SVOLT’s next-generation cell-to-pack EV batteries deliver superior energy density, extended lifespan, and rapid charging capabilities while ensuring best-in-class safety. This is achieved by innovative system design and battery cells which are specifically designed for cell-to-pack architecture.

The process of driving innovations in battery materials and cell concepts through lab-to-pilot scale-up involves transitioning promising developments from the laboratory to larger-scale production for testing and optimisation. This entails the exploration and development of novel materials, innovative cell architectures, and scalable production processes. 

As we push the specific energy over 250 Wh/kg in 21700 Li-ion cells with cathode metalized plastic current collectors (PCC), we lose tolerance to nail penetration. Adding thermally-stable separators, anode PCCs, and reducing cathode-active material adhesion to the collector didn't improve nail penetration safety. Jellyroll winding tension appears to play a major role in cylindrical cells since nail tolerance is achieved in prismatic pouch cells > 250 Wh/kg.

Failing batteries can lead to exothermic chemical reactions, ending up in thermal runaway (TR). Since many factors influence the results of TR experiments, it is important to analyze them—one important factor is the gravimetric energy density. In order to compare experiments with each other, they must be performed with high accuracy in a professional environment. In this presentation, results of failing state-of-the-art automotive cells will be presented and discussed. The focus will be on the comparison of NMC cells with different gravimetric energy density. The results will be compared in the categories: thermal behavior, vent gas production and vent gas composition.

To reconcile the two seemingly conflicting goals of highly flexible processes and high production volumes, new concepts are needed for singulation and stacking processes. Combining the traditional discrete stacking process with a continuous cutting operation will allow rapid changes in electrode dimensions. By setting up digital twins of the machinery, it is possible to virtually commission control components and deduce machine influences on material behaviour and product quality.

LFP based battery cells see increasing popularity in the e-mobility market promising a safe and cost-effective solution. To decrease dependency on Chinese import, more LFP cell capacities are planned to be installed in Europe—but can the technology keep its low cost footprint in a western environment? This question is answered by analysing the impact of local manufacturing conditions on the LFP cell cost structure.

In this talk we will discuss different performance targets of battery cells and how these are affected by material choice and cell design. We will illustrate some of the fundamental sensitivities of cell design by virtually designing and re-designing different cells and studying the impact on cell performance. Subsequently, we will use the data of our cell database to cross-check the results with measurement and cell-opening results of actual cells. Thereby we will reveal cell design trends of the market and derive cell design principles for cell design on target.

In this presentation, solid emissions from Li-ion batteries' fire are characterised by scanning electron microscopy in combination with energy-dispersive X-ray spectroscopy (SEM/EDX) and X-ray powder diffraction (XRD) to evaluate the size, morphology, and chemical composition of aerosol smoke particles allowing more quantitative risk assessment of such emissions for human health and the environment.

Battery management systems are a decisive factor for successful and fast development of batteries. Oftentimes, integrators struggle with managing the increasing software complexity in modern automotive and heavy-duty ECUs. Standards such as AUTOSAR, ISO 26262, Cyber Security or ASPICE have driven the time and cost for SW development. Yet, time to market is critical and battery and cell variants are only growing. This talk presents a view on future BMS Architectures, taking into consideration industry trends such as: The SW-defined vehicle, Ethernet to the Edge, and new Safety goals.

ENERGETIC project, funded by the EU Horizon Europe program, aims at developing the next generation BMS for optimising batteries’ systems utilisation in the first (transport) and the second life (stationary) in a path towards more reliable, powerful, and safer operations. It contributes to the field of translational enhanced sensing technologies, exploiting multiple AI models, supported by Edge and Cloud computing. ENERGETIC will monitor and predict the remaining useful life of a Li-ion battery through a digital twin.

About:Energy creates the best battery models with a bottom-up approach. Heat generation, thermal effects and thermal modelling for a huge part of this process. Here, the complexity of heat generation characterisation is introduced alongside the methods About:Energy uses to achieve accurate thermal control throughout thermal parameterisation. An example is given, showing the application of the models to compare performance of different cells, and the impact on system-wide design.

As new materials progress from laboratory to commercial reality, a key aspect in predicting final performance is device prototyping. This work demonstrates the effects of cell size and design on prototype prediction of final device performance. Through variation of design and size of Li-ion pouch cells, from single layer through many layer, relationships with parameters such as capacity, rate, resistance, and lifetime are considered relative to those of final device.