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VW, UT & RNL Working on Composites, Recycling & EV Wireless Charging
Volkswagen Group of America, Inc. (VWGoA) is boosting its automotive research in the United States to further accelerate electric mobility and sustainable transportation innovation. The company continues to center strategic areas of research in dedicated technology units across the country, as well as foster co-innovation with universities and federal research facilities. One key unit is located in Tennessee: Volkswagen’s Innovation Hub in Knoxville is driving applied materials science in collaboration with the University of Tennessee (UT) and Oakridge National Lab (ORNL). There, integrated teams are pushing breakthroughs in automotive lightweight composites, recyclable interior materials, and EV wireless charging.
“We are accelerating innovation within electric vehicles and contributing to more sustainable transportation in America by focusing our efforts on some of the most transformative automotive research being done in the country,” said Pablo Di Si, President and CEO at Volkswagen Group of America Inc. “Our technology teams in Tennessee are a great example. There, we are tapping American ingenuity fostered by the unique blend of world-class academic research and Volkswagen’s leading industry capabilities.”
Opened in 2020, Volkswagen’s Innovation Hub is located at the University of Tennessee Research Park at Cherokee Farm in Knoxville, in a region referred to as ‘the Materials Valley’ due to the concentration of research facilities. This includes the ORNL, of which VWGoA has also established research collaborations. Volkswagen researchers, UT faculty and doctoral students as well as ORNL scientists collectively drive research and co-innovation of applied materials research.
“Centering more knowledge in the United States is part of Volkswagen’s strategy for growth and is vital for sourcing and developing talent,” Di Si added.
“The Volkswagen Innovation Hub is a powerful example of the kind of scientific advances and industry-ready technology that you can bring to market when you locate scientists and researchers from across disciplines and organizations together in one place.”, said UT Chancellor Donde Plowman. “With partners like Volkswagen, Oak Ridge National Lab, and others industry leaders and tech startups located at UT’s Research Park, we have created a thriving innovation ecosystem.”
Volkswagen researchers are working on new material structures to reduce vehicle weight, which helps to increase the range of electric vehicles (EVs). As a first pilot, the team has chosen the steel frame that houses the EV battery pack in the vehicle and shields it from physical impacts.
By running a deep learning algorithm (simplified: artificial intelligence) with up to millions of parameters on UT’s high performance compute cluster, the team has developed a modular repeating structure in shapes of tiny pyramids. This structure can be 3D-printed from liquid resins and holds 30,000 times its own 0.15lbs-weight (68g). A newly created frame would be up to 60 percent lighter. Hardcore durability tests showed that it exceeds the conventional steel frame in energy absorption, and could serve as a lightweight, yet ultra-robust alternative.
The hub team at UT’s Center for Renewable Carbon is developing recyclable alternatives to plastic parts and foils in the vehicle interior. Their focus: paper. The team has patented a method of preforming and hot-pressing cellulose fiber reinforced thermoplastics into the durable interior parts customers expect.
These paper-based composites are not only recyclable, they can also be transformed into various interior shapes and sizes, including backlit and ambient light options. The team has also innovated ways to add different textures and colors, so vehicle interior designers enjoy flexibility and creative freedom.
The Volkswagen brand is already checking opportunities to include these paper-based interior parts in future model lines and work to support industry-scale production.
The Volkswagen team kicked off lightweight materials research with UT by recreating the lift gate of a MY2020 Volkswagen Atlas using sheet molding compound (SMC), a type of fiberglass reinforced plastic. The new lift gate proved to be 13 pounds lighter than the conventional metal-based version; a weight-savings of more than 35 percent, which could help to increase the range of electric vehicles and those powered with a combustion engine. In addition, the alternative composite lift gate does not need changes in assembly sequence compared to conventional versions – meaning those components are fit for high volumes.
The team’s research breakthrough has already found its way into vehicle production. Bentley and Lamborghini have adopted these new materials and the molding process for the Bentley Continental, and in the Lamborghini Aventador. The team in Knoxville has also started a research project to explore lightweight options for pickup beds and rugged components.
More recently, Volkswagen and UT researchers have further refined molding processes and ways to optimize durability, quality and design options. One specific take is to optimize the fiber-matrix-interface, a process called “sizing” – essentially creating the smoothest, most durable coat for fibers possible.
Volkswagen’s team has patented a unique coil and charging pad design with silicon-carbide materials to optimize charging speed and safety. Their goal: Help make charging an electric vehicle as easy and comfortable as pulling into a normal garage spot.
In the first early trials with a silicon-carbide inverter, this prototype system has shown high efficiency. Using Volkswagen’s expertise in vehicle power electronics, ORNL’s capabilities in high power wireless charging, and UT’s knowledge of power electronics optimization, the research team has been able to increase the charging power level up to 120 kW with this prototype from an earlier 6.6kW prototype, with a future goal of 300 kW.
Volkswagen’s Innovation Hub Knoxville is contributing to the global Volkswagen Group’s larger innovation ecosystem, including innovation centers in Belmont, California; Wolfsburg, Germany; and Beijing, along with hubs in Singapore, Tel Aviv and Tokyo.
Nikola Sells PPH to FFI
Nikola,and Fortescue Future Industries (FFI), a global green energy and metals company committed to leading the world in stepping beyond fossil fuels by developing green electrons, green hydrogen and green technology at scale, announced FFI will acquire Nikola’s Phoenix Hydrogen Hub (PHH) project. FFI will bring the capital and resources required to fully develop the project and the parties are working towards a hydrogen supply agreement to support Nikola’s Class 8 zero-emission trucks.
This agreement is fully aligned with Nikola’s capital efficient energy strategy to collaborate with partners interested in the hydrogen energy ecosystem that Nikola is pioneering.
The PHH is a fast-to-market, green hydrogen project located near Phoenix, in the city of Buckeye, Ariz., and is expected to be built in phases to scale alongside demand. The project is expected to progress towards its first hydrogen production by the middle of this decade.
ABC & Proterra Premier Largest Charging Motorcoach Place in US
ABC Companies, a leading provider of motorcoach, transit, and specialty passenger transport equipment and Proterra Inc, a leading innovator in commercial vehicle electrification technology, announced the official opening of the largest electric motorcoach charging facility in North America.
Located on a 3.5-acre campus in Newark, California, the facility is equipped to charge up to 40 electric motorcoaches with 20 dual-cable EV charging dispensers and can support up to 1.4 megawatts of EV charging power. The facility enables enhanced service, delivery, training and support for the growing number of Proterra Powered Van Hool 100% electric motorcoaches, which are powered by Proterra’s battery technology.
Developed in collaboration with EV charging and battery partner, Proterra, and local utility provider, Pacific Gas and Electric Company (PG&E), the ABC Companies charging facility demonstrates that both the power and charging solutions are available to meet fleet operators’ needs to scale their commercial EV operations.
TUV SUD Opens Lab in MI
TÜV SÜD America Inc., a global leader in testing, inspection, and certification services, officially opened its new state-of-the-art environmental laboratory in Auburn Hills, MI, reaffirming its unwavering commitment to advancing the highest quality and performance standards in EV battery and system solutions. Through rigorous product development and validation processes, TÜV SÜD ensures that EV batteries meet the highest standards of safety, reliability and sustainability in one of the most capable EV battery testing labs in the world.
“Today marks an exciting milestone as we open our state-of-the-art environmental testing laboratory in Auburn Hills, MI, solidifying our commitment to driving excellence in EV battery and system solutions. With our cutting-edge facility and unwavering dedication to safety, reliability, and sustainability, TÜV SÜD is at the forefront of shaping the future of the mobility industry. Through our $44M investment, TÜV SÜD’s largest ever in a laboratory site, we will continue to innovate and accelerate the transition towards a cleaner and more sustainable transportation ecosystem,” said Dr Johannes Bussmann, CEO & Chairman of the Board of Management of TÜV SÜD.
“We are proud to inaugurate our new environmental laboratory in Auburn Hills, MI, which demonstrates our commitment to driving excellence in the Electric Vehicle ecosystem including batteries, components and system solutions. Leveraging TÜV SÜD’s expertise from our global battery laboratory network, we have established this unrivaled testing facility in North America which will also facilitate the deployment of essential Charging Infrastructure and Energy Storage Solutions. This laboratory enables TÜV SÜD to provide cutting-edge solutions to our customers that meet the evolving needs and sustainability requirements and enables the safe and secure adoption of these essential technologies,” added Ishan Palit, COO and Member of the Board of Management of TÜV SÜD.
TÜV SÜD’s experience as a third-party independent test laboratory for batteries in North America dates to 2009. TÜV SÜD broke ground on this new laboratory in Auburn Hills, MI, in 2021, and is now ready to offer its services to accommodate the expanding EV market and the ever-increasing EV battery sizes. This new testing laboratory has also created new jobs in a critical industry in Southeast Michigan helping to grow the state’s economy and securing a strong future for the automotive and mobility workforce.
“We thank our partners in the state of Michigan, including Governor Gretchen Whitmer, the Michigan Economic Development Corporation (MEDC), the City of Auburn Hills, the government of Oakland County, Michigan and the Detroit Regional Partnership,” said Dr. Fabian Schober, CEO of TÜV SÜD America. “Our focus on safety and reliability is paramount in the development and validation of EV batteries and systems. Electrification transforms the mobility industry and presents major opportunities in all vehicle segments. Our passion for sustainability drives us to deliver innovative solutions that support the transition towards a more sustainable and eco-friendly future,” Dr Fabian Schober explains.
Alongside sustainable testing practices, the new facility is testament to TÜV SÜD’s own sustainability efforts. The electricity for the new EV lab is 100% compliant with MIGreenPower, a program dedicated to putting more clean energy on the grid. Additionally, TÜV SÜD’s design and construction of the laboratory includes other environmentally friendly features directed towards lowering the overall carbon footprint of the facility and demonstrating its unwavering commitment to sustainability. These features include the planting of more than 200 trees on site, the use of regionally sourced materials during the build, and the installation of LED automatic lights throughout the facility.
TÜV SÜD places great importance on testing methodologies and procedures to ensure accurate and reliable results. The company is committed to using industry-leading testing protocols and methodologies aligned with international standards. This dedication ensures that EV batteries undergo thorough and rigorous testing, providing manufacturers and consumers with confidence in their performance and safety. The new facility in Auburn Hills is dedicated to comprehensive battery testing and environmental evaluations, including:
- An impressive 80,000 square foot battery testing and environmental lab equipped to handle batteries up to 1200V/1000AW, ensuring comprehensive and rigorous testing procedures, while enabling comprehensive analysis and validation.
- Detroit’s largest electro-dynamic vibration table capable of generating forces up to 350kN, as well as an electro-dynamic MAST (Multi-Axis Shaker Table) system for 6 degrees of freedom (6 DOF) testing and high-frequency response.
- Capability of battery crush up to 1 Mega Newton, ensuring thorough evaluations.
- Ability to conduct fire testing indoors within the bunkers on site.
- Exclusive to Detroit, the lab provides five indoor safety / abuse bunkers constructed with steel-reinforced concrete, accommodating a remarkable quantity of chambers and ensuring the highest sustainability standards.
- In-house capability to handle both battery testing performance and safety / abuse testing.
- Coupled with the Plymouth Lab, TÜV SÜD can run high-voltage EMC testing on battery and BMS (battery management systems) for the customers.
- Through the testing services, TÜV SÜD helps ensure the overall safety and performance of vehicles through lifecycle-performance, battery abuse, environmental, transport and ECE R100 Homologation testing.
Precision with Purpose
TÜV SÜD recognizes the critical importance of safety and reliability in EV battery systems and emphasizes its impact on overall vehicle performance and user confidence to satisfy the growing market of EV battery testing. The EV battery industry has attracted more than $400 billion in investments over the last decade, with about $100 billion invested since the beginning of 2020.
As a trusted partner, TÜV SÜD works closely with the clients to provide tailored solutions that meet their specific requirements. The team of experts is readily available to address inquiries and provide support throughout the entire testing process, ensuring a seamless experience for its customers. TÜV SÜD is determined to keep paving the way for a successful electrification of the transport system. More information can be found here.
Nuvola’s DDS Prevents Battery Fires
Nuvola Technology (formerly Millibatt), a venture-funded battery materials start-up, announces its patented SafeCoat Direct Deposition Separator (DDS)™ material that eliminates the primary cause of lithium-ion battery fires. SafeCoat replaces the troublesome plastic sheet separator material used in today’s battery manufacturing process. Its ingenious spray-on coating fully encapsulates and protects the battery’s electrodes from a thermal runaway and a potential fire. Nuvola was selected as one of ten winners in LG Energy Solution’s annual 2022 Battery Challenge, competing with over 100 companies. The LG Battery Challenge competition is designed to accelerate the adoption of new battery technologies and business models.
The primary cause of battery fires is a manufacturing error internal to the battery cells of today’s electric vehicles (EVs), e-scooters, e-bikes, and cell phones. These batteries can contain thousands of tissue-paper thin folded sheets of a porous plastic membrane that keeps the internal battery electrodes from coming in contact. This 50-year-old sheet separator technology is prone to manufacturing assembly errors and failure. During the battery assembly process, a single sheet separator can become damaged, creating an undetectable wrinkle, misalignment, misfolding, or even a tiny tear allowing the electrodes to come in contact. This may cause a fire — days, months, or years later. SafeCoat solves this safety issue by replacing the sheet separator with a sprayed polymer electrode coating that ensures the electrodes never come into contact.
“Improving battery safety is one of the highest priorities for the EV market, with large, energy dense batteries representing a significant threat to public safety in the event of a fire,” said James Hodgson, Research Director, Automotive at ABI Research. “Nuvola Technology’s approach of separator coating offers the opportunity to improve both safety and production yield by modifying one step of the manufacturing process.”
The recent EV and e-bike fires are examples of this insidious and tragic battery failure that SafeCoat can eliminate. The Nuvola SafeCoat product is now under evaluation by several major battery and car manufacturers, with products utilizing the technology expected in the market in 2025.
Nuvola has a growing patent portfolio spanning several new battery materials for high-energy and microbattery applications. Its founders, Dr. Janet Hur and Dr. Leland Smith performed innovative battery material development while doing post-doctoral research at UCLA.
Nissan Adopts NACS in 2025
Nissan has reached an agreement with Tesla to adopt the North American Charging Standard (NACS) beginning in 2025, providing Nissan customers even more choices when it comes to charging their electric vehicle. Nissan is the first Japanese automaker to announce future product support for NACS.
From 2024, Nissan will make available a NACS charging adapter for Ariya models which are currently equipped with the Combined Charging System 1 (CCS1) for DC fast charging. This will enable customers to connect their vehicle’s charging port to NACS plugs at compatible chargers.
Starting in 2025, Nissan will begin offering EVs for the U.S. and Canadian markets with a NACS port. This will make charging on the Tesla Supercharger network seamless and convenient for drivers, significantly increasing the number of public fast-charging locations at which Nissan EVs can be charged1.
“Adopting the NACS standard underlines Nissan’s commitment to making electric mobility even more accessible as we follow our Ambition 2030 long-term vision of greater electrification,” said Jérémie Papin, chairperson, Nissan Americas. “We are happy to provide access to thousands more fast chargers for Nissan EV drivers, adding confidence and convenience when planning long-distance journeys.”
As part of Ambition 2030, Nissan is targeting more than 40% of its U.S. vehicle sales to be fully electric by 2030, with even more to be electrified. This includes two all-new, all-electric vehicles to be assembled2 at the Nissan plant in Canton, Mississippi, beginning in late 2025.ore details on the rollout of Nissan’s NACS compatibility will be communicated at a later date.
Miller Electric Starts EVIDC
Miller Electric Company, in partnership with CBRE, broke ground on Electric Vehicle Innovation Design Center (EVIDC) in Jacksonville FL. The cutting-edge facility creates the opportunity for clients and stakeholders to experience firsthand a wide range of electric vehicle (EV) solutions from various manufacturers. With a focus on providing tailored EV and microgrid solutions, the EVIDC aims to alleviate the challenges faced by clients when selecting the right EV charging options and infrastructure. WB Engineering+Consultants, Schneider Electric, and Graybar are supporting partners in the facility.
The EVIDC is the only client-driven center in the U.S. that welcomes public use. The center is set to house a diverse array of EV technologies and microgrid solutions. With seven Level 3 Chargers and four Level 2 Chargers from multiple manufacturers and software providers, the center offers abundant opportunities to test and evaluate different options. In addition, the EVIDC showcases the latest sustainable technologies, including inductive charging, solar canopies, battery storage, micro-grids, and transparent use-case data, allowing clients to witness the environmental benefits of these innovations.
Miller Electric is a leading EV solutions provider in the U.S., offering turnkey solutions, trusted partnerships, and innovative hands-on engagement. As a national electrical and technology contractor, Miller Electric is committed to driving innovation, growth, and sustainability in the EV market.
As a lead partner in the EVIDC, CBRE will use the center to demonstrate various EV-charging technologies and formats for its clients and as a training site for its technicians to stay up-to-speed on charging technologies and software. CBRE, the world’s largest commercial real estate services company, advises clients on rollouts of EV-charging networks as well as deployment and maintenance of EV fleets.
Local government officials were in attendance at the groundbreaking including Jacksonville Mayor, Donna Deegan and executives from JEA (Jacksonville Electric Authority) and JTA (Jacksonville Transportation Authority).