energy

Internet of Things (IoT) devices are often deployed in remote or challenging environments where reliable, maintenance-free power solutions are essential. Traditional battery-dependent systems not only face limitations in such scenarios but also contribute significantly to environmental challenges. In the United States alone, it is estimated that standard portable batteries (AA, C, D, etc.) account for 20% of household hazardous material in landfills.[1] Energy harvesting offers a promising alternative to power traditional battery-reliant systems, with the potential to enable self-sustaining IoT devices.This article explores the latest advancements in energy harvesting technology, focusing on its system design and practical applications. One of the primary areas of focus is Electronic Shelf Labels (ESLs), which showcase how energy harvesting can eliminate disposable batteries in smart retail stores. By examining the solutions and real-world use cases, we aim to provide insights into building sustainable IoT energy harvesting systems that address the limitations of current approaches and push the boundaries of what is possible.<h2>Energy Harvesting Methods</h2>Energy harvesting encompasses the conversion of ambient energy into electrical power, thereby reducing reliance on conventional batteries. This interdisciplinary field employs several methodologies, including:<ul><li>Photovoltaic Energy Harvesting: Transforms ambient light into electricity through photovoltaic cells.</li><li>Piezoelectric Energy Harvesting: Converts mechanical stress into electrical energy using piezoelectric materials.</li><li>Thermoelectric Energy Harvesting: Exploits temperature gradients via the Seebeck effect to generate electrical power.</li><li>Electromagnetic Energy Harvesting: Utilizes Faraday’s law of electromagnetic induction to convert mechanical motion into electrical energy.</li></ul>For a deeper exploration of energy harvesting, check out our previous article: <a href="https://www.wevolver.com/article/evaluating-the-feasibility-of-energy-harvesting-for-iot-products" target="_blank">Evaluating the Feasibility of Energy Harvesting for IoT Products</a><h2>Energy Harvesting for ESLs: Addressing the E-Waste Problem</h2>ESLs are digital displays used in retail environments to dynamically show pricing and product information. Widely deployed in supermarkets, ESLs offer efficiency and flexibility for updating prices in real-time. However, a major drawback of current ESL systems is their reliance on disposable batteries, which are discarded once depleted. A study suggests that soon around 78 million batteries powering IoT devices will be dumped globally every day if nothing is done to improve their lifespan.[1] This results in significant electronic waste and increases operational costs for frequent replacements.<h2>Case Study: A Sustainable Supermarket Initiative</h2>The environmental impact of disposable batteries in retail is substantial. A large supermarket typically deploys around 10,000 Electronic Shelf Labels (ESLs), each powered by a battery with an average lifespan of five years. This means a single store disposes of approximately 2,000 batteries annually. When scaled to a supermarket chain with 500 locations, the total number of discarded batteries reaches 1 million per year—contributing significantly to global e-waste concerns.Beyond environmental implications, the operational costs associated with ESL maintenance are considerable. Labor costs in supermarkets are high, and when a single ESL battery fails prematurely, it is often more cost-effective for stores to replace all ESLs at once rather than conducting individual replacements. This reactive approach leads to unnecessary waste and increased expenses.Recognizing this growing challenge, a leading supermarket chain sought a more sustainable solution. The company partnered with engineers to design and implement an energy-harvesting digital pricing system using Nexperia’s innovative energy harvesting power management ICs (PMICs). The supermarket’s primary goal was to eliminate the reliance on disposable batteries for their ESLs while maintaining seamless functionality. This approach addresses a critical limitation in battery technology, as even with 100% recycling rates, there is not enough lithium available to power the growing number of IoT devices worldwide.[1] By integrating energy harvesting techniques, the supermarket decided to take a step toward reducing its environmental footprint while ensuring reliable, long-term operation of its digital pricing systems.<h3>Design and Testing Phase</h3>To develop a sustainable energy-harvesting system for ESLs, the engineering team focused on designing a robust system architecture capable of eliminating disposable batteries while maintaining seamless functionality in supermarket environments. The system architecture is illustrated in the diagram below:<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQ0NjU1MTQzMzc1LWltYWdlMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" alt="nexperia-pmic-block-diagram" />A block diagram illustrating the ESL system architecture powered by Nexperia’s PMICThis design comprises the following components:<ul><li>Photovoltaic Cells: Solar cells integrated into the system serve as the primary power source, effectively converting supermarket’s indoor ambient lighting into a steady and renewable energy supply.</li><li>Energy Harvesting PMIC: This module specializes in converting the captured ambient energy from the supermarket environment into stable electrical power. It operates in a harvesting power range of up to 50 mW, ensuring broad adaptability to various energy sources. Key features include ultra-fast Maximum Power Point Tracking (MPPT), which uses an embedded hill-climbing algorithm to detect maximum power points in just 0.5 seconds, optimizing efficiency in dynamic environments. Additionally, the PMIC offers a number of battery protection features and can be configured via hard-coding or I²C, allowing for tailored solutions. The PMIC is compatible with batteries, supercapacitors, and hybrid capacitors, making it a versatile and efficient solution for sustainable IoT applications.</li><li>Microcontroller: Acting as the system's control center, the microcontroller processes operational logic, including data updates for pricing and communication with external systems.</li><li>Flash Memory: Ensures data persistence during power fluctuations, enabling secure storage of pricing information and operational states.</li><li>Radio Frequency (RF) Front-End: This module facilitates wireless communication using protocols such as Bluetooth, NFC, and Wi-Fi, enabling seamless updates to pricing and product details from a central management system.</li><li>Sensors (Digital and Analog): Enhance the ESL system by enabling functionalities such as inventory tracking and monitoring environmental factors like temperature.</li></ul>The design focused on achieving the following goals:<ol><li>Efficient Energy Management: The PMIC, combined with Nexperia's MPPT algorithm, ensures optimal energy conversion and utilization under varying lighting conditions.</li><li>Operational Reliability: The microcontroller and flash memory guarantee uninterrupted functionality, even during brief energy dips.</li><li>Scalability and Connectivity: The RF front-end enables seamless integration with existing store systems, supporting real-time updates.</li></ol>During testing, Nexperia’s evaluation board enabled the team to:<ul><li>Measure indoor ambient light levels in different sections of the supermarket, ensuring photovoltaic cells could generate sufficient power consistently.</li><li>Simulate the energy demands of ESLs during peak operations, such as mass price updates, to confirm the system's ability to handle high loads.</li><li>Test the system's response to fluctuating lighting conditions, ensuring reliable performance without the need for disposable batteries.</li></ul>These tests demonstrated the feasibility and robustness of the energy-harvesting design, making it ready for full-scale implementation.<h3>Implementation Phase</h3>Following successful testing, the supermarket chain deployed energy-harvesting ESLs across multiple store locations. Key steps in implementation included:<ul><li>Fitting ESLs with Nexperia’s ICs and integrated photovoltaic cells.</li><li>Training store staff on maintaining the new system and monitoring its performance.</li><li>Collecting data on energy usage and cost savings to evaluate the system’s impact.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQ0NjU1NzM5NDQ4LWltYWdlNS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" alt="esl-in-retail" />ESLs can be used to display various details, including discounts, promotional messages, price validity periods, product expiry dates, and real-time stock availability.The new system met the sustainability goals of the supermarket and reduced operational costs associated with battery replacements and disposal.<h3>Broader Implications</h3>The global ESL market is projected to grow at a compound annual growth rate of 18.3% from 2024 to 2034, reaching a valuation of $1.4 billion by 2034.[2] This growth will be driven by the increasing adoption of technologies like energy harvesting, which revolutionize digital pricing systems in retail. According to a report, ESLs also enhance accuracy by reducing price errors by 5% to 10% compared to traditional paper shelf labels.[3] By integrating Nexperia’s energy harvesting technology, supermarkets can achieve greater sustainability, reduce electronic waste, and improve operational efficiency—key factors driving the broader market expansion.<h2>Other Applications of Energy Harvesting</h2>Energy harvesting has proven its versatility and potential across various industries. Below are some other notable applications of the technology:In wearable technology, energy harvesting enables devices such as smartwatches, fitness trackers, and health monitors to operate with significantly extended battery life or no battery at all. By incorporating photovoltaic and kinetic energy harvesting methods, these devices reduce maintenance requirements and improve user convenience.In IoT systems, autonomous sensors and remote monitoring solutions benefit greatly from energy harvesting. These systems, often deployed in remote locations, eliminate the need for frequent battery replacements, thereby reducing operational costs. Solar and RF energy harvesting have been successfully implemented in agricultural IoT solutions, leading to improved crop yields and optimized resource management.Industrial operations have also adopted energy harvesting for machinery condition monitoring. Piezoelectric harvesters, for example, convert mechanical vibrations into electrical energy to power real-time diagnostics systems.<h2>Addressing Challenges and Exploring the Future</h2>Despite its transformative potential, energy harvesting faces several challenges:<ul><li>Low Power Density: Current technologies often fall short of powering high-demand applications. Advances in material science and hybrid system architectures are addressing this limitation.</li><li>Environmental Variability: Ambient energy sources are inherently inconsistent, necessitating sophisticated storage and regulation systems.</li><li>Economic Barriers: High initial implementation costs pose significant entry barriers, though economies of scale and continuous R&amp;D are driving cost reductions.</li></ul><h2>Nexperia’s NEH Series PMICs: Advancing Energy Harvesting Solutions</h2>Nexperia’s energy harvesting PMICs, including the <a href="https://www.nexperia.com/product/NEH7110BU" target="_blank">NEH71x0</a> series, offer cutting edge capabilities in power management for low-power applications. These modules are designed to cater to a wide range of energy harvesting requirements with flexibility and efficiency. Key features and capabilities include:<ul><li>Wide Harvesting Power Range: The modules support a power range of 15 μW to 50 mW, making them suitable for various energy sources, including photovoltaic cells. They are optimized for harvesting ambient indoor light energy, enabling efficient power generation even under low-light conditions, making them ideal for indoor IoT applications like Electronic Shelf Labels (ESLs) and smart sensors.</li><li>Ultra-Fast MPPT Interval: Utilizing an embedded hill-climbing algorithm, some of the PMICs identify maximum power points within 0.5 seconds, ensuring efficiency in dynamic and fluctuating conditions.</li><li>Battery Protection Features: Integrated safeguards include Over-Voltage Protection (OVP), Low-Voltage Detection (LVD), and Over-Current Protection (OCP) to protect energy storage components.</li><li>Support for Battery-Less Designs: Cold-start functionality enables systems to operate without traditional batteries, reducing maintenance needs and electronic waste.</li><li>USB Charging and Configurable Outputs: The modules support USB charging up to 200 mA and feature a Low Dropout Regulator (LDO) with configurable output voltage for flexible designs.</li><li>Compact Form Factor: Housed in a 16-terminal Quad Flat Package (3 mm x 3 mm), these PMICs minimize external component requirements, reducing the Bill of Materials (BOM).</li><li>Inductorless Design: By eliminating the need for external inductors, these PMICs simplify circuit design, reduce overall BOM costs, and minimize complexity in compact applications.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQ0NjU1MzEzMzQ5LWltYWdlNC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" alt="nexperia-pmic-nex71x0" />Package diagram of Nexperia NEH71x0<h2>Conclusion</h2>Energy harvesting with <a href="https://www.nexperia.com/product/NEH2000BY">Nexperia’s PMICs</a> presents an opportunity for industries seeking sustainable and efficient power solutions for IoT devices. As demonstrated through the case study of ESLs, these ICs offer a pathway to eliminate disposable batteries and reduce electronic waste. Nexperia’s PMICs are equipped with features like ultra-fast MPPT and compatibility with various energy sources. They are enabling scalable, reliable, and cost-effective implementations across industries.Beyond retail, energy harvesting technologies are driving advancements in wearables, IoT sensors, industrial monitoring, and automotive systems, showcasing their far-reaching potential. While challenges such as low power density and environmental variability remain, continuous innovation and research promise to bridge these gaps and unlock new possibilities.<h2>References</h2>[1] Mesquita R. Nexperia. Harvesting Sustainable Battery Power [Internet]. December 20, 2023. Available from:<a href="https://efficiencywins.nexperia.com/innovation/harvesting-sustainable-battery-power" target="_blank"> https://efficiencywins.nexperia.com/innovation/harvesting-sustainable-battery-power</a>[2] Pott J. Electronic shelf labels: Retailers are testing ESL [Internet]. 2024 Sep 6. Available from: <a href="https://www.euroshop-tradefair.com/en/euroshopmag/electronic-shelf-labels-retailers-are-testing-esl" target="_blank">https://www.euroshop-tradefair.com/en/euroshopmag/electronic-shelf-labels-retailers-are-testing-esl</a>[3] Zignani A. ABI Research. Electronic shelf labels in retail [Internet]. 2023 Oct 24. Available from: <a href="https://www.abiresearch.com/blogs/2023/10/24/electronic-shelf-labels-in-retail/" target="_blank">https://www.abiresearch.com/blogs/2023/10/24/electronic-shelf-labels-in-retail/</a>[4] Nexperia. Electronic Shelf Label Applications [Internet]. Available from: <a href="https://www.nexperia.com/applications/industrial-and-power/electronic-shelf-label" target="_blank">https://www.nexperia.com/applications/industrial-and-power/electronic-shelf-label</a>[5] Nexperia. Energy Harvesting Solutions: Enabling a Sustainable IoT Future [Internet]. Available from: <a href="https://assets.nexperia.com/documents/leaflet/nexperia_leaflet_energyharvesting_2025.pdf" target="_blank">https://assets.nexperia.com/documents/leaflet/nexperia_leaflet_energyharvesting_2025.pdf</a>[6] Nexperia. White Paper: Advanced Energy Harvesting for IoT Applications with Murata and Nexperia [Internet]. Available from: <a href="https://assets.nexperia.com/documents/white-paper/v06_White-paper_Murata-DT-Nexperia.pdf" target="_blank">https://assets.nexperia.com/documents/white-paper/v06_White-paper_Murata-DT-Nexperia.pdf</a>[7] Nexperia. NEH7100: Energy Harvesting PMIC Data Sheet [Internet]. Available from: <a href="https://assets.nexperia.com/documents/data-sheet/NEH7100.pdf" target="_blank">https://assets.nexperia.com/documents/data-sheet/NEH7100.pdf</a>

Energy harvesting ICs by Nexperia enable devices to capture and utilize ambient energy from sources like light, heat, and motion, offering sustainable and maintenance-free power solutions for a wide range of applications.

Building Sustainable IoT Energy Harvesting Solutions: A Case Study of Electronic Shelf Labels in Smart Retail

The ability to harness the energy of the sun has existed for millenia, with evidence of magnifying and mirroring techniques used to light fires dating back to Ancient Greece. When we talk about solar energy today, however, it bears little resemblance to these ancient practices. Rather, it has its roots in the 1950s, when scientists at Bell Labs developed the first silicon photovoltaic cell capable of converting the sun’s rays into electrical power.[1]Fast forward several decades and solar power represents a growing share of energy sources globally, with the International Energy Association (IEA) predicting that between 2024 and 2030, it will account for 80% of the growth in global renewable capacity, an increase driven by the construction of solar power plants and growing adoption of rooftop solar panels.[2]While solar energy is growing rapidly, there are still some hurdles keeping it from reaching its full potential, such as the cost of the equipment and the efficiency of solar panels. In recent years, however, 3D printing has emerged as a solution that can help take solar power to the next level.<h2>Manufacturing Solar Panels</h2>Solar panels generate power through the reaction of the sun’s rays hitting photovoltaic cells. These cells are made from two layers of silicone, one positively charged and the other negatively charged, creating an electric field. When the sun rays hit the solar panel, the light frees electrons in the cells, which are then transported by the electric field, generating a direct current. In order to power homes, this current must be converted into an alternating current, which is achieved using a solar inverter.Presently, the main method for manufacturing solar panels involves several labour-intensive and energy-intensive steps, including the production of Polysilicon, the processing of the silicone into an ingot, and the slicing of the ingots into wafers using diamond-coated wire saws. The silicone wafers must then be post-processed using a combination of techniques, like chemical texturing, coatings, and screenprinting of conductive traces, before final assembly and encapsulation in protective glass and polymer housings.[3] All in all, this production approach is associated with high costs, high energy use, and significant waste. That’s where additive manufacturing technologies come in. <h2>Printing Solar Panels</h2>While still an emerging technology for the production of solar panels, printing has the potential to radically transform how the renewable energy equipment is made, allowing for more cost-efficient production, as well as faster, more scalable manufacturing, and greater customization opportunities. These benefits are the result of the nature of <a href="https://xtpl.com/understanding-the-additive-manufacturing-process-from-design-to-finished-product/">additive printing processes</a>, which are engineered to selectively and precisely deposit materials onto a substrate—reducing material waste. On top of that, printing technologies are digitally controlled, which means they print patterns based on a CAD design. This allows for users to benefit from fast production setups and eliminates reliance on manufacturing tools and multi-step production processes. In terms of cost, additive manufacturing technology has the ability to print functional materials onto low-cost substrates to impart photovoltaic properties, including polymer films (i.e. PET). In one research project out of the University of Newcastle in Australia, production costs were estimated at under $10 per square meter.[4]When we look at scalability in particular, one of the most game-changing printing technologies in this segment is roll-to-roll printing (R2R). This printing technique, though still not industrially mature, involves the continuous deposition of materials (like perovskite, organic compounds, and conductive inks) onto a flexible substrate in selective patterns. This process not only eliminates the need for silicone wafers, it is also highly scalable and can produce more discreet solar panels, including flexible solar cells that can conform to building features and even car roofs.[5]<h2>The Future of Solar Energy</h2>While the role of additive manufacturing technology in the production of solar panels is still largely limited to the research field and small-scale applications, there is enormous potential for it in the future. As the technology matures, printed solar cells could become key to increasing the adoption of solar energy. Not only because solar panels will be more affordable, but also because they will be less bulky and unsightly. Picture a thin, flexible sheet that could be seamlessly applied to curved structures and even textiles to generate power far more discreetly. Moreover, thanks to the mass customization unlocked by additive manufacturing processes, solar panels could be tailored to meet specific requirements and be made to conform to unconventional architectural structures, rather than the other way around. Down the line, 3D printing could also unlock greater power conversion efficiency, using a combination of advanced materials with photovoltaic properties and micro-scale structures optimized for light absorption. Being able to enhance the efficiency of solar power conversion at much a level, made possible through nanomaterial printing technologies like XTPL’s <a href="https://xtpl.com/ultra-precise-dispensing/">Ultra-Precise Dispensing (UPD)</a>, would mean that solar cells could become far more compact, thus requiring less space for the same amount of energy generation.Of course, more than technological advancements are needed for this future to materialize: significant investments and government policies are imperative for solar energy to really reach its full potential.<hr /><h2 id="isPasted">Resources</h2>[1] The History of Solar. U.S. Department of Energy, 2025. <a href="https://www1.eere.energy.gov/solar/pdfs/solar_timeline.pdf">https://www1.eere.energy.gov/solar/pdfs/solar_timeline.pdf</a> [2] Solar PV. International Energy Association (IEA), 2025. <a href="https://www.iea.org/energy-system/renewables/solar-pv">https://www.iea.org/energy-system/renewables/solar-pv</a> [3] Solar Photovoltaic Manufacturing Basics. U.S. Department of Energy, 2025. <a href="https://www.energy.gov/eere/solar/solar-photovoltaic-manufacturing-basics">https://www.energy.gov/eere/solar/solar-photovoltaic-manufacturing-basics</a> [4] Public Debut for Printed Solar. University of Newcastle Australia, 2020. <a href="https://www.newcastle.edu.au/newsroom/featured/public-debut-for-printed-solar">https://www.newcastle.edu.au/newsroom/featured/public-debut-for-printed-solar</a> [5] Parvazian E, Watson T. <a href="https://www.nature.com/articles/s41467-024-48518-4">The roll-to-roll revolution to tackle the industrial leap for perovskite solar cells</a>. nature communications. 2024 May 11;15(1):3983.

Additive manufacturing can enhance solar energy tech in exciting ways, such as by printing functional materials onto low-cost substrates like polymer films to impart photovoltaic properties

The Future of Solar Energy: Enhancing Efficiency through Innovative Printing Techniques

A modified manufacturing process for electric vehicle batteries, developed by University of Michigan engineers, could enable high ranges and fast charging in cold weather, solving problems that are turning potential EV buyers away.“We envision this approach as something that EV battery manufacturers could adopt without major changes to existing factories,” said <a href="https://me.engin.umich.edu/people/faculty/neil-dasgupta/" target="_blank" rel="noreferrer noopener">Neil Dasgupta</a>, U-M associate professor of mechanical engineering and materials science and engineering, and corresponding author of the study published in Joule.“For the first time, we’ve shown a pathway to simultaneously achieve extreme fast charging at low temperatures, without sacrificing the energy density of the lithium-ion battery.”Lithium-ion EV batteries made this way can charge 500% faster at temperatures as low as 14 F (-10 C). The structure and coating demonstrated by the team prevented the formation of performance-hindering lithium plating on the battery’s electrodes. As a result, batteries with these modifications keep 97% of their capacity even after being fast-charged 100 times at very cold temperatures.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1744070040526-cold-ev-charging-featured.jpg" style="width:100%px" class="fr-fic fr-dib" />Engineering student Chloe Acosta plugs in an EV for charging in snowy weather on the University of Michigan’s North Campus. EV charging becomes less efficient in colder weather, but a new strategy for manufacturing battery electrodes could enable charging in 10 minutes in temperatures as cold as -10C. Photo: Marcin Szczepanski, Michigan EngineeringCurrent EV batteries store and release power through the movement of lithium ions back and forth between electrodes via a liquid electrolyte. In cold temperatures, this movement of the ions slows, reducing both battery power as well as the charging rate. To extend range, automakers have increased the thickness of the electrodes they use in battery cells. While that has allowed them to promise longer drives between charges, it makes some of the lithium hard to access, resulting in slower charging and less power for a given battery weight.Previously, Dasgupta’s team improved battery charging capability by <a href="https://www.sciencedirect.com/science/article/pii/S0378775320307795">creating pathways—roughly 40 microns in size—in the anode</a>, the electrode that receives lithium ions during charging. Drilling through the graphite by blasting it with lasers enabled the lithium ions to find places to lodge faster, even deep within the electrode, ensuring more uniform charging.This sped up room-temperature charging significantly, but cold charging was still inefficient. The team identified the problem: the chemical layer that forms on the surface of the electrode from reacting with the electrolyte. Dasgupta compares this behavior to butter: you can get a knife through it whether it’s warm or cold, but it’s a lot harder when it’s cold. If you try to fast charge through that layer, lithium metal will build up on the anode like a traffic jam.“That plating prevents the entire electrode from being charged, once again reducing the battery’s energy capacity,” Manoj Jangid, U-M senior research fellow in mechanical engineering, and co-author of the study. The team needed to prevent that surface layer from forming. They did this by coating the battery with a glassy material made of lithium borate-carbonate, approximately 20 nanometers thick. The addition of this coating sped up cold charging significantly, and when combined with the channels, the team’s test cells were 500% faster to charge in subfreezing temperatures. “By the synergy between the 3-D architectures and artificial interface, this work can simultaneously address the trilemma of fast charging at low temperature for long-range driving,” said Tae Cho, a recent Ph.D. graduate in mechanical engineering and first author of the study.In the past two decades, EVs have become more commonplace on roadways as consumers look for better environmental options, but <a href="https://newsroom.aaa.com/2024/06/is-the-ev-hype-over" target="_blank" rel="noreferrer noopener">AAA survey results</a> showed that the momentum is hard to maintain. From 2023 to 2024, the number of U.S. adults who would be “likely” or “very likely” to buy a new or used EV dropped from 23% to 18%. And 63% said they would be “unlikely” or “very unlikely” to make an EV their next vehicle purchase. Part of the concerns are <a href="https://www.pbs.org/newshour/economy/cold-weather-can-cut-electric-vehicle-range-and-make-charging-tough-heres-what-you-need-to-know" target="_blank" rel="noreferrer noopener">range drops over the winter, combined with slower charging</a>, which was widely reported during the January 2024 cold snap.“Charging an EV battery takes 30 to 40 minutes even for aggressive fast charging, and that time increases to over an hour in the winter. This is the pain point we want to address,” Dasgupta said.Follow-on work to develop factory-ready processes is funded by the Michigan Economic Development Corporation through the <a href="https://innovationpartnerships.umich.edu/resource/mtrac-innovation-hub-for-advanced-transportation/" target="_blank" rel="noreferrer noopener">Michigan Translational Research and Commercialization (MTRAC) Advanced Transportation Innovation Hub</a>.The devices were built in the <a href="https://umbatterylab.engin.umich.edu/" target="_blank" rel="noreferrer noopener">U-M Battery Lab</a> and studied at the <a href="https://mc2.engin.umich.edu/" target="_blank" rel="noreferrer noopener">Michigan Center for Materials Characterization</a>.The team has applied for patent protection with the assistance of U-M Innovation Partnerships. Arbor Battery Innovations has licensed and is working to commercialize the channel technology. Dasgupta and the University of Michigan have a financial interest in Arbor Battery Innovations.

A stabilizing coating on an electrode, combined with microscale channels, helps solve the trade-off between range and charging speed, even in cold temperatures.

Charging electric vehicles 5x faster in subfreezing temps

Wevolver: Hello, my name is Kyran. I'm part of the Wevolver team and today we are with Goeffroy at e-peas. Could you introduce yourself?Goeffroy: Sure. I'm Geoffroy, CEO and Co-Founder of e-peas, a semiconductor company focusing on delivering energy harvesting dedicated PMICs to the market.Wevolver: Great. We're really curious to learn more about your products. Let's have a look behind us. Could you a bit more about what we're looking at here?Goeffroy: So you're looking at our first commercial successes in the remote control market especially. We've seen a great traction with remote controls that do not need battery swaps while being used by consumers, which is, we believe, a great asset. And also on the other side you can see another consumer product which is solar keyboards, which we believe is also very nice for consumers that will not have to either use cable or recharge their Bluetooth based keyboards.Wevolver: Awesome. Can we have a look at the ones in the back that I'm seeing over there? And also could you dive a bit more into the applications of them?Goeffroy: So on the back there, it's not really applications, it's more our products that we are focusing on and also the partners that we are working with. You can see PV cell partners, but also partnerships we build with big semiconductor companies like Qorvo, Silicon Labs and others with which we are working to promote energy harvesting on the market. Wevolver: E-peas is at the forefront of energy saving. I'm curious if you could tell a bit more about this. How you trying to make it more energy efficient?Goeffroy: Well, from the first day of e-peas creation, we strongly believe that using primary non-rechargeable batteries is definitely a waste of people's time and generating a lot of waste for the environment. So our goal from day one has been to replace those primary batteries with much more environmental friendly innovations that prevent leaving primary batteries on the field and polluting our environment, but also reducing the overall total cost of ownership of devices.Wevolver: Let's dive a bit deeper into the partnerships with Qorvo. Could you talk a bit more about this collaboration?Goeffroy: So with Qorvo, what we did is that we've been collaborating with them building this reference design that integrates their most advanced Bluetooth chipset, lowest power Bluetooth chipset together with our energy harvesting solutions to demonstrate to the market that you can actually supply Bluetooth-based devices thanks to the ambient energy that surrounds the device rather than using non-rechargeable batteries. So indeed, we are collaborating with other semiconductor companies because we are pushing a new technology on the market. And we believe that the best way to convince people to switch to this new technology is to have different people carrying the same message to the industry. For example, we've built this reference design with Qorvo that is basically their newest matter chipsets that they combine with our energy harvesting chipsets to show to their customers that you can build a Matter wireless device working on energy harvesting. We've also developed what they call at Silabs, energy harvesting shields that go together with their wireless boards and also one of their newest wireless chipsets that combines Bluetooth and Zigbee capabilities to promote energy harvesting on the smart home smart building applications.Wevolver: Geoffroy, why is the smart home market interested in energy saving? And also what are the biggest pain points you can see and trends in the future?Goeffroy: As you know, smart home and smart buildings are more and more connected with security devices and other kind of sensors and I think we need to differentiate smart home and smart building. Smart home is your place, my place, where I'm going to go to the shop and buy a device, whether it's a fire detector or other window door sensors. And the thing is that we will have to be taking care of replacing the batteries of those devices. And since they tend to multiply in our households, I think having devices that do not require those battery swaps is very important and is an added value for the customers. And in the smart building it's even worse because, well, the people that are deploying those sensors in the smart buildings are usually responsible for swapping the batteries. And when you are dealing with multiple buildings at some point, replacing those batteries is a real pain. So again, having energy autonomous devices that you can install and forget is definitely an added value for the smart building market as well.Wevolver: So over the years at e-peas, you have been doing a lot of innovation. I'm curious if all this innovation you've been accumulating is being translated into new products.Goeffroy: Yeah, absolutely. So, less than a year ago, we launched on the market our most advanced PMIC that combines two different energy sources and also almost all of the innovations that we've been developing over the years. So this chipset is the 13920. You can combine two different sources, like two different PV cells, an indoor and an outdoor PV cell, or combine a PV cell with a thermoelectric generator to harvest energy from heat, temperature differences and light to build more reliable devices. So, take as an example, a thermostatic valve. You can combine, harvesting energy from the heater to which it is connected and also light in the room to make the system more reliable. And, yeah, just make it last longer.Wevolver: Thanks, Geoffroy, for all the latest products you've been sharing with us. I'm really curious to learn a bit more. You know, what can we expect from e-peas in the future? What are some trends or are you going to work on in the future? Whatever you're able to share.Goeffroy: Well, what you can expect is more innovation from e-peas. We already have a large portfolio of products for energy harvesting, covering multiple sources and multiple storage elements going from 3 microwatts to half a watt that can be harvested, extracted from energy harvesters. Now we see some applications where more power has to be extracted. So the next product we'll be releasing will be able to extract up to 3 watts of power. And that's something we'll announce, I would say, in the next three to five months. So just stay tuned and you'll know more about us.Wevolver: Awesome. All the best.Goeffroy: Thank you.

e-peas, a semiconductor company focusing on delivering energy harvesting dedicated PMICs to the market.

E-peas on their energy harvesting and processing solutions at Embedded World

Wevolver: So we are here at Embedded World together with Axel from our partners at ITEN. Axel, good to see you here. Excited for this interview. Could you maybe give us an introduction about yourself?Axel: It's a pleasure, thank you. My name is Axel Fischer, I'm the Chief Commercial Officer of ITEN. I've been working a very long time in the semiconductor industry. Basically, devices which are consuming energy. Recently, I joined ITEN. We have the mission to bring green energy. So it feels like giving back something to the industry. Wevolver: Awesome. Well, thanks for that introduction of yourself and the company. Could we dive a bit more deeper in talking about ITEN's, technology and how does it set itself apart in this market? Right, like your solid state micro battery technology. Axel: Yes, ITEN, as we say in French or in English, ITEN. We're still a fairly young company. We have been founded 13 years ago. We are French and the mission and the vision of the company has been to introduce a battery which can be used almost over the entire lifetime. Today, we see that coin cells are being thrown away and exchanged on a daily basis with actually 100 million and more per day. So we have developed a technology, solid state, which has very good product markers. Solid state is safe. It cannot burn, it cannot explode, it cannot overheat. We achieve a very high power density and a very high energy density as well. Power and energy. And for those of you who are familiar with batteries, we have a stunning C rate of 100. And this comes in a very ecological format as the batteries are recyclable. And for the microelectronics industry, we can even solder it directly on the board, which is very efficient.Wevolver: Axel, we see in the IoT market that devices continue getting smaller. They keep on integrating more sensors, which makes the power management and power constraints more critical. How does ITEN's technology support this ongoing miniaturization and how does it support energy harvesting solutions?Axel: Excellent point. In general, the microelectronics device market is maniacal about shrinking, making smaller, more performance, lower energy consumption and more efficient power concepts. So we respond perfectly to that concept by bringing out this ultra small battery which perfectly integrates in small form factor into electronic devices.Axel: Second point, as you asked about energy harvesting devices here, I would like to give you a very practical example which we have developed in conjunction with partners energy harvesting taking place by photovoltaic and inside. We have then here as well all and some sensors as well. Put this into your pocket. Wevolver: Will do. Thanks.Wevolver: We've seen ITEN's technology get integrated into various industrial devices, various connected devices. Could you share some of the collaborations and partnerships that you've been working on and how are they moving forward the boundaries in micro battery technology?Axel: Yeah, we are feeling very comfortable and are a strong participant as well in different kind of ecosystems. I would say one ecosystem is in conjunction with partners who are building the other devices, whether it is for connectivity, power management and as well Sensors. The other category is in terms of energy harvesting, where we are a strong partner as well in that ecosystem. Last but not least, we work with customers who provide as well collaboration and partnership which is driving our product availability and roadmap.Wevolver: Axel, on a forward looking note, could you share us some of the innovations that ITEN is working on in pushing forward the boundaries in your sphere and maybe also your views on how do you see the micro battery technology evolve to meet the future demands of AI, of IoT and edge computing?Axel: All right, so today we are demanded partnered by customers in various applications already the strongest demand today is coming from the IoT markets. There's a strong interest as well from healthcare and I would like to mention also about wearable. To satisfy in the different device categories, we have two product families. One is called POWENCY, which is a very capable device to deliver strong power during a short moment. The other device family is called FLOWENCY which has a much longer endurance and is much more capable in that regards. Expect from us more in the future to bring out more devices in each product category of POWENCY and FLOWENCY. Everything is made in house. We have as well the production. We are scaling this accordingly with raising customer demand. Wevolver: That's exciting. Well Axel, thanks for the very nice interview. I wish you and ITEN continued success here at Embedded World and obviously with your future innovations for which we're quite excited about.Axel: Thank you. I hope to see you soon again. Wevolver: Thanks.

Exploring ITEN's Solid State Micro-Battery and Energy Harvesting Technology at Embedded World 2025

ITEN on Their Solid State Micro-Battery And Energy Harvesting Technology at Embedded World 2025

Our interactions with energy are evolving due to several driving trends. The increasing popularity of electric vehicles (EVs) has created a demand for a comprehensive charging network. Meanwhile, the surge in information technology has fueled the rapid growth of the data center market, which has a continually growing need for power.Consumers are seeking a more sustainable energy market. New sources of energy are seen as key to tackling climate change. Governments around the world are incentivizing the use of renewable energy, and environmental regulation seeks to enforce these changes. With these new sources comes the challenge of managing how energy is stored and distributed. An energy storage system, often abbreviated as ESS, is a device or group of devices assembled together, capable of storing energy in order to supply electrical energy at a later time. Battery ESS are the most common type of new installation and use the latest advances in Lithium-Ion technology to provide a means to store energy until needed. In this case study, we examine a small but essential part of the future of energy storage systems - Energy Storage Connectors. <h1>Global Trends and Demand Drivers in the Energy Storage Connector Market</h1>The ESS market was valued at USD 7.8 billion in 2024. Expansion is being driven by new demands across several sectors. The market is predicted to reach USD 25.6 billion before the end of the current decade, a growth of more than 300%, and is expected to continue growing at a CAGR of 26.9%.  A prime example of the growing ESS market is China, where the country’s enormous energy demand makes it a key market for ESS manufacturers.  This expansion is further supported by government initiatives, with several provinces setting ambitious goals to integrate energy storage into the grid. ESS also supports the rise of renewable energy production, a growing sector in the Chinese economy. China’s energy capacity from non-fossil fuels surpassed fossil fuel energy for the first time in June 2023, demonstrating the country’s commitment to new energy solutions and further driving the need for ESS.<h1>Adam Tech’s Energy Storage Connector Solutions</h1>Adam Tech has launched its ESF/ESM Series of high-efficiency connectors, designed to meet the needs of the energy storage market. These connectors, available in both orange and black, link battery modules to various energy storage systems, including electric vehicle charging and renewable energy devices. They offer a critical, safe, and reliable connection with a range of mated pairs that support various voltage and current ratings, along with different wire gauges.The series provides current ratings from 90A to 350A and voltage ratings from 1000VDC to 1500VDC. Additionally, these connectors are IP67-rated waterproof when mated, which prevents water and dust ingress. Available termination options cater to BESS installations in confined spaces, enhancing the flexibility and safety of the systems. Dust covers and PA66 material, meeting UL 94V-0 flame retardant standards, add an extra layer of protection. The ESF/ESM family is UL-certified and complies with RoHS and REACH standards.<h2>Adam Tech Storage Connector Solutions Applied Across Industries</h2><h3>Electric Vehicle Charging Infrastructure</h3>The market for electric vehicles (EVs) is one of the most important for ESS. More than 120 countries have announced legislation intended to limit emissions in the coming decades, with many countries committing to the phasing out of internal combustion engines. However, the public’s confidence in this new technology is driven by range anxiety. Compared to the convenience of the existing fueling infrastructure that has serviced the public for decades, the lack of charging stations is a barrier to the widespread adoption of EVs.Achieving widespread acceptance of EVs will require a massive investment in charging equipment. ESS are essential to this infrastructure, helping to make it a practical alternative to fossil fuels. They serve to create a ready store of energy, enabling the faster charging that the public will require if they are to overcome their range anxiety. There are several key connectivity challenges when installing a robust charging network. By necessity, the equipment required for charging vehicles will be fitted in outdoor locations exposed to the elements. Not only will connectors need to be sealed against the dangers of moisture ingress, but they must also be easy to install and withstand a high number of mating cycles.Connectors also need to be efficient. Fast-charging applications require a higher energy transfer rate, resulting in significant temperature increases. So the connectors that form the electrical network within charging stations must deliver low contact resistance. The ESC series of ESS connectors from Adam Tech use a cage spring design that maximizes contact surface area and reduces contact resistance. The cage spring design effectively prevents poor contact caused by misalignment or vibration, improving system fault tolerance. Even with slight misalignment, the terminals can maintain effective conductivity, enhancing connector stability and reliability under harsh conditions.Adam Tech’s series of connectors also employ a shortened conductor distance to minimize conduction paths. Traditional connectors with long conductor distances often cause excessive temperature rise, impacting system performance. Adam Tech's design controls the conductor distance to within 1.5mm, reducing temperature rise risks from excessively long conduction paths, thereby improving current conduction efficiency and safety.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyOTA5MTc1OTQyLXAxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" /><h3 id="isPasted">Renewable Energy, Microgeneration and the Smart Grid</h3>Microgeneration refers to the local, small-scale energy production facilities capable of powering individual households or small communities. Known as distributed energy resources (DERs), these facilities typically operate with a capacity of less than 10 megawatts and often utilize technologies like wind and solar to reduce reliance on fossil fuels. However, the reliability of these localized resources can be challenging, as many depend on unpredictable weather conditions. This necessitates effective energy storage solutions to ensure power is available when needed.To address these challenges, Energy Storage Systems (ESS) play a crucial role in the emerging dynamic power network or smart grid. ESS devices act as a buffer between energy producers and the network, stabilizing the power supply and enhancing flexibility. This allows the system to absorb fluctuations in demand without increasing production. Additionally, ESS connectors, which link energy sources, storage systems, and the grid, are vital for ensuring safety, reliability, and ease of use.Furthermore, the smart grid relies heavily on data flow. Battery management systems and smart monitoring are essential for providing the feedback required to make the smart grid functional. Users of microgeneration systems can not only decrease their dependence on traditional power sources and mitigate disruption risks but can also resell excess energy, creating a more resilient and sustainable energy landscape.Adam Tech's energy storage connectors are specifically engineered to support high current transmission, playing a crucial role in stabilizing energy storage systems. This capability ensures efficient and safe energy management within the smart grid, thereby enhancing the system's overall energy efficiency. Moreover, when paired, these connectors achieve an IP67 waterproof rating, effectively preventing water and dust ingress, which significantly enhances the safety and longevity of the system.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyOTA5MTg0MTM5LXAyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" /><h3 id="isPasted">Data Centers</h3>Data is the raw material of the future, and every aspect of modern life is using more data than ever before. This surge is driven by high-speed Internet and particularly the widespread introduction of 5G wireless connectivity. To keep up, hardware solutions and power supplies must evolve to efficiently process and store this ever-growing volume of information.The data center sector is rapidly growing and is poised to become a major global energy consumer.  In many large economies today, data centers account for between 2% and 4% of total electricity consumption.  A key requirement for any data center is energy security.  Providers rely on a stable power supply to ensure consistent service and need facilities that can scale quickly with fluctuating demand, while maintaining operations even during power outages. Connectivity is crucial for data center managers, as energy costs represent a significant portion of their operational expenses.  Reliable and efficient connectors are vital not only for keeping these costs under control, but also for enabling the rapid reconfiguration of servers as needed.<iframe width="640" height="360" src="https://www.youtube.com/embed/zTL5zB3ZnE4?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0"></iframe>Data centers involve numerous stakeholders, and quality assurance is key. Adam Tech ESS connectors use PA66 material which meets UL 94V-0 flame retardant standards, enhancing safety. Further, all connectors are UL certified and meet RoHS and REACH standards, ensuring environmental sustainability and safety.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQyOTA5MTkzMTUzLXAzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Conclusion</h2>Battery Energy Storage Systems (BESS) are revolutionizing energy management, driving sustainability and efficiency while enhancing grid reliability. With increasing demands across a range of industries, the need to store and distribute energy grows. Connectors that deliver high current capacity and reliability, even in harsh environments, will be essential for installers and users around the world. Adam Tech’s advanced solutions support this exciting market with dedicated power connectors optimized for delivering power in tough conditions.For more details on Adam Tech's ESF/ESM family of connectors, contact a Powell representative directly at <a target="_blank">adamtechinfo@powell.com</a>, or visit <a href="http://www.powell.com" target="_blank">www.powell.com</a> to shop from distributor stock for next-day shipping.

The rise of EVs and data centers boosts demand for ESS, which manages energy storage and distribution. Adam Tech's ESF/ESM connectors support this shift with high efficiency and reliability.

Energy Storage Connectors: The Future of High-Power Energy Storage Systems (ESS) Management

Read Article #2 of 2 in the Solderless Magnet Wire Solutions Mini-Series.

Solderless Magnet Wire Solutions For Electric Vehicle Air Conditioner Compressors And Electronic Parking Brake Motors

Read Article #1 of 2 in the Solderless Magnet Wire Solutions Mini-Series.

Solderless Magnet Wire Solutions for Electric Vehicle Applications

The AI revolution has ushered in an era of exponential power and energy consumption. According to the <a href="https://www.energy.gov/articles/doe-releases-new-report-evaluating-increase-electricity-demand-data-centers" rel="noopener" target="_blank">US Department of EnergyOpens in new window</a>, energy consumed by AI data centers could triple by 2028. Today, up to 40% of data center power use comes from cooling high-power chips—an astounding amount equivalent to the state of California’s entire electricity consumption.To combat this, Sheng Shen, professor of mechanical engineering at Carnegie Mellon University, has developed an innovative thermal interface material (TIM) that outperforms existing state-of-the-art solutions. His design, now published in <a href="https://www.nature.com/articles/s41467-025-56163-8" rel="noopener" target="_blank">Nature CommunicationsOpens in new window</a>, achieves ultra-low thermal resistance while increasing cooling efficiency via improved heat dissipation. It also proves to be highly reliable.<blockquote>While an immediate need is cooling data centers, this innovation can break through in industries that have been stuck using outdated thermal interface materials.<cite>Sheng Shen, Professor, Mechanical Engineering</cite></blockquote>“The material is like a bridge between the nano- and macroscopic worlds,” explained Zexiao Wang, Ph.D. candidate in Shen’s lab. “Because the nanoscale material can be created using macroscale approaches, we can see with our own eyes the impact of the material on the world.”Not only is Shen’s thermal interface material the best-performing on the market, it is also highly reliable. The team tested the material at extreme temperature ranges from -55 to 125 degree Celsius for more than 1,000 cycles, and the material showed no performance degradation.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740445088809-0211-em-ai-data-center-cooling-breakthrough.png" style="width: 100%px;" class="fr-fic fr-dib">Novel thermal interface material designed by Sheng Shen.&nbsp;Source:&nbsp;College of Engineering“This material solves a lot of existing challenges, and is ready to be used today,” said Shen. “While an immediate need is focused on cooling data centers, the application for this innovation is extensive. It can break through in industries that have been stuck using outdated thermal interface materials. It can be used for pre-packaging, reworked when using non-adhesives, and enables thermal bonding of two substrates at room temperature.”“Oftentimes work at the nanoscale is foundational for a device that we might not see for decades,” said Qixian Wang, Ph.D. candidate. “It’s been exciting to see the real-world impact our material can have today because it is so easy to use.”“Our material will have great benefits to the field of AI computing,” said Rui Cheng, postdoc and innovation commercialization fellow of CMU and the lead author of the paper published in Nature Communications. “Beyond reducing energy consumption, we can make AI development more affordable, more renewable, and more reliable.”<iframe width="640" height="360" src="https://www.youtube.com/embed/BG4Ct4jYh3k?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>This research was supported by the National Science Foundation and ARPA-E (Advanced Research Projects - Energy). Collaborators included Tianyi Chen and Ana V. Garcia-Caraveo from the Oregon State University, and Navid Kazem and Loren Russell from Arieca, Inc.<hr>Sheng Shen and Rui Cheng are making this technology commercially available via their startup company,&nbsp;<a href="https://www.novolinc.com/" rel="noopener" target="_blank">NovoLINC, Inc.Opens in new window</a>

Novel thermal interface material cools chips better than existing state-of-the-art solutions.

Slashing AI data center cooling cost, GPU-CPU power use

Cost-effective, safe and made from widely available raw materials - the advantages of sodium-ion batteries over today's ubiquitous lithium batteries are obvious. But despite similar electrical properties, lithium and sodium cannot simply be interchanged. Chemical differences between the elements currently still lead to technical challenges, such as the short lifespan of sodium batteries and scaling for large margins. In the&nbsp;<a href="https://www.ifam.fraunhofer.de/de/Presse/bmbf-projekt-natrium-ionen-technologie.html" target="_blank" id="isPasted">SIB:DE FORSCHUNG (Sodium-Ion-Battery Germany Research)</a> project , the Karlsruhe Institute of Technology (KIT) and 20 partners from science and industry are pooling their expertise to address remaining obstacles and enable a rapid transfer of sodium technology into industrial mass production.<h2>Active materials and electrodes from KIT</h2>"At KIT, we are working on scalable manufacturing processes for particularly high-performance active materials and are demonstrating production on a kilogram scale," says Professor Helmut Ehrenberg from the KIT's Institute of Applied Materials (IAM). "Being able to produce these cost-effectively and scalably is a crucial step for an industrial roll-out of sodium ion technology." Researchers at the Helmholtz Institute Ulm are also working on electrodes that they are optimizing for long-lasting battery performance. The results are then analyzed and tested in the BELLA (Battery and Electrochemistry Laboratory) research laboratory operated jointly by KIT and BASF.<hr><h3>About SIB:DE FORSCHUNG</h3>In total, SIB:DE FORSCHUNG consists of 7 industrial partners and 14 academic partners as well as an expanded circle of currently 42 associated partners, making it the largest consortium in Germany on this topic. The Federal Ministry of Education and Research is funding the research with 14 million euros. KIT is the largest grant recipient with around 3.8 million euros, which is distributed between IAM, BELLA and the HIU. BASF coordinates SIB:DE FORSCHUNG.

KIT researchers are working on scalable manufacturing processes for the active materials in sodium-ion batteries. Credit: Amadeus Bramsiepe, KIT

KIT researchers are working together with partners on the industrial transfer of the pioneering sodium technology

Sodium-ion batteries on the way to application

Recycling lithium-ion batteries to recover their critical metals has significantly lower environmental impacts than mining virgin metals, according to a new Stanford University lifecycle analysis <a href="https://www.nature.com/articles/s41467-025-56063-x" data-extlink="">published in Nature Communications</a>. On a large scale, recycling could also help relieve the long-term supply insecurity – physically and geopolitically – of critical battery minerals.Lithium-ion battery recyclers source materials from two main streams: defective scrap material from battery manufacturers, and so-called “dead” batteries, mostly collected from workplaces. The recycling process extracts lithium, nickel, cobalt, copper, manganese, and aluminum from these sources.The study quantified the environmental footprint of this recycling process, and found it emits less than half the greenhouse gases (GHGs) of conventional mining and refinement of these metals and uses about one-fourth of the water and energy of mining new metals. The environmental benefits are even greater for the scrap stream, which comprised about 90% of the recycled supply studied, coming in at: 19% of the GHG emissions of mining and processing, 12% of the water use, and 11% of the energy use. While it was not specifically measured, reduced energy use also correlates with less air pollutants like soot and sulfur.“Recently, I was in an Uber electric vehicle. The driver asked me if EVs really are ‘good’ for the environment because he recently had read that maybe they aren’t. All he knew was that I was faculty at Stanford,” <a href="https://profiles.stanford.edu/william-tarpeh" data-extlink="">William Tarpeh</a>, assistant professor of chemical engineering in the&nbsp;School of Engineering&nbsp;and the study’s senior author, recalled with a chuckle.“I told him that EVs definitely are good for the environment, and we’re now finding new ways to make them even more so,” said Tarpeh. “This study, I think, tells us that we can design the future of battery recycling to optimize the environmental benefits. We can write the script.”<h2>Location, location</h2>Battery recycling’s environmental impacts depend heavily on the processing facility’s location and electricity source.“A battery recycling plant in regions that rely heavily on electricity generated by burning coal would see a diminished climate advantage,” said <a href="https://www.linkedin.com/in/samanthabunke/" data-extlink="">Samantha Bunke</a>, a PhD student at Stanford and one of the study’s three lead investigators.“On the other hand, fresh-water shortages in regions with cleaner electricity are a great concern,” added Bunke.Most of the study’s data for battery recycling came from Redwood Materials in Nevada – North America’s largest industrial-scale lithium-ion battery recycling facility – which benefits from the western U.S.’s cleaner energy mix, which includes hydropower, geothermal, and solar.Transportation is also a crucial factor. In the mining and processing of cobalt, for example, 80% of the global supply is mined in the Democratic Republic of the Congo. Then, 75% of the cobalt supply for batteries travels by road, rail, and sea to China for refining. Meanwhile, most of the global supply of lithium is mined in Australia and Chile. Most of that supply also makes its way to China. The equivalent process for battery recycling is collecting used batteries and scrap, which must then be transported to the recycler.&nbsp;“We determined that the total transport distance for conventional mining and refining of just the active metals in a battery averages about 35,000 miles (57,000 kilometers). That’s like going around the world one and a half times,” said <a href="https://www.linkedin.com/in/michael-machala-4a4983111/" data-extlink="">Michael Machala</a>, PhD ’17, also a lead author of the study.“Our estimated total transport of used batteries from your cell phone or an EV to a hypothetical refinement facility in California was around 140 miles (225 kilometers),” added Machala, who was a postdoctoral scholar at Stanford’s <a href="https://energy.stanford.edu/" data-extlink="">Precourt Institute for Energy</a> at the time of research and is now a staff scientist for the Toyota Research Institute. This distance was based on presumed optimal locations for future refining facilities amid ample U.S. recyclable batteries.<h2>Patent advantage</h2>Redwood’s environmental outcomes do not represent the nascent battery recycling industry’s overall environmental performance for recycling used batteries. Conventional pyrometallurgy, a key refining step, is very energy intensive, usually requiring temperatures of more than 2,550 degrees Fahrenheit (1,400 degrees Celsius).Redwood, however, has patented a process called “reductive calcination,” which requires considerably lower temperatures, does not use fossil fuels, and yields more lithium than conventional methods.“Other pyrometallurgical processes similar to Redwood’s are emerging in labs that also operate at moderate temperatures and don’t burn fossil fuels,” said the third lead author, <a href="https://www.linkedin.com/in/xi-chen-4023417b/" data-extlink="">Xi Chen</a>, a postdoctoral scholar at Stanford during the time of research and now an assistant professor at City University of Hong Kong.“Every time we spoke about our research, companies would ask us questions and incorporate what we were finding into more efficient practices,” added Chen. “This study can inform the scale-up of battery recycling companies, like the importance of picking good locations for new facilities. California doesn’t have a monopoly on aging lithium-ion batteries from cell phones and EVs.”<h2>Looking ahead</h2>Industrial-scale battery recycling is growing, but not quickly enough, according to senior author Tarpeh.“We’re forecast to run out of new cobalt, nickel, and lithium in the next decade. We’ll probably just mine lower-grade minerals for a while, but 2050 and the goals we have for that year are not far away,” he said.While the U.S. now recycles about 50% of available lithium-ion batteries, it has successfully recycled 99% of lead-acid batteries for decades. Given that used lithium-ion batteries contain materials with up to 10 times higher economic value, the opportunity is significant, Tarpeh said.“For a future with a greatly increased supply of used batteries, we need to design and prepare a recycling system today from collection to processing back into new batteries with minimal environmental impact,” he added. “Hopefully, battery manufacturers will consider recyclability more in their future designs, too.”<hr>Co-authors of the study not mentioned above are Stanford faculty members&nbsp;<a href="https://profiles.stanford.edu/ines-azevedo" data-extlink="">Inês L. Azevedo</a>&nbsp;and&nbsp;<a href="https://profiles.stanford.edu/sally-benson" data-extlink="">Sally Benson</a>; adjunct faculty member&nbsp;<a href="https://www.linkedin.com/in/jacquesdechalendar/" data-extlink="">Jacques A. de Chalendar</a>; graduate student&nbsp;<a href="https://profiles.stanford.edu/gregory-forbes" data-extlink="">Gregory Forbes</a>, and former Stanford intern&nbsp;<a href="https://www.linkedin.com/in/akarys-yegizbay-10/" data-extlink="">Akarys Yegizbay</a>. William Tarpeh is also a fellow at the Precourt Institute for Energy and at the&nbsp;<a href="http://woods.stanford.edu/" data-extlink="">Woods Institute for the Environment</a>, both of which are part of the&nbsp;<a href="http://sustainability.stanford.edu/" data-extlink="">Stanford Doerr School of Sustainability</a>. This study was supported by the Stanford&nbsp;<a href="http://storagex.stanford.edu/" data-extlink="">StorageX Initiative</a>&nbsp;within the Precourt Institute for Energy. Redwood Materials was consulted for primary industrial data, but results were analyzed and interpreted by the listed authors.

Chemical Engineering Assistant Professor William Tarpeh and PhD student Samantha Bunke in the Tarpeh lab. | Bill Rivard / Precourt Institute for Energy

According to new research, greenhouse gas emissions, energy consumption, and water usage are all meaningfully reduced when – instead of mining for new metals – batteries are recycled.

Recycling lithium-ion batteries delivers significant environmental benefits

Radiation testing suggests that solar cells made from carbon-based, or organic, materials could outperform conventional silicon and gallium arsenide for generating electricity in the final frontier, a study from the University of Michigan suggests.While previous research focused on how well organic solar cells converted light to electricity following radiation exposure, the new investigation also dug into what happens at the molecular level to cause drops in performance.&nbsp;“Silicon semiconductors aren’t stable in space because of proton irradiation coming from the sun,” said <a href="https://eecs.engin.umich.edu/people/li-yongxi/" target="_blank" rel="noreferrer noopener">Yongxi Li,</a> first author of the study to be published in Joule and a U-M associate research scientist in electrical and computer engineering at the time of the research. “We tested organic photovoltaics with protons because they are considered the most damaging particles in space for electronic materials.”Space missions often land on gallium arsenide for its high efficiency and resistance to damage from protons, but it’s expensive and, like silicon, is relatively heavy and inflexible. In contrast, organic solar cells can be flexible and are much lighter. This study is among those exploring the reliability of organics, as space missions tend to use highly trusted materials.&nbsp;Organic solar cells made with small molecules didn’t seem to have any trouble with protons—they showed no damage after three years worth of radiation. In contrast, those made with polymers—more complex molecules with branching structures—lost half of their efficiency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1737053221925-1737053221925.png" class="fr-fic fr-dib">“We found that protons cleave some of the side chains, and that leaves an electron trap that degrades solar cell performance,” said <a href="https://eecs.engin.umich.edu/people/forrest-stephen-r/" id="isPasted">Stephen Forrest</a>, the Peter A. Franken Distinguished University Professor of Engineering at U-M, and lead corresponding author of the study.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1737053244779-alkyl-trap-healing-opvs-1.jpg" style="width: 100%px;" class="fr-fic fr-dib">The diagram shows the alkyl side chain extending from the organic molecule that converts energy from photons into free electrons. The gray electron hops from carbon to carbon on the way to the electrode. When hit with proton radiation, hydrogen breaks off and leaves behind electron-hungry traps. However, when exposed to temperatures of about 100°C (212°F), the hydrogen can re-bond with the carbon, healing the damage and eliminating the electron traps. Credit: Yongxi Li, Optoelectronic Components and Materials Group, University of MichiganThese traps grab onto electrons freed by light hitting the cell, preventing them from flowing to the electrodes that harvest the electricity.&nbsp;“You can heal this by thermal annealing, or heating the solar cell. But we might find ways to fill the traps with other atoms, eliminating this problem,” said Forrest.It’s plausible that sun-facing solar cells could essentially self-heal at temperatures of 100°C (212°F)—this warmth is enough to repair the bonds in the lab. But questions remain: for instance, will that repair still take place in the vacuum of space? Is the healing reliable enough for long missions? It may be more straightforward to design the material so that the performance-killing electron traps never appear.Li intends to explore both avenues further as an incoming associate professor of advanced materials and manufacturing at Nanjing University in China.The research is funded by Universal Display Corp and the U.S. Office of Naval Research.The devices were built in part at the&nbsp;<a href="https://lnf.umich.edu/" target="_blank" rel="noreferrer noopener">Lurie Nanofabrication Facility</a>, exposed to a proton beam at the&nbsp;<a href="https://mibl.engin.umich.edu/" target="_blank" rel="noreferrer noopener">Michigan Ion Beam Laboratory</a>, and studied at the&nbsp;<a href="https://mc2.engin.umich.edu/" target="_blank" rel="noreferrer noopener">Michigan Center for Materials Characterization</a>.The team has applied for patent protection with the assistance of U-M Innovation Partnerships. Universal Display has licensed the technology from U-M and filed a patent application. Forrest has a financial interest in Universal Display Corp.

Some carbon-based solar cells already show no drop in performance after three years’ worth of radiation, and the cause of degradation in others could be preventable.

Light, flexible and radiation-resistant: organic solar cells for space

Perovskite solar cells are considered a flexible and sustainable alternative to conventional silicon-based solar cells. Researchers at the Karlsruhe Institute of Technology (KIT) are part of an international team that has found new organic molecules within a few weeks that can be used to increase the efficiency of perovskite solar cells. The team cleverly combined the use of AI with fully automated high-throughput synthesis. The strategy developed can be transferred to other areas of materials research, such as the search for new battery materials. The researchers are currently reporting in Science <a href="https://doi.org/10.1126/science.ads0901" target="_blank">(DOI: 10.1126/science.ads0901)</a> .&nbsp;If you want to find out from 1,000,000 molecules which make perovskite solar cells particularly efficient as conductors of positive charge, you have to produce and test these million molecules - or proceed as researchers led by Tenure Track Professor Pascal Friederich from the KIT Institute of Nanotechnology and Professor Christoph Brabec from HI ERN have done. "With just 150 targeted experiments, a breakthrough was achieved that would otherwise have required hundreds of thousands of tests. The workflow developed opens up new possibilities for the rapid and cost-efficient discovery of high-performance materials in a wide range of application areas," says Brabec. Using one of the materials discovered in this way, they increased the efficiency of a reference solar cell by around two percent to 26.2 percent. "This success shows that with a clever strategy, enormous time and resources can be saved when developing new energy materials," says Friederich.The starting point at HI ERN was a database with the structural formulas of around one million virtual molecules that could be produced from commercially available substances. The researchers at KIT used established quantum mechanical methods to calculate energy levels, polarity, geometry, and other characteristics of 13,000 of these virtual molecules, which were randomly selected.&nbsp;<h2>AI training with data from only 101 molecules</h2>From these 13,000 molecules, the researchers then selected 101 molecules that differed as much as possible in their characteristics. These were produced automatically at HI ERN using a robot system, thereby producing otherwise identical solar cells. They then measured their efficiency. "The key to the success of our strategy was that, thanks to our highly automated synthesis platform, we were able to produce truly comparable samples and thus determine reliable values for the efficiency," says Christoph Brabec, who led the work at HI ERN.&nbsp;The KIT researchers trained an AI model using the achieved efficiencies and the characteristics of the associated molecules. The model then suggested another 48 molecules for synthesis based on two criteria: an expected high efficiency and unpredictable properties. "If the machine learning model is unsure about predicting the efficiency, it is worth producing the molecule to examine it more closely," Pascal Friederich explains the second criterion. "It could surprise with a high efficiency."&nbsp;In fact, the molecules proposed by the AI could be used to build above-average efficient solar cells, including ones that outperform other state-of-the-art materials. "We cannot be sure that we have really found the best among a million molecules, but we are certainly close to the optimum," says Friederich, tenure-track professor for artificial intelligence in materials science.<h2>AI versus chemical intuition</h2>The researchers can understand the AI's molecule suggestions to a certain extent because the AI used indicates which features of the virtual molecules were decisive for its suggestions. It turned out that the AI's suggestions were partly based on features, such as the presence of certain chemical groups such as amines, which chemists had previously paid less attention to.Christoph Brabec and Pascal Friederich are convinced that their strategy is promising for materials research in other application areas or can be extended to the optimization of entire components.The research results, which were developed in collaboration with researchers from the University of Erlangen-Nuremberg, the Ulsan National Institute of Science in South Korea, the Xiamen University in China and the University of Electronic Science and Technology in Chengdu, China, were recently published in the renowned journal "Science". (ffr)<hr><h3>Original publication</h3>Jianchang Wu, Luca Torresi, ManMan Hu, Patrick Reiser, Jiyun Zhang, Juan S. Rocha-Ortiz, Luyao Wang, Zhiqiang Xie, Kaicheng Zhang, Byung-wook Park, Anastasia Barabash, Yicheng Zhao, Junsheng Luo, Yunuo Wang, Larry Lüer, Lin-Long Deng, Jens A. Hülse, Dirk M. Guldi, M. Eugenia Pérez-Ojeda, Sang Il Seok, Pascal Friederich, Christoph J. Brabec: Inverse design of molecular hole-transporting semiconductors tailored for perovskite solar cells. Science, 2024. <a href="https://doi.org/10.1126/science.ads0901%C2%A0" target="_blank">DOI 10.1126/science.ads0901.</a>

One in a million: Artificial intelligence helps researchers find new materials for highly efficient solar cells. (Photo: Kurt Fuchs/HI ERN)

Researchers show how the use of machine learning enormously accelerates the search for new semiconducting molecules for perovskite solar cells

Using AI to develop better photovoltaic materials faster

The use of passenger electric vehicles (EVs) is expected to rise to 28% by 2030 and 58% by 2040, globally. The existing supply chain for EV batteries relies mostly on recycling to close the loop to recover critical minerals such as cobalt, nickel, or copper. However, conventional battery recycling methods are energy-intensive, produce significant quantities of greenhouse gases, and lead to large volumes of waste deposited in landfills.To catalyze the transition from a linear to a circular supply chain for domestic EV batteries, the U.S. Department of Energy Advanced Research Projects - Energy (ARPA-E) has announced <a href="https://arpa-e.energy.gov/news-and-media/press-releases/us-department-energy-announces-13-projects-strengthen-domestic" rel="noopener" target="_blank">$36 million for 13 projectsOpens in new window</a> to accelerate technologies and pursue solutions to extend battery life and facilitate repair and reuse to reduce waste.<a href="https://sealionenergy.com/" rel="noopener" target="_blank">SeaLionOpens in new window</a><a href="https://sealionenergy.com/">&nbsp;Energy</a>, a startup company founded by <a href="https://engineering.cmu.edu/directory/bios/jayan-reeja.html">Reeja Jayan</a>, professor of <a href="https://www.meche.engineering.cmu.edu/index.html" rel="noopener" target="_blank">mechanical engineeringOpens in new window</a> and fellow of the <a href="https://www.cmu.edu/energy/" rel="noopener" target="_blank">Scott Institute for Energy InnovationOpens in new window</a>, was selected to receive $1.6 million to develop a low-cost and low-greenhouse gas coating technology that significantly extends battery cycle life. SeaLion Energy’s project, known as TARDIS-J (Tunable Activation &amp; Regeneration in Devices using In-Situ Jamming), will also reduce waste by regenerating “dead” battery cells.Redefining the future of energy storage, SeaLion Energy’s patented innovation also reduces charging times and improves operating safety.“We need to rethink the way batteries are manufactured from the ground up so that every element can be carefully designed, taking into consideration not just cost and performance but also what happens to the battery at end of life,” said Jayan. “When an EV driver wants to upgrade their vehicle, the battery should live on at a grid storage facility to power peoples’ homes; it shouldn’t sit in a landfill.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734397421219-1010-em-sealion-energy.png" style="width: 100%px;" class="fr-fic fr-dib">Each of the 13 ARPA-E funded projects will be managed under the Catalyzing Innovative Research for Circular Use of Long Lived Advanced Rechargeables (CIRCULAR) program.“ARPA-E turns bold ideas into transformative breakthroughs,” said ARPA-E Director Evelyn N. Wang. “We identified the need for more effective alternatives to the current battery recycling paradigm. I look forward to seeing how these CIRCULAR projects develop regeneration, repair, reuse, and remanufacture technologies to create a sustainable EV battery supply chain.”U.S. Congresswoman Summer Lee <a href="https://summerlee.house.gov/posts/rep-lee-celebrates-1-6-million-in-federal-investment-for-circular-battery-innovation-in-pittsburgh">celebrated SeaLion’s&nbsp;</a><a href="https://summerlee.house.gov/posts/rep-lee-celebrates-1-6-million-in-federal-investment-for-circular-battery-innovation-in-pittsburgh" rel="noopener" target="_blank">achievementOpens in new window</a>, “With projects like this, Pittsburgh is proving itself as a national leader in clean technology and sustainable innovation. Federal investments in transformative projects like SeaLion’s TARDIS-J are critical not only to supporting local talent and job creation but also to advancing a sustainable future. This is what it means to invest in our communities—solutions that benefit the people and the planet.”<blockquote>We need to focus on innovations that lead to cost-effective, scalable solutions that prolong battery life and reduce waste.<cite>Reeja Jayan, Professor, Mechanical Engineering</cite></blockquote>With funding and comprehensive support from the Scott Institute for Energy Innovation, <a href="https://engineering.cmu.edu/mfi/index.html">The Manufacturing Futures Institute</a>, <a href="https://www.cmu.edu/swartz-center-for-entrepreneurship/">The Swartz Center for Entrepreneurship</a>, and <a href="https://www.cmu.edu/cttec/">The Center for Technology Transfer and Enterprise Creation</a>, Jayan credits CMU for helping to accelerate the spin-out of her startup company.“I am very grateful for this support,” she said. “I hope SeaLion Energy’s story can serve as a blueprint for the entrepreneurial pursuits of CMU students and faculty.”With climate change no longer just a possibility, but a reality, Jayan believes that everyone who is capable of doing something to mitigate it, should.“Instead of mining entire ecosystems out of existence to collect very limited minerals, we need to focus on innovations that lead to cost-effective, scalable solutions that prolong battery life and reduce waste. By doing so, we can realize a fully circular and domestic EV battery supply chain for the USA.”

SeaLion Energy, a CMU-led startup, received funding from the U.S. Department of Energy ARPA-E to extend EV battery life and facilitate repair and reuse to reduce waste.

Domestic, circular supply chain for EV batteries

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