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VW’s US Innovation Hub just announced four breakthroughs in electric mobility and sustainable transport – here’s what the research center has achieved.

Volkswagen’s Innovation Hub opened in 2020 at the University of Tennessee (UT) Research Park at Cherokee Farm in Knoxville. The federally funded Oakridge National Laboratory (ORNL) is there too. VW collaborates with UT and ORNL scientists on its EV research. Here’s what the VW Innovation Hub has been up to:

AI-optimized EV battery pack frame

Volkswagen researchers are working on new material structures to reduce vehicle weight, which in turn helps to increase the range of EVs. The aim of the first pilot is to replace the steel frame that houses the EV battery pack with something lighter.

The team used artificial intelligence (AI) with millions of parameters on UT’s high-performance computer cluster to develop a modular repeating structure in the shape of tiny pyramids (main photo). The structure can be 3D-printed from liquid resins and can hold 30K times its own 0.15 lb weight (68g). So this frame would be up to 60% lighter than the steel frame. The researchers found that the resin frame absorbs more energy than the steel frame (they’re testing its durability in the photo above), which means it’s robust.

Electrek’s Take: Intriguing. As VW is claiming that its resin frame is lighter and stronger – and we’re going to assume it’s made sustainably – I hope to see this progress beyond the pilot stage and will keep an eye on it.

EV interiors made of paper

Scientists at UT’s Center for Renewable Carbon are using paper as a recyclable alternative to plastic parts and foils for EV interiors. The team has patented a method of preforming and hot-pressing cellulose fiber-reinforced thermoplastics into durable interior parts.

The recyclable paper-based composites can be transformed into various interior shapes and sizes, and different textures and colors can be added.

VW says it’s “checking opportunities” to include paper-based interior parts in future models and “work to support industry-scale production.”

Electrek’s Take: Any move toward recyclable materials and away from plastics can’t come fast enough. No timeline is given here from VW on industry-scale production plans; it’d be great to see this material used by VW in mass-produced EVs.

Lightweight fiber composite body parts

Researchers re-created the liftgate of a 2020 Volkswagen Atlas using sheet molding compound, a type of fiberglass-reinforced plastic. The new liftgate was 13 pounds lighter than the metal one, resulting in a weight savings of more than 35%. That would help increase the range of EVs.

VW says that the fiber composite liftgate doesn’t need changes in assembly sequence compared to metal liftgates, so the former can be produced in high volumes.

Researchers have recently further refined molding processes and ways to optimize durability, quality, and design options.

Electrek’s Take: Fiber composite body parts are already in production at Bentley and Lamborghini, which are part of the Volkswagen Group. They’re using the new materials and the molding process for the Bentley Continental and the Lamborghini Aventador. Those are luxury cars, so it’s not exactly mass production, but researchers are also exploring fiber composite pickup truck beds and other components.

Wireless EV fast charging

VW’s team has patented a coil and charging pad design with silicon-carbide materials. In early trials, the automaker says that the prototype silicon-carbide inverter system has proven to be highly efficient. The research team has been able to increase the charging power level up to 120 kW with this prototype from an earlier 6.6 kW prototype, and their goal is to reach 300 kW.

Electrek’s Take: There’s no further elaboration from VW on what’s next for its wireless EV fast charging project, so I’m guessing this is still in early stages. It’d really need a lot of finessing to be viable on a widespread scale. Still, to progress from 6.6 kW to 120 kW is an achievement. It’d be nice to just pull up over a charging pad in a parking spot and start charging, especially when it’s extremely hot – that’s you down south – or when it simply won’t stop raining, like us up here in the Northeast.

I hope at least half of these projects go into mass production and become cost-effective. But seeing how VW has implemented a short-term spending freeze, it’s probably not going to happen soon.

Photos: Volkswagen


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JackRabbit’s new solar charging kit keeps your e-bike topped up from the sun

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JackRabbit's new solar charging kit keeps your e-bike topped up from the sun

JackRabbit, the maker of pint-sized electric microbikes, is back with a new product designed to quickly recharge their batteries from pure, uncut photons mainlined into an e-bike directly from the sun. In true independent charging form, the Solar Charging Kit from JackRabbit keeps riders rolling even when there’s not a convenient AC outlet in sight.

Unveiled this week, the Solar Charging Kit consists of a single folding solar panel and a tiny voltage converter that is configured to output 42.0V, which is the exact voltage required by JackRabbit’s little e-bike batteries. There’s also an added USB-A and a USB-C charging port for powering other devices in addition to charging JackRabbit batteries.

“This Solar Charging Kit plugs directly into your bike,” explained the company, “letting you recharge without needing an outlet, but with a speed comparable to the charger that comes with the OG/OG2 (42V, 2A).”

That would mean the panel outputs around 80W of solar power, which the company says can recharge its batteries in just three hours. That fairly quick recharging speed is helped by the fact that JackRabbit’s batteries are a mere 151 Wh, or around a third of the size of most e-bike batteries.

If that sounds small, then you’re right – it is. But JackRabbit is all about going micro, offering barely 25 lb rideables that are easy to store and bring on adventures, even when they aren’t actually being ridden.

With small batteries that fit under the 160Wh limit for many airlines in the US, the batteries can be quickly charged and taken to the widest number of locations. And for riders that want to go further than a single 10-mile (16-km) battery will allow, extra batteries are small enough to fit a pants pocket. The company also offers much larger Rangebuster batteries, though they won’t pass by TSA and make it onto an airplane in your personal item.

It sounds like the Solar Chargking Kit should be able to charge up JackRabbit’s large RangeBuster batteries, though likely in more than three hours.

The $349 Solar Charging Kit is a bit pricier than building something similar yourself, but it’s also safer and more convenient than hacking together your own battery charger since it’s designed to work with JackRabbit’s batteries right out of the box.

Technically it’s only inteded for JackRabbit’s micro e-bikes (themselves technically seated scooters, even if they look and feel more like a typical bike), but it’d probably work for just about any 36V e-bike that requires 42.0V to charge.

This isn’t the first time we’ve seen solar charging kits for electric bikes, and it’s a trend that is certainly appreciated by outdoors and camping enthusiasts, festival goers, or anyone who finds themself and their bike spending extended periods in the great, sunny outdoors.

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Polestar hopes to steal Tesla sales, CATL revenue dips, and feeding the orcas

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Polestar hopes to steal Tesla sales, CATL revenue dips, and feeding the orcas

On today’s episode of Quick Charge, Polestar hopes to steal customers from Tesla now that Elon is involved in politics, CATL revenue dips for the first time ever, and a whole new way to feed the orcas drops down under.

As above, Polestar is hoping Elon’s descent into politics spells opportunity for the struggling Swedish/Chinese performance brand, CATL has big news in Europe, and Scooter Doll shows off a new electric submarine that’s so expensive, they won’t even tell us the price.

Prefer listening to your podcasts? Audio-only versions of Quick Charge are now available on Apple PodcastsSpotifyTuneIn, and our RSS feed for Overcast and other podcast players.

New episodes of Quick Charge are recorded, usually, Monday through Thursday (and sometimes Sunday). We’ll be posting bonus audio content from time to time as well, so be sure to follow and subscribe so you don’t miss a minute of Electrek’s high-voltage daily news.

Got news? Let us know!
Drop us a line at tips@electrek.co. You can also rate us on Apple Podcasts and Spotify, or recommend us in Overcast to help more people discover the show.

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Solar overtakes coal in the EU, and gas declines for 5th year running

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Solar overtakes coal in the EU, and gas declines for 5th year running

Solar generated 11% of EU electricity in 2024, overtaking coal which fell below 10% for the first time, according to the European Electricity Review published today by think tank Ember.

EU gas generation declined for the fifth year in a row, and total fossil generation fell to a historic low.

“Fossil fuels are losing their grip on EU energy,” said Dr Chris Rosslowe, senior analyst and lead author of the report. “At the start of the European Green Deal in 2019, few thought the EU’s energy transition could be where it is today; wind and solar are pushing coal to the margins and forcing gas into structural decline.”

The European Electricity Review published today by global energy think tank Ember provides the first comprehensive overview of the EU power system in 2024. It analyzes full-year electricity generation and demand data for 2024 in all EU-27 countries to understand the region’s progress in transitioning from fossil fuels to clean electricity.

Wind and solar continue their meteoric rise in the EU

The EU power sector is undergoing a deep transformation spurred on by the European Green Deal. Solar generation (11%) overtook coal (10%) for the first time in 2024, as wind (17%) generated more electricity than gas (16%) for the second year in a row.

Strong solar growth, combined with a recovery of hydropower, pushed the share of renewables to nearly half of EU power generation (47%). Fossil fuels generated 29% of the EU’s electricity in 2024. In 2019, before the Green Deal, fossil fuels provided 39% of EU electricity, while renewables provided 34%.

Solar is growing in every EU country and more than half now have either no coal power or a share below 5% in their power mix. Coal has fallen from being the EU’s third-largest power source in 2019 to the sixth-largest in 2024, bringing the end into sight for the dirtiest fossil fuel. EU gas generation also declined for the fifth year in a row (-6%) despite a very small rebound in power demand (+1%). 

The EU is reaping the benefits of reduced fossil fuel dependency

The surge in wind and solar generation has reduced the EU’s reliance on imported fossil fuels and its exposure to volatile prices since the energy crisis. Ember’s analysis found that without new wind and solar capacity added over the last five years, the EU would have imported an additional 92 billion cubic meters of fossil gas and 55 million tonnes of coal, costing €59 billion. 

“While the EU’s electricity transition has moved faster than anyone expected in the last five years, further progress cannot be taken for granted,” continued Rosslowe. “Delivery needs to be accelerated particularly in the wind sector, which has faced unique challenges and a widening delivery gap. Between now and 2030, annual wind additions need to more than double compared to 2024 levels. However, the achievements of the past five years should instil confidence that, with continued drive and commitment, challenges can be overcome and a more secure energy future be achieved.” 

Walburga Hemetsberger, CEO of SolarPower Europe said: “This milestone is about more than just climate action; it is a cornerstone of European energy security and industrial competitiveness. Renewables are steadily pushing fossil fuels to the margins, with solar leading the way. We now need more flexibility to kick-in, making sure the energy system is adapting to new realities: more storage and more smart electrification in heating, transport and industries.”

Read more: China installed a record capacity of solar and wind in 2024 – in numbers


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