Imagine a battery pack that is lighter and holds more energy, like swapping a heavy suitcase for a slim, high-capacity backpack. It uses a smart plastic shell and a special cooling system to keep the batteries from overheating or catching fire. It even uses AI to manage energy, making the battery last longer and perform better in freezing weather.
Current battery packs are often too heavy, expensive to manufacture due to potting materials, and struggle with thermal management during fast charging or in cold weather.
A lightweight battery pack using 4695 cylindrical cells in a recycled thermoplastic housing with integrated indirect cooling and AI-driven thermal management.
If you are an EV manufacturer dealing with limited driving range and heavy battery weights — this project developed a Cell To Pack approach using recycled thermoplastics that achieves 230 Wh/kg energy density. This is 19% higher than current standards, allowing for lighter cars with longer ranges.
If you are an aircraft developer dealing with strict weight limits and safety risks — this project developed a lightweight housing with fire-retardant nanomaterials and soft-venting. This ensures the battery is safe for flight while reducing overall aircraft weight.
If you are a pack assembler dealing with expensive potting materials and slow charging speeds — this project developed a cell-holder that removes the need for potting and supports C-rates higher than 4.5C. This reduces assembly costs and enables ultra-fast charging.
The use of thermoplastic materials and the removal of potting materials help drive down the overall cost of ownership throughout the battery pack's lifetime.
Based on available project data, the consortium includes 5 industrial partners and 2 SMEs, suggesting a strong focus on industrial scalability and manufacturing integration.
Based on available project data, the project is currently in the signed phase (2025-2028); specific licensing terms are not yet disclosed.
The project implements a soft-venting concept and integrates fire-retardant nanomaterials into the cell-holder to prevent thermal propagation.
The project period runs from 2025-07-01 to 2028-06-30, indicating that final results will be available by mid-2028.
The consortium is heavily industry-driven, with 56% of the 9 partners coming from the industrial sector, including 2 SMEs. This balance, combined with 2 universities and 2 research institutes across 6 countries, indicates a strong pipeline from academic research to commercial application, specifically targeting the automotive and aerospace supply chains.
Contact KAUTEX TEXTRON GMBH & CO KG for partnership opportunities regarding thermoplastic battery housings.
Contact SciTransfer to identify potential licensing partners for this high-density battery technology.
