Research Projects


      EMBATT – 1,000 kilometers all-electric range


      The "ePadFab" and "EMBATT2.0" projects are developing the new EMBATT battery technology with revolutionary characteristics

      At the moment, electric vehicles only have a limited traveling range. IAV is involved in a research project with its partners for doubling the energy density of batteries from currently around 250 watt hours per liter (Wh/l) to 500 Wh/l. At the same time, production costs are to fall well below € 200 per kilowatt hour. In the end, this could produce all-electric traveling ranges of up to 1,000 kilometers.

      Project objective

      Two approaches lend themselves to increasing the battery capacity of e-vehicles: using new storage materials with a higher energy density, and new integration concepts for getting more storage material into the car. The project partners champion the latter: using large, planar-type lithium-ion bipolar batteries that can be integrated directly into the vehicle’s chassis. In future, the batteries are to consist of stacked cells connected in series, with two sets of cells each sharing an electric arrester. One side serves as an anode, the other as a cathode. This makes it much easier to connect the cells because the active material carrier foils themselves act as large-scale cell connectors, with large electrode surfaces resulting in reduced inner resistance. The consortium calls the concept EMBATT ("Chassis-Embedded Energy",

      Today’s lithium-ion batteries consist of a round, wound structure ("jelly rolls) inserted into the cylindrical or square cell housings, or parallel-connected cell stacks sealed in a pouch. As a result, they fail to take up all the space inside the cells or battery package; furthermore, complex contacting elements are needed to connect the individual cells. The active material in current systems only uses approx. 40 percent of the volume. EMBATT aims to increase this value to 80 percent. Depending on package, voltages of 850 volts are possible at present and maybe up to 1,200 volts in future. This could result in all-electric traveling ranges of up to 1,000 kilometers.
      Besides looking at how to make the new lithium-ion batteries, the agenda also includes specific material and process developments, including new high-voltage active materials, polymer arresters, polymer electrolytes, bipolar cell elements and optimization of the stack concept, as well as electrochemical simulation and modeling of the overall concept. The market launch for EMBATT could take place approximately in 2025.

      IAV, IKTS (Fraunhofer Institute for Ceramic Technologies and Systems), thyssenkrupp System Engineering (coordination ePadFab), Glatt Ingenieurtechnik GmbH, Leibniz Institute of Polymer Research, Isocoll Chemie GmbH, KMS Technology GmbH, Litarion GmbH, ULT GmbH (coordination EMBATT 2.0)

      Funding body
      Sächsische Aufbaubank (Development Bank of Saxony), European Union, German Federal Ministry of Education and Research

      Project sponsor
      Sächsische Aufbaubank (Development Bank of Saxony), project sponsor Jülich

      Project duration
      ePadFab: 2014 to 2018
      EMBATT2.0: 2016 to 2019

      Further information:

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