How to achieve: In the EXTENDED project, state-of-the-art models and sizing methods will be applied at different levels (electrical, mechanical, and thermal) to develop and optimise the battery systems in a modular and scalable way for different applications. Hereby, the focus will be to develop modular battery systems based on solid-state battery cell technology with its specific characteristics in terms of pressure control and thermal management, for different applications. To achieve those aspects number of innovative models and simulation tools will be used such as Ansys, Comsol, Solidworks, and Matlab, among others. The development process will be carried out in an iterative process whereby the defined application requirements will be used as a basis.

How to achieve: The BMS and electrical system developed in the EXTENDED project will focus on reduced complexity to achieve a high level of scalability for various domains (e.g., automotive, Urban Air Mobility (UAM), road transport) enabling a highly automated process of assembly and disassembly. These objectives will be achieved in the project by the combination of various novel concepts. First, a distributed sensor matrix using near-field wireless components will ensure precise and safe sensing of critical operating parameters of the novel solid-state battery system. The sensors (e.g., temperature, strain, humidity, mechanical pressure) will base on advanced printing techniques and the applicability to cells and battery system structure will be investigated. In addition, a second temperature estimation method will be implemented in the BMS to enhance the safety of the battery system through a simplified single frequency impedance estimation method when using an immersion or direct cooling thermal system. Further, an optical wireless safe and scalable BMS-Slave to BMSMaster communication will be developed to completely remove any wire harness within the battery system. Within the project, this communication architecture will be physically integrated into the battery system housing and its structural elements.

How to achieve: The mechanical design of the novel SSB pack in EXTENDED will focus on lightweight design with optimum and safe thermal properties as well as simplified manufacturability and function integration. Specific lightweight design materials and structures will be applied to decrease the SSB pack weight and increase energy density. The battery enclosure and cell holders will exhibit significantly enhanced safety against fire using a combination of optimized design and flame retardant material additives. For this purpose, different polymer-based materials will be evaluated in the first step regarding lightweight design potential and thermal safety properties as well as compatibility with novel high-efficiency manufacturing techniques. In a second step, experimental campaigns on a coupon scale will be conducted to evaluate material and structure demonstrators regarding the anticipated mechanical and thermal safety properties. Based on the coupon scale evaluation, prototype components will be manufactured, demonstrating lightweight design and optimum safety properties as well as the targeted cost efficiency and recyclability.

How to achieve: The Solid-State battery thermal management solution developed in the EXTENDED project aims to control the cell surface temperature at optimum values to maximize performance and minimize materials degradation. These objectives will be achieved by the combination of numerical and experimental tools. First, a single cell will be thermally characterized to understand the behaviour under different electrical requests and ambient conditions. Secondly, a virtual Solid-State module will be created to test different cooling and heating solutions for optimum cell surface temperature. The results will be validated with an experimental module testing under different current requests representative of battery vehicle operation, fast charging, and constant discharge currents. Further, the safe of the system will be evaluated at a package level with virtual tools. A single cell will be tested experimentally to feed the numerical models. After, different safety tests will be performed to understand the risk of the system with the novel numerical tool developed in the EXTENDED project. Within the project, this battery thermal management system will be physically integrated into the battery system enclosure and its structural elements.

How to achieve: The battery module prototypes based on the solid-state battery technology that will be developed in the EXTENDED project, will be experimentally tested, and validated considering the real-world conditions ensuring the applicability of the developed battery systems to various use-cases (passenger car, heavy-duty vehicle, and aviation). To achieve this, realistic load profiles and environmental conditions will be considered for each application. Downscaled lab testing will be performed by employing battery module/pack testers to apply the load profiles, climate chambers representing the environmental condition and thermal management test setup to ensure the efficient, safe and long-life performance of the system following the requirements and specifications related to each application.

How to achieve: The environmental, economic, and social performance will be optimized through the development of supporting studies for the design, manufacturing, and recycling of the SSB, in a holistic perspective. Making use of design-for-eXcellence approaches, the project will apply lean-based tools for the optimization of the SSB design in terms of second-life applications and recycling processes, considering material and energy efficiency, battery durability, as well as material and component recovery, and recycling. Through the development of life cycle models for battery manufacturing, use and final disposal, a life cycle sustainability assessment will quantify the environmental impact reduction achieved by the new EXTENDED battery system.

How to achieve: Early deployment of safe and energy-saving solutions for transport applications, and development and assessment of a technical roadmap, including the monitoring of indicators (such as cost, size, safety, lifetime, etc) for success and barriers along with the roadmap. Establishing links and organising meetings with European funded projects within a similar topic (such as Battery2030+) and carrying out a roadshow to connect with 3 (to 5) stakeholders that are relevant for the project in reducing the barriers and enable the project results to be brought closer to exploitation.