Summary
- COOLBat project aims to develop next-generation battery enclosures for electric vehicles
- The project goal is to make enclosures lighter, reduce carbon dioxide emissions by 15%, and improve range
- Interdisciplinary research is being conducted to improve lightweight construction materials and production methods
- Using new lightweight construction methods can increase energy density and range of electric cars
- Results from the project will be extended to other industries such as trains, aircraft, and boats for future sustainable applications
Article
The COOLBat joint research project aims to develop next-generation battery enclosures for electric vehicles with higher charging power, greater range, and lower environmental impact. The goal is to make the enclosures lighter and reduce the carbon dioxide emitted during their manufacturing process by 15%. Researchers are focusing on innovative lightweight construction principles, materials, and production methods to achieve climate-friendly production of battery enclosures and reduce the carbon footprint of electric vehicles.
The project involves 15 partners working on interdisciplinary research to develop lightweight construction solutions demonstrated by next-generation battery housings. By reducing the mass of the enclosures and incorporating new lightweight construction methods, the project aims to increase energy density and range of electric cars while cutting carbon emissions. The partners are focusing on aspects such as circularity, resource efficiency, energy efficiency, safety, and fire protection at the design and material levels to improve the properties of battery system enclosures.
One approach to reducing weight is by combining individual systems in the enclosure that previously performed separate thermal and mechanical functions. Cooling channels are integrated into load-bearing structures, and the cooling unit function is combined with underride protection in a single component, the base plate. This configuration helps protect battery cells from mechanical loads and overheating simultaneously. Additionally, the researchers are using the Mercedes EQS battery as a reference and technological demonstrator for their developments.
The researchers are also working on replacing heavy, non-sustainable thermal conductive pastes with eco-friendly heat-conductive materials to improve heat dissipation from batteries toward the exterior shell. New flame retardant coatings developed by the Fraunhofer Institute for Wood Research are being used to enhance fire protection. The coatings contain lignin, a non-flammable bio-based material that replaces petroleum-based materials. The design of the enclosure components is focused on reuse and recyclability to promote a circular economy and reduce the carbon footprint.
Future plans for the project include transferring its results to other applications and industries where large batteries are used, such as trains, aircraft, and boats. The cooling systems developed in the project could also be used for transporting food and medications, while the fire protection solutions could find applications in buildings. The project partners include various organizations and companies working together to develop innovative solutions for reducing carbon emissions and improving the performance of electric vehicles.
Overall, the COOLBat project aims to revolutionize the design and production of battery enclosures for electric vehicles by implementing lightweight construction principles, new materials, and advanced production methods. By focusing on reducing mass, improving energy density, enhancing safety and fire protection, and promoting circularity and recyclability, the project aims to contribute to the development of climate-friendly electric vehicles with lower carbon emissions. The innovative solutions developed in the project have the potential to have a significant impact on the automotive industry and other sectors where large batteries are used.
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