Effective thermal management is one of the most critical aspects of EV battery pack design. Engineers must not only ensure efficient heat dissipation during charging and discharging cycles but also maintain uniform temperature across all cells to optimize performance and extend battery life. This requires integrating advanced materials—such as flame-retardant foams, adhesives, and gap fillers—that can simultaneously control heat flow, provide structural reinforcement, and improve overall safety.

To learn more about addressing these thermal challenges at the material level, Charged recently chatted with Germaine Mariaselvaraj, Technical Service Manager at H.B. Fuller. Germaine explained how their EV Protect foam series addresses a core challenge in EV battery design: preventing thermal runaway from propagating between cells. The foam acts as a fire‐retardant barrier, helping isolate a single failing cell so that the rest of the pack remains intact. Beyond just safety, it also delivers structural and vibration-resistance benefits, which many battery integrators rely on to meet durability standards without adding heavy metal or plastic stiffeners.

H.B. Fuller’s first offering, EV Protect 4006, is a semi-structural foam that flows into cavities and expands to encapsulate components. As market demands shifted toward more structural solutions, H.B. Fuller introduced EV Protect 5006, 5008, and 5009—versions with increased stiffness that allow for the reduction or replacement of traditional structural parts. The upshot: reduced part count, lower mass and a more integrated pack layout that supports newer architectures like cell-to-pack or cell-to-chassis.

Beyond thermal management, the foam contributes to noise, vibration and harshness (NVH) control and thermal insulation. Some customers rely on the foam to help them pass vibration testing that they could not achieve with bare components, and because the foam envelops the cells, it also mitigates temperature swings in extreme ambient conditions. In cold or hot environments, the foam moderates local temperatures, helping reduce the impact on range or battery performance.

Germaine also discussed H.B. Fuller’s EV Bond 775, a reactive hot-melt adhesive that streamlines battery module assembly. By replacing tape or multi-step adhesive processes, this reactive hot-melt enables faster bonding of mica to lids, cells and cooling tubes. That accelerates cycle time, reduces handling, and cuts scrap or rework—all valuable in high-volume battery manufacturing.

On the gap-filling and thermal interface front, H.B. Fuller’s EV Them 288 (a silicone-free MS polymer) competes with traditional silicone gap fillers. Because it’s silicone-free, it helps meet stricter OEM constraints on materials in the manufacturing environment.

Learn more about H.B. Fuller’s battery pack materials portfolio https://www.hbfuller.com/ev.

UK battery technology company EQONIC has announced a “breakthrough battery technology” that it says offers lower cost along with increased safety and sustainability compared to current designs.

After years of development, EQONIC says it has created a new battery system that achieves material costs of just 30% compared to traditional lithium metal batteries. This translates to a target manufactured cost of £50/kWh at scale, approximately half the current industry average.

EQONIC says its proprietary composite materials are inherently non-flammable, eliminating fire risk. The technology uses only abundant materials—no rare earth metals, no lithium and no sodium. The company’s batteries are designed for complete recyclability from conception.

“The energy storage industry is stuck in a compromise, choosing between cost, safety or sustainability,” said Jas Kandola, founder and CEO of EQONIC Group. “While others were rushing to market with incremental improvements, we took a different path: develop breakthrough technology first, then build the business around it. We hand-picked cross-industry experts and assembled a highly experienced scientific and engineering team from diverse sectors to tackle the fundamental challenges. The result is technology that costs 70% less (at material level) than traditional lithium batteries while being completely safe and sustainable.”

Rather than building its own factory, EQONIC plans to license its technology and to secure collaborations and partnerships to commercialize its innovations. By partnering with established partners, EQONIC aims to be a technology provider rather than competing directly with large-scale Asian producers.

While developing its battery technology, EQONIC has established a commercial operation selling and installing complete LFP-based energy storage solutions for B2B clients. Its current product portfolio offers low- and high-voltage batteries, on-grid and hybrid inverters, customizable power conversion systems, and air- and liquid-cooled cabinet batteries.

Source: EQONIC

Battery material manufacturer ACT-ion Battery Technologies has signed a lease for a new facility in Carrollton, Texas.

The site will house a pilot plant dedicated to scaling the company’s clean high-throughput manufacturing process for battery cathode active materials (CAMs).

The process aims to eliminate byproducts and reduce energy consumption, water usage and the overall physical footprint associated with traditional CAM production, the company said.

By locating in Carrollton, in the Dallas-Fort Worth metroplex, the company said it is positioning within a robust industrial and technological ecosystem to strengthen the local supply chain for the EV and energy storage sectors.

The scale-up of the technology has been supported by the US Department of Energy’s Advanced Materials & Manufacturing Technologies Office (AMMTO) and the Vehicle Technologies Office (VTO).

ACT-ion raised $7.5 million in a funding round earlier this year led by BASF Venture Capital and including participation from Hunt Energy Enterprises, Mirae Asset Capital, Arosa Capital Management and LG Technology Ventures.

“This pilot plant is where our vision for a cleaner and more economical battery future begins to take physical form,” said Jin Lim, CEO of ACT-ion. “Choosing Carrollton was a strategic decision; the city’s proactive support for innovation and its prime location in a major logistics hub provide the ideal environment for us to scale our operations and attract top talent.”

Source: ACT-ion Battery Technologies

Sponsored by Heilind.

Hirose delivers innovative connector solutions that power the future of automotive technology. Trusted by the world’s leading OEMs and Tier 1 suppliers, its portfolio addresses the full spectrum of applications—from EV powertrains and charging systems to ADAS, LiDAR, infotainment, and in-vehicle networks.

With expertise in miniaturization, high-speed transmission, and rugged power delivery, Hirose connectors combine compact footprints with robust mechanical reliability, vibration resistance, and waterproof options.

Hirose’s portfolio addresses the toughest challenges in modern automotive design. Standout series include the KW30, a compact 1 mm-pitch connector engineered for vibration resistance in harsh environments; the GT50, an ultra-small, lightweight connector rated to 125 °C with robust vibration performance for camera and LiDAR subsystems; the DF60FS, a compact right-angle variant supporting up to 65 A with finger-safe design and secure locking for EV power distribution; and the HVH-280, a high-voltage waterproof connector rated 30 A/600 V, providing reliable performance in EV battery packs, inverters, and on-board chargers.

Beyond individual products, Hirose connectors are designed to simplify integration and enhance system reliability. With features such as EMI shielding, IP-rated waterproof sealing, vibration resistance, and floating designs for misalignment tolerance, Hirose solutions are tailored for the realities of automotive environments.

Download the full eBook on Hirose’s Impact on LiDAR Technologies

By combining global manufacturing strength with more than 80 years of engineering expertise, Hirose empowers automakers to deliver vehicles that are safer, smarter, and more sustainable. Whether for power, signal, or high-speed communication, Hirose connectors are built to support the future of electrification and intelligent mobility.

For a deeper understanding of Hirose’s large portfolio of automotive connector solutions, watch this video or visit Heilind.com.

The road remains rough for Canadian EV maker Lion Electric. As recently as early 2024, the company was riding high, working through orders for thousands of electric buses and electric trucks, building its own batteries and piloting V2G applications. Later that year, it was forced to file for bankruptcy.

In May 2025, the company was acquired by a group of Quebec investors, who renamed the company LION and announced that it would drop electric trucks and focus entirely on electric school buses.

Was the lack of an ALL CAPS name the root of the company’s financial troubles? Well, maybe, but a highly-publicized (of course) September bus fire in Montreal was probably a contributing factor. As it turns out, the fire, which caused no injuries, has since been traced to faulty HVAC fuses, a defect that also affected the company’s diesel buses.

Be that as it may, several buyers have reported problems with their Lion Electric buses that necessitated costly repairs, and some US school districts have pulled them from service.

Now LION has announced that all of the 1,200 Lion Electric LionC school buses operating in Quebec are back in service. However, the company also says it will not honor warranties on any of the buses sold outside of Quebec, leaving US school districts in a bind.

The US schools purchased the buses with funding from the EPA’s now-defunct Clean School Bus Program.

Clean Trucking contacted the US DOJ, EPA and NHTSA regarding the situation. All three agencies appear still to be functioning, and responded to CT, but none has announced a formal investigation into Lion Electric.

The DOJ told Clean Trucking that it can “neither confirm nor deny the existence of an investigation.”

The EPA said it “understands Lion Electric’s bankruptcy has put school districts who chose that company as a vendor in a difficult position,” and added that it is “actively monitoring the bankruptcy proceedings and evaluating all options to support impacted school districts.”

NHTSA is “aware of the issues that school districts have had with Lion Electric buses and is evaluating the situation. NHTSA encourages school districts to call the Vehicle Safety Hotline at 888-327-4236 or file a complaint online regarding any safety concerns.”

Source: Clean Trucking

The US Department of Energy has announced that the Loan Programs Office, an entity within the department that provides loans and loan guarantees to help deploy innovative clean energy and transportation technologies, has restructured the department’s deal with Lithium Americas with support from General Motors.

The department cited the need to “further protect taxpayers and solidify the launch of the only domestic source of lithium carbonate here in America” as the justification for the restructuring.

As part of the restructuring, the US government will take a 5% equity ownership stake, which is in addition to a 5% stake in the company’s joint venture with GM in Nevada. The equity is in exchange for releasing the initial $435 million of a $2.23-billion loan intended to accelerate development of the mine.

Once it opens in 2028, the mine at Thacker Pass is expected to become the largest producer of lithium in the Western Hemisphere.

“The revised agreement includes robust loan amendments as well as more than $100 million of new equity,” the Department of Energy said.

Lithium Americas secured a $2.26-billion loan from the Biden administration in October 2024.

Currently, China, which is the world’s third-largest producer of lithium after Australia and Chile, produces 40,000 metric tons on an annual basis, while US production is under 5,000 metric tons. Once fully operational, the Thacker Pass mine will dramatically change that equation, bringing US production to approximately 40,000 metric tons.

The Thacker Mine has not been without controversy, however—it has faced significant opposition from nearby Native American tribes. Human Rights Watch and the American Civil Liberties Union found that the federal government’s permitting of the mine violated the rights of Indigenous people, detailing the violations in a February 2025 report wherein it alleged that the government failed to “obtain free, prior and informed consent” from tribes that were impacted by its construction. Ranchers and environmental groups have voiced concerns over the mine’s potential impact on local water sources, and endangered species advocacy groups have also opposed the mine’s construction.  

Source: US Department of Energy

Sponsored by Pickering Interfaces.

Discover how the shift to 800 V power system architectures is revolutionizing electric vehicle design and testing. This white paper delves into the reasons behind the move to 800V charging, the challenges it poses for test professionals, and the critical role of hardware-in-the-loop (HIL) simulation in this transition.

Learn how 800V systems enhance efficiency, range, and charging times while increasing complexity in battery management and component durability. Explore strategies for building HIL test platforms, identifying early design issues, and leveraging high-voltage switching, RTD simulation, and fault insertion for cost-effective EV development.

OMI’s Fusion Drive is a hybrid powertrain designed to optimize power and efficiency in challenging off-road conditions. Charged recently chatted with Paul Brewster, Chief Sales Officer at OMI, to learn more. Rather than simply chasing novelty, OMI is a pragmatic innovator, creating systems designed to tackle real-world challenges.

The Fusion Drive system features electric and combustion power in a unified drivetrain. Riders can toggle between stealth mode (electric only), boosted or hybrid modes, or fallback to traditional combustion. This flexibility enables operators to adapt according to the mission profile, terrain, noise constraints or thermal signature requirements. In addition to recreational and agricultural vehicles, Brewster highlighted military applications, noting that quiet, heat-reduced approaches may prove decisive in life-or-death scenarios.

Complementing the powertrain is the Nexus user interface, a console built for modularity and control. Rather than viewing the drive system in isolation, OMI treats it as a hub for broader integration. The Nexus UI can manage auxiliaries like winches, cameras, lights and tie in with third-party hardware or software. Whether through an onboard keypad or via smartphone, the control is placed directly in the user’s hands. The emphasis is on seamless integration and modular growth, rather than forcing rigid system constraints.

In terms of deployment, OMI has already announced a collaboration with Upfit UTV to integrate the Fusion Drive into a Polaris Ranger 1500 platform. The system is designed to drop in without structural chassis changes, which helps expedite adoption and reduce retrofitting barriers. The target availability is early 2026. By leveraging its global R&D and manufacturing bases in China, Mexico, and the US, OMI plans to scale into markets where regulatory and economic environments align favorably.

To learn more, visit https://omi1.com/, and follow them on social media.

Facebook: https://www.facebook.com/omi.mecatronicsolutions/
LinkedIn: https://www.linkedin.com/company/omi-electromechanical/
YouTube: https://www.youtube.com/@OMI-ElectromechanicalSolutions

Sunrise (Guizhou) New Energy Material, a subsidiary of Chinese graphite anode material manufacturer Sunrise New Energy, has been granted a US patent titled Preparation Method of an Anode Material for Lithium-Ion Batteries.

The method improves the initial Coulombic efficiency and power performance of graphite composites for next-generation high-energy and high-power lithium-ion batteries, according to the company.

The company expects the patent to enhance its ability to collaborate with North American partners and expand in the region.

The patent discloses a novel method for preparing graphite-based composites through titanium/nitrogen/fluorine co-doped porous titanium dioxide. The process includes dispersing tetrabutyl titanate in a glycerol solvent, adding hexadecyl trimethyl ammonium bromide, and adjusting the pH with tetramethyl ammonium hydroxide. That is followed by adding ammonium fluoride solution and heating at 150-200° C for 1-6 hours.

The resulting product is centrifuged, washed and vacuum-dried to obtain the doped porous titanium dioxide. This material is then combined with lithium salts and graphite, spray-dried to form porous lithium titanate-coated graphite composites and subsequently carbonized in a tube furnace under argon protection.

Sunrise (Guizhou) New Energy Material has completed the construction of a manufacturing facility with a production capacity of 50,000 tons in Guizhou Province, China.

“The granting of this US patent reaffirms our commitment to advancing core technologies in anode materials, further supporting our strategic vision of ‘leading in the United States, expanding globally,’” said Mr. Haiping Hu, founder and CEO of Sunrise. “We will continue to increase our R&D investments and accelerate the industrial application of our patented innovations.”

Source: Sunrise New Energy