Long-term reliable electrical contacts in EVs - application phase and beyond (ELYFOG)

Purpose and goal:

The main goal is to minimize energy losses in electrical connections due to degradation of the joints by thermal, environmental and mechanical loads, for primary and recycled material streams. Create the conditions for long-term stable electrical connections in electric cars throughout the application phase and beyond. The project will apply a holistic approach to optimize joint configuration, durability, sustainability, costs, reusability and recyclability. The results will be available as web-based guidelines.

Expected results and effects:

Reducing the life-cycle environmental footprint of the applied materials and processes for electrical connections and minimize costs.

Conclusions about correlation between configuration and functional and mechanical service life, allowing for assessment of reuse and remanufacturing possibilities.

Instructions and guidelines for testing, material selection and assembly to improve the connection lifetime and guidelines for the reuse of connection parts and the use of recycled materials in electrical connections. Approach and implementation:

The project will start with Work Package WP1 (Concepts and requirement specifications). WP2 (Test methodologies) and WP3 (Testing, comparative studies and optimization) will start in parallel and involve several loops to get insights as fast as possible and to allow for optimization of the new test method/test rig. WP4 (Guidelines and dissemination) will start after the main results are evaluated and summarize the project results.

WP5 (Project management) will overview the activities and support the parties involved over the whole duration of the project.