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Robust, Economical, Silicon-rich, Lightweight and Thermally Efficient battery packs

Project description

Safer, smarter and more sustainable battery packs

As demand for electric vehicles and aircraft grows, current battery packs face limitations in energy density, safety and efficiency. Improving these factors is essential for longer range, faster charging and enhanced reliability. With this in mind, the EU-funded RESiLiTE project will develop a battery pack with over 19 % higher energy density using tightly packed cylindrical cells housed in lightweight, recycled fibre-reinforced thermoplastics. Advanced cooling, fire-retardant nanomaterials and integrated sensors will boost safety and performance. A neural network-supported algorithm will be used to optimise thermal management, extending battery life even in cold conditions. This innovative approach is aimed at reducing costs while delivering a resilient, efficient and environmentally friendly power source for the next generation of electric vehicles and aircraft.

Objective

The RESiLiTE project (Robust, Economical, Silicon-rich, Lightweight, and Thermally Efficient battery packs) aims at increasing the energy density, energy efficiency, operative temperature range, fire safety and sustainability of upcoming battery packs for automotive vehicles and, subsequently, aircrafts. To achieve the project goals, cylindrical cells in the format 4695 will be tightly packed via a Cell To Pack (C2P) approach within a lightweight housing. The housing will be made of recycled fiber-reinforced thermoplastic materials. A cell-holder structurally integrated in the housing will allow the complete removal of potting materials. With the proposed concept, 230 Wh/kg energy density at pack level is aimed. This is more than 19% higher than the present SotA. Charging/discharging C-rates higher than 4.5C will be achieved thanks to the combined indirect cooling solutions integrated within the housing's cell-holder. Fire safety will be improved via a soft-venting concept, coupled with fire-retardant naomaterials integrated in the cell-holder. In order to achieve a high degree of redundance for safety measures, advanced diagnostics software will be accompanied by the implementation of Electrochemical Impedance Spectroscopy (EIS) sensors. Model-based SoX estimation algorithms will be implemented on the BMS to improve the diagnostic capability of the system. Thermal management control will be designed via a scenario-based algorithm with the help of Neural Networks (NN). This will increase the pack's energy efficiency. The employment of thermoplastic materials for the housing will also thermally insulate the pack, resulting in longer stand-time in cold environments before the need for active heating solutions. The proposed measures and materials help drive down the overall cost of ownership throughout the lifetime of the battery pack, offering a more resilient system with respect to the SotA.

Fields of science (EuroSciVoc)

Keywords

Programme(s)

Topic(s)

Funding Scheme

HORIZON-IA - HORIZON Innovation Actions

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Call for proposal

(opens in new window) HORIZON-CL5-2024-D2-02

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Coordinator

KAUTEX TEXTRON GMBH & CO KG
Net EU contribution
€ 1 272 271,00
Address
KAUTEXTRASSE 52
53229 Bonn
Germany
Region
Nordrhein-Westfalen Köln Bonn, Kreisfreie Stadt
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Links
Total cost
€ 1 817 530,00

Participants (8)