Fisker Automotive Signs Supplier Agreement with BMW

Fisker Automotive announced today the signing of an agreement with BMW that will cover the supply of engines and other components for future Fisker models.

BMW will supply a four-cylinder turbocharged engine for the next generation of Fisker cars, code-named ‘Project Nina’, which are scheduled to go into production in the re-commissioned former GM plant in Wilmington, Delaware at the end of 2012 and be on sale globally in 2013.

The agreement calls for up to 100,000 engine units per year at peak volume.

The first ‘Project Nina’ derivative will be a mid-size premium sedan utilizing Fisker’s EVer™ (electric vehicle with extended range) technology to deliver on Fisker’s corporate vision of Uncompromised Responsible Luxury.

Fisker ‘s CEO and Executive Design Director, Henrik Fisker, comments; “The BMW engine was an obvious choice for us, as BMW is known for producing the best and most fuel efficient gasoline engines in the world. We are very pleased to have signed this agreement with BMW."

Fisker’s Chief Operating Officer, Bernhard Koehler, adds; “This is an important agreement for Fisker. We are focused on building environmentally responsible cars that deliver Pure Driving Passion to our discerning customers. Who better to be a part of this exciting ‘recipe’ than BMW – the makers of the Ultimate Driving Machine?”

California-based Fisker Automotive recently established a European office in Munich, Germany and has publicly stated that both the Fisker Karma Sedan and ‘Project Nina’ lines are global vehicles with sales likely to be split equally in the US and Europe (40% each), with Asia (20%) providing the remainder.

BMW opens new Moses Lake carbon fiber factory

BMW's new carbon fiber factory in the United States has brought advanced, lightweight materials developed in Formula One racing one step closer to consumers' driveways.

The German carmaker opened the ultra-modern production plant in Moses Lake, Washington state, on Thursday to supply carbon fiber for its highly anticipated, all-electric i3 Concept car.

Built through a 2009 joint venture with materials specialist SGL Carbon, the $100 million (70 million euro) facility is powered entirely by locally generated hydroelecricity. It will produce up to 3,000 metric tons of carbon fiber annually.

"The facility has been erected in only 10 months and will be the most cost efficient carbon fiber plant using modern technologies," said Andreas Wüllner, Managing Director of SGL Automotive Carbon Fibers.

The fibers produced in Moses Lake will be woven into lightweight fabrics at a second joint venture site in Wackersdorf, Germany, before being formed into carbon fiber reinforced plastic (CFRP) parts and components at the BMW plant in Landshut. From there they will be transported to Leipzig, where series production of the i3 is due to start in 2013.

Electric era

The i3 urban vehicle will be the first model in BMW's new i sub-brand of lightweight, energy efficient models. The larger and sportier i8 is expected to be released in 2014.

"Carbon fibers are a key construction material for the automotive industry of the 21st century and will change the way we develop and build cars," BMW chief executive Norbert Reithofer said in a statement.

"It's a revolution in automotive design," Klaus Draeger, the company's head of development, said earlier.

Fiber of the future

Because of its lightweight properties and proven strength, carbon fiber has long been used in the construction of high-performance racing cars and aircraft.

When carbon fibers are woven, they weigh in around 50 percent lighter than steel and roughly 30 percent lighter than aluminum, making CFRP the lightest material that can be used in a car body without sacrificing safety.

The i3's carbon fiber passenger shell makes it 250 to 350 kilograms lighter than a conventional electric car. BMW said that means more dynamic handling and improved range.

Other benefits of CFRP include corrosion resistance and resilience in severe climate conditions. The material shows little change in shape and size regardless of temperature fluctuations.

"Carbon is the fiber of the future," said Ferdinand Dudenhöffer, an automotive expert at the University Duisburg-Essen. "The heavy use in Formula One racing cars is an indicator that it will filter down to the mass market once the cost of production becomes more affordable. BMW is the closest to achieving solutions on a large scale."

Daimler & Volkswagen follow suit

BMW is not alone in the race to make carbon fiber vehicles easily available to consumers. In April of 2010 Daimler followed BMW's lead by forming a partnership with Toray Industries, a Japanese carbon producer. The group plans to begin mass production of carbon parts for the Mercedes-Benz brand in 2012 at a plant outside Stuttgart, Germany.

With no new plans to mass produce carbon fiber technology in car bodies, Daimler's efforts have focused on high end of the auto market. In 2004, Daimler began offering the Mercedes-Benz McLaren SLR with a carbon-fiber body to match its ceramic disc brakes and 377,000-euro price tag. About 2,000 of the vehicles were sold before production ceased in 2009.

Last, but certainly not least, Volkswagen became the latest German automaker to invest in a major carbon fiber producer when it announced in February of this year that it had purchased an 8.18 percent stake in SGL Carbon. While Volkswagen stated that it does not intend to increase its stake in SGL Carbon, the news certainly came as a surprise to BMW, which had previously bought into the company.

Volkswagen has been pouring resources into its XL1 concept vehicle, which debuted at this year's Qatar Motor show. With a prototype that can travel 100 kilometers on just one liter of diesel fuel, the vehicle is fitted with a lightweight passenger shell constructed of carbon fiber.

Despite the innovations and progress being made in carbon fiber production, Stefan Bratzel, director of the Center of Automotive Management in Bergisch-Gladbach, said carmakers were yet to answer one major question: "A full carbon body could be quite difficult to repair. What will be key is if there's a strategy to deal with that issue."

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Graphene battery could triple Electric Vehicle range

Researchers with the U.S. Department of Energy’s Lawrence Berkeley National Laboratory (Berkeley Lab) have created a graphene and tin nanoscale composite material for high-capacity energy storage in renewable lithium ion batteries. By encapsulating tin between sheets of graphene, the researchers constructed a new, lightweight “sandwich” structure that should bolster battery performance.

“For an electric vehicle, you need a lightweight battery that can be charged quickly and holds its charge capacity after repeated cycling,” says Yuegang Zhang, a staff scientist with Berkeley Lab’s Molecular Foundry, in the Inorganic Nanostructures Facility, who led this research. “Here, we’ve shown the rational design of a nanoscale architecture, which doesn’t need an additive or binder to operate, to improve battery performance.”

Graphene is a single-atom-thick, “chicken-wire” lattice of carbon atoms with stellar electronic and mechanical properties, far beyond silicon and other traditional semiconductor materials. Previous work on graphene by Zhang and his colleagues has emphasized electronic device applications.

In this study, the team assembled alternating layers of graphene and tin to create a nanoscale composite. To create the composite material, a thin film of tin is deposited onto graphene. Next, another sheet of graphene is transferred on top of the tin film. This process is repeated to create a composite material, which is then heated to 300˚ Celsius (572˚ Fahrenheit) in a hydrogen and argon environment. During this heat treatment, the tin film transforms into a series of pillars, increasing the height of the tin layer.

“The formation of these tin nanopillars from a thin film is very particular to this system, and we find the distance between the top and bottom graphene layers also changes to accommodate the height change of the tin layer,” says Liwen Ji, a post-doctoral researcher at the Foundry. Ji is the lead author and Zhang the corresponding author of a paper reporting the research in the journal Energy and Environmental Science.

The change in height between the graphene layers in these new nanocomposites helps during electrochemical cycling of the battery, as the volume change of tin improves the electrode’s performance. In addition, this accommodating behavior means the battery can be charged quickly and repeatedly without degrading — crucial for rechargeable batteries in electric vehicles.

“We have a large battery program here at Berkeley Lab, where we are capable of making highly cyclable cells. Through our interactions in the Carbon Cycle 2.0 program, the Materials Science Division researchers benefit from quality battery facilities and personnel, along with our insights in what it takes to make a better electrode,” says co-author Battaglia, program manager in the Advanced Energy Technology department of Berkeley Lab’s Environmental and Energy Technologies Division. “In return, we have an outlet for getting these requirements out to scientists developing the next generation of materials.”

“With a graphene battery the same amount of weight and volume as a current one, you could drive 300 miles instead of 100,” said Yuegang Zhang, a principal investigator at the lab. “In that case, you’ll like to buy an electrical car.”

Buckeye Bullet 3 to Attempt 400 MPH Electric Vehicle Speed Record

Last year Ohio State’s streamlined Buckeye Bullet supercar made headlines as it shattered the world speed record for an electric vehicle by clocking in a blistering 291 miles per hour. The team is back this year with plans for their next-generation racer, which they expect will be able to hit speeds in excess of 400 mph.

The Buckeye Bullet 3 is being built from the ground up on an entirely new platform that includes an optimized aerodynamic shape, two custom-made electric motors by Venturi, and a set of prismatic A123 batteries.

In order to improve upon the performance of the Buckeye Bullet 2.5, the team is harnessing the Ohio Supercomputer Center to develop their next-gen land speed racer. Through a series of aerodynamic simulations they have come up with a completely new platform for the Buckeye Bullet 3 that will reduce drag by 5%, place the driver in front of the tires to conserve volume, and improve the vehicle’s overall handling and balance.

The team is also developing wind deflectors to be installed beneath the vehicle to improve stability and further minimize drag. According to the project’s chief engineer Cary Bork, “What sets the new design apart from the previous Buckeye Bullet vehicles is that at these higher speeds it is possible to produce shock waves under the vehicle. Such shock waves under the vehicle negatively affect the vehicle drag and can produce lift. Lift is undesirable in this application. Minimizing or eliminating these shock waves is critical to ensuring the safety and stability of the vehicle.”

Design work on the project is expected to be completed by the end of this summer, and the vehicle will be constructed over the course of the coming academic year.

Buckeye Bullet

UQM Receive $3M DOE Grant to Develop Non-rare-earth EV motors

UQM will develop a unique motor design to use non-rare-earth magnets

--Non-rare-earth magnets may lower overall motor cost while providing better efficiency than other alternative motor technologies

--UQM is a leading developer and manufacturer of electric motors and generators for electric and hybrid electric vehicles

The U.S. Department of Energy (DOE) has awarded $3 million to UQM Technologies, Inc. for the development of non-rare-earth magnet electric motors for use in electric and hybrid electric vehicles. UQM will cost-share 25 percent of the $4 million effort under the development program.

"We are pleased that the DOE has again selected our company to assist in advancing the state-of-the-art in motor and generator technology for electric and hybrid electric vehicles," said Eric Ridenour, UQM Technologies' President and Chief Executive Officer. "This DOE grant will help us apply our extensive experience with the design and engineering of electric motors to the exploration of non-rare-earth magnet motor technology. Our objective is to identify and evaluate magnet materials and technology that can deliver the performance our customers expect, broaden our product portfolio, potentially lower magnet cost and limit our exposure to price and supply concerns associated with rare earth magnets."

Under the award, the engineering team at UQM will work collaboratively with Ames Laboratory, the National Renewable Energy Laboratory and Oak Ridge National Laboratory to develop and apply these new magnet materials in a high performance permanent magnet motor.

"The goal of this new technology that we are developing will be motor designs that apply to a full range of vehicle electrification, from mild hybrid to heavy hybrid to full electric vehicles," said Jon Lutz, UQM Technologies' Vice President of Engineering. "We believe that our unique motor concepts coupled with our extensive experience in motor design will allow us to achieve the objectives of this program."

UQM PowerPhase(R) electric propulsion systems have been selected to power the Saab 9-3 ePower, Audi A-1 etron and Rolls-Royce 102EX Electric Phantom pre-production test fleet vehicles. UQM is also powering Proterra's electric composite transit buses, as well as Electric Vehicles International's all-electric medium-duty truck and walk-in van. The company has a new facility with 40,000 units of annual production capacity for its PowerPhase electric propulsion systems.

Nanosys Receives $11 Million Funding From U.S. Department of Energy

Nanostart-holding Nanosys, Inc. today announced that the U.S. Department of Energy (DOE) has awarded it funds to refine and bring to scale its SiNANOde™ materials for the automotive market. These innovations will enable Electric Vehicles (EVs) to travel 300 miles on a single charge.

In addition to the primary DOE award of USD 4.8 million, approximately USD 6 million will be spent, through sub-awards and matches by the DOE and Nanosys, in the development and commercialization of advanced material technologies and manufacturing in the United States.

"We are honored the DOE has selected Nanosys for this grant," said Jason Hartlove, president and CEO of Nanosys. "The future of a clean energy economy depends on increased adoption of electric and hybrid electric (PHEV) vehicles. Until such vehicles are able to achieve substantial operating range on a single charge with the economics of combustion vehicles, acceptance will be limited to early adopters. The commercialization of architected material solutions like SiNANOde™ provide the breakthroughs needed to progress on the path to achieving those goals."

The grant is a part of the DOE's larger mission to accelerate the development and deployment of advanced vehicle technologies through targeted programs aimed at increasing vehicle efficiency.

DOE's comprehensive approach is aimed at creating new innovations throughout the vehicle, including high capacity electric vehicle batteries and components that should significantly exceed existing state-of-the-art technologies in terms of performance and/or cost.

The agency has set a target for bringing the cost of lithium-ion batteries down to USD 250/kWh and increasing capacity to 300 miles per charge for the next generation of EVs. In recent tests, Nanosys' SiNANOde™ anode material has doubled capacity while providing breakthrough charge/discharge cycle life improvements. Nanosys will use the DOE funds to accelerate development through purchases of additional equipment and the hiring of additional staff.

"The Department of Energy is investing in new advanced technologies that will significantly improve vehicle fuel economy, save consumers money, and create skilled jobs for Americans," said U.S. Energy Secretary Steven Chu in a DOE press release. "Investments in the next generation of autos will strengthen our economy and lead to a more fuel-efficient, clean energy future."

In addition to EVs, Nanosys is currently working with domestic and international battery manufacturers to improve lithium-ion battery capacity using SiNANOde™ in batteries for laptops and tablets, smart phones and other electronic devices

GE gets $5.9M research grant to develop non-rare earth EV motors

The General Electric Global Research Center has been awarded a $5.9 million grant for advanced vehicle technology by the U.S. Department of Energy.

GE will provide an additional $6 million for the project, which will develop new high-performance electric motors with non-rare earth materials.

The availability of rare earths has been limited as China, the major supplier, limits exports.
The GE funding is part of $175 million that the Department of Energy is doling out to 40 projects in 15 states for advanced vehicle research over the next three to five years.

The projects, which are expected to leverage additional investments totaling over $300 million, will target new innovations including better fuels and lubricants, lighter weight materials, longer-lasting and cheaper electric vehicle batteries, and more efficient engine technologies.

As China tightens its grip on rare-earth minerals, which play a vital role in smartphones, TVs and computer hard drives, the Energy Department has been making a push to produce electric vehicles and turbines without them.

The U.S. consumes about 10,000 metric tons of rare-earth materials annually, according to the U.S. Geological Survey, and increasingly relies on metals like neodymium and dysprosium for the powerful magnets used in the high-performance drive systems of electric motors and turbines.
China controls 97 percent of supplies of these 17 elements. There are currently no mines for rare-earth minerals in the U.S.

Rare earth minerals have magnetic and conductive properties not found in the rest of the periodic table. Research like that being conducted at GE aims to work around limitations on supply.

"This announcement is a win-win for the Capital Region and will be a shot in the arm for our clean energy economy," U.S. Sen. Charles Schumer said Wednesday. "This funding will help improve the fuel efficiency of next generation vehicles and advanced motor designs."

The award will help automakers achieve recently announced fuel efficiency standards, Schumer said. Last month, President Obama announced mileage standards for cars and light trucks that will bring fuel efficiency to 54.5 miles per gallon by the 2025 model year.

DOE Awards $175 Million in Vehicle Efficiency Development Grants

U.S. Energy Secretary Steven Chu announced that the DOE is providing more than $175 million to 40 projects across 15 states over the next three to five years to accelerate the development of energy-efficient-vehicle technologies.

The projects will pursue innovations in fuels and lubricants, lighter weight materials, longer-lasting and cheaper electric vehicle batteries and components, and more efficient engine technologies, according to a DOE announcement.

Among the grant recipients, United States Automotive Materials Partnership will validate crash models for carbon-fiber composites that would enable the use of lightweight composites in primary-structural automotive crash and energy management applications.

Penn State University will develop a high energy density lithium-sulfur cell technology that significantly reduces battery size, and improves performance and life.

MIT will investigate the use of new lubricant formulations that target differing lubrication requirements of the major engine subsystems.

A complete list of the 40 grant recipients is available at the link below.

DOE Funded Projects

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Fisker promises Bugatti Veyron levels of performance

The Fisker Karma is still MIA, but that hasn't stopped the company from having grand ambitions.

According to CEO Henrik Fisker, engineers are developing a new gearbox that will give their range-extended electric vehicles "[ Bugatti] Veyron levels of performance." That's not much to go off, but the executive hinted the transmission would increase the amount of torque that is sent to the wheels.

For comparison, the Bugatti Veyron 16.4 accelerates from 0-100 km/h in 2.5 seconds while the Fisker Karma takes 5.9 seconds.

Source: Autocar