A European project is developing a new propulsion system for medium-range aircraft with up to 35 passengers, writes Nick Flaherty.
Several Fraunhofer Institutes and Brandenburg University of Technology Cottbus-Senftenberg, under the leadership of Rolls-Royce Germany and other partners such as research institution ACCESS, are collaborating on the hybrid electric-propulsion system. Read more…

StoreDot has developed a cell-to-pack architecture for its silicon-based fast-charging batteries, writes Nick Flaherty.
The I-BEAM XFC is a patented cell design that accelerates the integration of extreme fast charging (XFC) into EVs using StoreDot’s proprietary 100in5 electrode technology. The silicon anodes enable charging for 100 miles of range in just five minutes. Read more…

Volvo Cars has partnered Breathe Battery Technologies (Breathe), becoming the first car company to gain access to the latest version of its patented, algorithm-enabled charging software.
By integrating Breathe’s software into its in-house developed battery management platform, Volvo Cars aims to offer customers faster charging times and an enhanced driving experience. Read more…

Peter Donaldson examines the finer points of potting and encapsulation
Many electrical and electronic components last longer, perform better and stand up to the stresses and strains of hard use with fewer complaints if they are potted or encapsulated in a polymer. While the two terms are often used interchangeably, they don’t quite mean the same thing.
Potting is a process by which a form or ‘pot’ containing the parts to be protected is filled with a polymer resin and becomes part of the finished component. Read more…

When Toyota unveiled plans for its next generation of EV technology in June 2023, the company made it clear that bipolar batteries would play a central role. The company is already using bipolar architecture in the nickel-metal hydride batteries in its Crown and Aqua hybrids, and it is extending the technology to BEVs with lithium-ion batteries. Its product plans include ‘popular’ and ‘performance’ versions of liquid-electrolyte bipolar batteries, writes Peter Donaldson. Read more…

Lightweight with higher temperature resistance, thermoplastics are ideal for e-mobility powertrains, Nick Flaherty reports
The push to make e-mobility designs lighter to boost range is driving significant innovation in materials. Thermoplastics are being redesigned to provide various combinations of temperature and flowability for manufacturing and plating capabilities. Read more…

Nick Flaherty discovers how the world of power semiconductor devices is shifting away from silicon
Power semiconductors are used across many areas of e-mobility, with different technologies suitable for each part of a vehicle, depending on the voltage and current requirements, while emerging tech is allowing smaller systems to be implemented. Read more…

Modern inverters are including more intelligent features to work with other vehicle systems, reports Peter Donaldson
Inverters do the conceptually straightforward job of converting an electric current from DC into AC form. As such, they create an essential link between the energy storage system and the motor.
Modern inverters use solid-state semiconductor switches, connected to form combinations of half-bridges and activated by smaller switching circuits known as gate drivers, which in turn are under the control of processors that implement control logic embodied in hardware, software or both. Read more…

ENNOVI has launched the CellConnect-Prism, a prismatic battery cell contacting system that aims to redefine the connectivity and efficiency of battery modules.
The product gives engineers flexibility by enabling the seamless integration of individual prismatic cells to create larger battery modules, or advanced cell-to-pack (CTP) and cell-to-chassis (CTC) configurations. By streamlining the assembly process and eliminating inefficiencies, it accelerates battery pack production while optimising material usage and cutting costs. Read more…

Foam Expo, the largest, free-to-attend trade fair and conference for foam products and manufacturing in North America, is returning for its seventh edition from June 25-27, 2024, in Novi, MI. Register to attend and you’ll gain easy access to the co-located Adhesives & Bonding Expo taking place in the same hall. Read more…

Viritech has launched the 60 kW VPT60N Ready to Run powertrain for OEMs, Tier 1 suppliers and research bodies, enabling the rapid deployment of hydrogen fuel-cell electric vehicles.
The complete powertrain includes the fuel cell, hydrogen storage, energy store, power electronics, e-machine and transmission. It is suitable for cars, light commercial vehicles and off-highway applications. Read more…

A new beam-shaping welding technology has been developed by Cailabs with the aim of significantly improving accuracy and efficiency in the construction of electric mobility parts. This is key to the construction of the battery assembly and is often important for other parts of the vehicle, such as motor hairpins or battery cases. Read more…

Peter Donaldson explores a new generation rigid hull inflatable boat that obtains benchmark performance from electrical energy.
While sailing is emissions free, the IC-engined boats that regularly support sailing events and training operations tarnish that clean image somewhat. This led the principals at RS Sailing, now part of the RS Marine Group, to begin development of an electrical Rigid Hull Inflatable Boat (RHIB) in 2018, incorporating a new company, RS Electric Boats. The resulting Pulse 63 is now operational in its intended role as a sailing coach boat and is also offered as a work boat, a leisure boat and a superyacht tender. Read more…

Alpha and Omega Semiconductor (AOS) has developed lead-less packaging for its automotive grade 80V and 100V MOSFET transistors for two and three wheelers, writes Nick Flaherty.
The lead-less packaging is a key step in making battery packs and brushless DC motors smaller in two and three wheel scooters. Removing the leads inside and outside the package helps to lower the resistance to 1.25 mOhms and 1.7 mOhms, giving lower losses and allowing higher efficiency for light vehicles. Read more…

Adhesives & Bonding Expo, the largest, free-to-attend trade fair and conference for industrial bonding products and manufacturing in North America, is returning for its fourth edition from June 25-27, 2024, in Novi, MI. Register to attend and you’ll gain easy access to the co-located Foam Expo taking place in the same hall. Read more…

As system voltages in EV powertrains increase to enable the use of higher power levels without creating excessive currents and the associated energy losses and heat dissipation problems, so does the importance of wide bandgap semiconductors, writes Peter Donaldson. Ones such as silicon carbide (SiC) and gallium nitride (GaN) in applications such as traction inverters, DC-DC converters and onboard chargers. Read more…

Eatron Technologies and About:Energy are developing a decision-engine for battery management systems (BMS) that combines machine learning and electrochemical models, writes Nick Flaherty.
The aiMAGINE project aims to use machine learning frameworks in the BMS to extend the life of a battery pack in electric vehicles and scooters. Read more…

Webasto offers three electric High Voltage Heaters (HVH) with 10-12 kW of power for electric cars, trucks, buses, construction machinery and special vehicles.
The adjustable HVH 100 Compact, HVH 100 Compact+ and HVH 120 heaters are no larger than an A4 sheet of paper, and they convert direct electric current into heat with practically no losses. Read more…

Primarily known as a producer of chemical solutions across several different industries, German multinational group Henkel has launched the Battery Engineering Center (BEC) within its Inspiration Center Dusseldorf, aimed at providing strategic partnerships with battery developers (and others in the e-mobility space). Read more…