Researchers from Dresden (Saxony), Germany, have developed the world's lightest lithium-ion battery system. Scaba, a branch of the Institute for Lightweight and Synthetic Materials Technology at the Technical University of Dresden, has achieved this. Sebastian Prengel, General Manager of Scaba, stated that they have successfully incorporated 30% more battery cells than Tesla cars while maintaining the same structural space. This research project is a collaboration with EnvitesEnergy in Nordhausen (Thuringia). This partnership between Scaba and EnvitesEnergy aims to apply the research findings to standardized, mass-produced batteries, allowing customers greater freedom in choosing battery types and manufacturers.
Based on a patented lightweight design, lithium batteries are assembled into various geometries. This battery structure boasts a novel lightweight design and extremely high safety. Therefore, these lithium batteries not only vary in geometry but also in voltage levels. Furthermore, Marco Zichner, founder of the Scaba Institute, stated, "We have mastered and safely controlled this high-voltage battery technology with rated voltages up to 1000V," and the specific energy of this battery system has been proven to be 230Wh/kg.
High-voltage battery systems with higher active and passive safety
To reduce the number of parts and improve production efficiency, the consortium uses pre-assembled hybrid plastic and metal components in its production process. When developing high-voltage battery systems, the active and passive safety of the vehicle are the most critical considerations. For example, the consortium has devoted considerable effort to developing a fiber composite housing capable of diverting fault currents and performing intrusion detection. The system developed by the consortium, featuring insulation fault detection and intermediate circuit voltage monitoring, already meets ASIL-D and SIL-Level 3 standards.
In addition, a self-developed cross-domain safety design solution has also been patented. This patented technology can safely and quickly autonomously disconnect high-voltage power when necessary. Another integrated achievement is the "DryCloud system" developed by EnvitesEnergy. This system eliminates the risk of battery fire in extreme situations. The Scaba Institute believes that this flexible lithium-ion high-voltage battery system can be applied to electric vehicles, automotive electrical systems, and medical devices.
Tim Schöfer of EnvitesEnergy stated that although their independent mass production site has not yet been determined, with the help of corresponding investments, it is still possible to increase annual power production to over 100 megawatt-hours within a year. "Currently, our initial pilot orders mainly come from the industrial battery sector, the electric bus sector, and automotive suppliers."
