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Solid-state batteries – cutting-edge technology for EVs

30 March 2021

The solid-state battery could completely revolutionize the electric car sector. This innovation definitely promotes the rapid development of electromobility. How do we keep up with modern revolutions and take an active part in the significant changes in the automotive market?

How does a solid-state battery work?

A car battery that uses a solid-state design is ideal for use in modern vehicles. This type of energy storage uses an electrolyte that is a solid and not a liquid – in contrast to how lithium-ion batteries work. The solid-state battery overcomes the problems associated with conventional solutions, such as relatively small capacity, which results in a modest vehicle range, as well as the deterioration of the cell after many charging cycles and the generation of considerable amounts of heat.

Electromobility solutions are becoming increasingly innovative and solid-state batteries are no longer just part of distant plans. The biggest barrier to this technology so far has been the development of large-scale production methods. However, engineers at major automotive companies are working to develop an electrolyte that meets the expectations of the EV market and provides the performance expected by customers.

Solid-state batteries and customer expectations in the EV sector

Among the target group for electric cars, there is considerable interest in the topic of vehicle power. A larger cell size translates into a better range, which in turn significantly affects the perception of a given model. It is therefore worth contributing to the promotion of solid-state batteries as an alternative to lithium-ion batteries. Due to the relatively young age and low popularity of this technology, awareness in this area is currently at a low level.

The possibility of installing higher capacity cells, which at the same time take up less space in the vehicle's structure, clearly means a significant increase in the range of an electric car. This is a key parameter when choosing a car powered by alternative energy sources. Another aspect of EV use is battery deterioration, which causes the cell to lose its original properties. The charge cycle for solid-state batteries could potentially be greater than for conventional counterparts. Developing this type of cell would therefore address two of the most important customer needs.

Solutions designed for solid-state automotive batteries

An effective solid-state battery should not be limited to using cell technology alone. However, for it to provide adequate performance, it is necessary to adapt the vehicle design to the needs of such a solution. Innovation should focus on developing strategies to effectively implement batteries – not only modular – in vehicle design. Electromobility should be based on ecological and lightweight solutions, which are also durable, promote economical driving and make it possible to effectively protect batteries from damage that may occur as a result of everyday car operation.

Even now, before solid-state battery technology is fully implemented, it is worth considering supporting its potential with the right automotive parts. EPP foam battery components and shock management solutions made by Knauf Automotive are the result of modern process developments in the automotive sector. The design of such components takes into account highly complex physical models that determine the most a propriate parameters for parts made of plastic. They are commonly used in lithium-ion batteries, but can be quickly adapted to new solid-state cells.

Knauf Automotive's offer – solutions for the deployment of solid-state batteries

At Knauf Automotive, we focus on implementing successful technologies related to Industry 4.0 and 3D printing. Projects involving components designed to support the construction of lithium-ion batteries have resulted in outstanding insulation solutions. We have been working with well-known brands in the automotive sector for years. Our products are the result of a combination of research, development, testing (prototyping) and use of state-of-the-art technologies. Throughout our cooperation, we offer support at every level of component manufacture – from development, through production and implementation, to recycling.

The thermal and electrical insulators available within the Knauf Automotive range are tailored to the needs of a conventional road vehicle, taking into account actual conditions. They provide shock absorption and reduction; they also protect battery modules from the shock that can result when one module fails. The heat-insulating properties of this type of solution are another advantage – uncontrolled heat flow leads to degeneration or damage to the power cells.

Our comprehensive range also includes mountings for battery components and packs. Our solutions add value by extending the life of the battery, reducing battery failure and promoting safe fast charging, as well as reducing the weight of the vehicle, resulting in a longer range. Parts are made from environmentally friendly materials such as recyclable foamed polypropylene, the price of which has little impact on the cost of vehicle manufacture.

Do not hesitate to contact with our engineers for more information about our offer for foam car battery components.

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