Leitspalt develops core solutions for EV battery pack engineering, focusing on enhancing performance metrics. Their technology increases the cooled surface area of battery cells to enable ultra-fast charging rates exceeding 3C. This optimization also improves energy density and reduces component count, leading to lower manufacturing costs and extended vehicle range.
Funding
Funding not disclosed
Founders
Product
Problem
Conventional EV battery packs rely on separate cooling systems and structural components that limit the cooled surface area of cells, resulting in slow charging rates, lower energy density, added weight, higher manufacturing costs, and challenges with recyclability.
Solution
Leitspalt delivers a multifunctional sandwich‑core architecture that integrates thermal management, structural support, and cell housing into a single component. By interlocking extruded parts to form sealed cooling channels, the design achieves approximately 80 % lateral surface contact with each cell, enabling charging rates above 3 C and full pack charging in under ten minutes. The integrated approach eliminates redundant casings and separate coolant hardware, raising energy density by up to 7 % and reducing pack weight. Manufacturing leverages aerospace‑grade extrusion and assembly processes, cutting part count and delivering cost savings of roughly €7 per kWh. The mechanical clamping method also facilitates disassembly, supporting emerging EU battery‑recycling regulations.
Target Audience
Automotive OEMs and EV manufacturers seeking high‑performance, fast‑charging battery packs, as well as commercial‑vehicle, marine, and aviation makers requiring lightweight, cost‑effective, and recyclable energy storage solutions.
Features
- Interlocking extruded core elements that create sealed internal cooling channels without additional serpentine tubes or cold plates
- 80 % lateral cell surface contact for thermal performance exceeding that of immersion‑cooling solutions
- Integrated sandwich structure provides both structural rigidity and cell fixation, removing the need for separate module casings
- Scalable design compatible with multiple cell formats (cylindrical, prismatic, pouch) and adaptable to various vehicle platforms
- Manufacturing process based on low‑cost extrusion and simple assembly, achieving ~20 % reduction in part count and €7/kWh cost savings
- Recyclable mechanical clamping enables easy disassembly, aligning with EU Battery Regulation requirements
- Enables safe ultra‑fast charging (>3 C) while maintaining uniform temperature distribution to mitigate thermal‑runaway risk
- Provides a unified engineering platform for OEMs to integrate thermal management, structural support, and pack integration in a single package