AUTOMOTIVE DESIGN
The LFP battery pack
DRIVING ELECTRIFICATION
This manufacturer reveals how its latest product launches are set to drive innovation in the commercial electric vehicle market
F
or more than a century, Borgwarner has been supplying the automotive industry with innovative
products for conventional Internal Combustion Engine (ICE) vehicles. Now a global manufacturer of electrifi cation and mobility solutions, the company is continuing to develop advanced products and technologies that are helping to improve the sustainability of commercial transportation. The latest spate of product launches from the manufacturer holds true to this mission, from innovations in Lithium Iron Phosphate (LFP) battery packs and DC fast charging to advanced components for electric powertrains.
A BOOST FOR LFP BATTERIES In February, Borgwarner announced a strategic eight-year partnership with FinDreams Battery, a subsidiary of BYD Company Limited, to become the only non-OEM localised manufacturer with rights to localise LFP battery packs for commercial vehicles in Europe, the Americas and select regions of Asia Pacifi c. “Since the announcement, we’ve
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been working hard on our new LFP battery designs and also talking to customers,” says Harry Husted, CTO of Borgwarner. “FinDreams will supply BorgWarner with its LFP blade cells and some production equipment for battery pack assembly. The design of the battery packs is being done by BorgWarner, using some design elements from FinDreams to ensure compatibility with their manufacturing process steps.” The term ‘blade cell’ refers to its
structural design as a long, thin battery cell with side terminals. Husted explains: “The cross-beam-like design of the cell and the terminals on the side of the cell bring benefi ts in volumetric energy density and electrical interconnection while reducing battery pack assembly complexity. This gives BorgWarner LFP battery packs a competitive combination of cost and performance that we can off er to our customers.” According to Husted, one of the
standout advantages of LFP battery packs is their cost eff iciency. “They are less expensive to produce than other lithium-ion batteries, primarily because they do not rely on scarce and expensive materials like cobalt
and nickel,” he continues. “This cost advantage can signifi cantly reduce the total cost of ownership for commercial fl eet operators.” LFP batteries also typically have a
longer cycle life, meaning they can endure more charge and discharge cycles before their capacity degrades. “This longevity is particularly valuable for commercial vehicles to deliver improved TCO, long-term reliability and minimal downtime,”
FAST CHARGING BorgWarner is also making an impact with its new DC charging system, which Husted describes as an, “excellent solution for rapid charging, with a scalable power range of 120kW up to 360kW, making it suitable for fast charging CV depots and also in public and high traff ic areas.” The conversion from AC to DC voltage happens within the charging station power electronics to deliver DC directly to the battery, greatly reducing charging times. “The primary benefi t of DC fast
charging is signifi cantly reduced charging times because higher power is delivered directly to the battery,” Husted says. “AC chargers run at
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