Paving the way towards a new generation of EV battery packs
With the promise of near-zero emissions, increased efficiency, enhanced performance and reduced fuel consumption, electric vehicles (EVs) have the potential to help Europe achieve its climate and energy goals. However, turning this potential into reality requires that these vehicles offer a performance comparable to traditional motor vehicles. That’s currently not the case. For instance, most EVs have a significantly lower range than gas-fuelled cars, and the fact that charging a battery can take up to an hour – or much more – can make driving them less convenient. What EVs need is a better battery – which is exactly what the EU-funded HELIOS(opens in new window) project set out to help build. “Applying a holistic approach, the HELIOS project investigates optimal eco-designs and advanced processes to demonstrate innovative, lighter and eco-friendly EV battery packs as effective models for urban electromobility,” says Tomas Jezdinsky, a freelance consultant to the International Copper Association, the partner responsible for disseminating the results.
Two fully functional electric vehicle battery pack concepts
At the heart of the project is a unique battery pack concept that is both modular and scalable. The pack is also hybridised, meaning it contains both high-energy (HE) and high-power (HP) battery cells – a concept that decouples energy from power and thus increases the concept’s flexibility. “Using a combination of high-energy and high-power cells, our solution is designed to extend an EV’s range and speed up charging times – thus addressing two of the key roadblocks to EV adoption,” explains Jezdinsky. The project ultimately developed two fully functional EV battery pack concepts; one intended for a small passenger car and the other for an electric bus. Each concept uses a wireless battery management system (BMS) architecture and features a closed thermal circuit subpack consisting of four modules (either HP or HE). “This configuration not only means our battery pack can be scaled and adapted to various EV use cases, it future-proofs it by ensuring that next-generation cells can be easily integrated into the existing pack,” adds Jezdinsky.
A sustainable, longer lasting and recyclable battery pack
Not only did the HELIOS project build a better battery pack, it took steps to ensure that its pack is sustainable. For example, its modular design means the pack can be easily reconfigured for energy storage purposes – a reconfiguration that extends the system’s overall life cycle. Furthermore, by implementing eco-design principles into its material selection, design and assembly, the project helps improve the pack’s overall life cycle and the recycling of its components. It also means the solution supports such EU initiatives as the Critical Raw Materials Act(opens in new window) and Batteries Regulation(opens in new window).
Collaborating with other battery-related EU-funded projects
While the HELIOS hybrid solution remains a concept, it moves the needle towards a new generation of battery packs. “By exploring the pros and cons of a hybrid approach, we’ve provided new insights that other projects can use to further develop a sustainable EV battery pack solution,” concludes Jezdinsky. Some of the innovative technologies developed during the project, such as the wireless BMS system, are already being advanced towards commercialisation via the project’s partners. As part of the COLLABAT Cluster(opens in new window) of battery R&D projects, HELIOS researchers continue to collaborate with other EU-funded projects, including ALBATROSS, LIBERTY, MARBEL, InnoBMS, iBattMan, ARISE and S4MILE.
