and build the first working prototype. From the beginning, it was clear that the product must be designed to be built without any special tools, machinery, or components. After observing that in many African countries, products are manufactured from local plastic waste, we had the idea to reuse plastic enclosures from our old devices. MySol 3.5k can be made from simple extruded plastic panels from our own plastic waste, cut to different sizes.

Qué lo hace diferente

Giving printed circuit boards a second life, especially in the battery sector, is an innovative approach that has not been done before. The advantages include a significant reduction in electronic waste, reduced costs for the customer, and decreased resource consumption for the company. Additionally, the battery modules of MySol 3.5k are fully repairable thanks to their compression-based electrical contact. While there are a few products available that offer a similar approach, they all require specially manufactured components. MySol 3.5k, however, is made entirely from standard components. You don’t need anything more than a drill and a screwdriver to build it, making it feasible to construct in many developing countries by following simple instructions. This offers a practical and accessible solution for many.

Planes para el futuro

The finished prototype will be tested for several months in Zambia. Solar panels, an inverter, and appliances will be connected to the battery pack to assess its real-life performance. The system will be monitored carefully, and data will be captured to predict its lifespan. If everything goes as planned, the company can align with customer needs to determine various battery sizes before a potential start of production.

Premios

Green Concept Award 2024 Winner in the Building Components category; 2023 European Product Design Award / Green Energy Solutions Winner; UNESCO 2023 Future Designer IIDA Silver Award