Structural Supercapacitor Pack for Automotive Applications Embedded in a Reinforced Carbon Fiber Shell
PSCARF PROJECT
High-power structural battery packs for lighter and more efficient electric vehicles.
The SCARF project develops and optimizes high-power structural supercapacitors integrated into carbon fiber shells.
The goal is to provide an additional power reserve for electric vehicles while reducing the weight and size of traditional battery systems.
months of development
prototype demonstration
target cycles
process compatibility
FUNDING INFORMATION
The SCARF project is supported by Area Science Park under the “Deep Tech Revolution” program, a new initiative titled “Dalla ricerca all’impresa del futuro” (From Research to the Enterprise of the Future) designed to support high-impact technological solutions granting access to specialized Advanced Technology Services, including Atomic Force Microscopy (AFM), Scanning Electron Microscopy (SEM), and patent landscape analysis
Project overview
The SCARF project (Structural Supercapacitor pack for Automotive applications embedded in a Reinforced carbon Fibre shell) is a 12-month initiative led by Novac S.r.l., an Italian innovative startup. The project focuses on developing and optimizing structural supercapacitors (SCs), specifically Electric Double Layer Capacitors (EDLCs), designed to be integrated directly into a vehicle’s bodywork or chassis.
By embedding these energy storage systems within carbon fiber shells, the project utilizes volumes of the vehicle that are typically unused for power storage This hybrid approach allows for the downsizing of main battery packs, significantly reducing the overall weight and volume of the vehicle while optimizing internal space.
MAIN OBJECTIVES
The SCARF project aims to transition this technology to a TRL 4, which involves prototype demonstration in an operational environment.
Longevity and Reliability
Validating a long service life for the SCs, guaranteeing more than 100.000 cycles before reaching the end-of-life stage.
Material Compatibility
Ensuring the supercapacitors can withstand the standard carbon fiber forming processes, specifically maintaining performance at temperatures as high as 120°C.
Intellectual Property Protection
Performing comprehensive patent landscape and prior art analyses to strengthen Novac’s IP position regarding low-cost SC manufacturing and structural energy storage.
Energy integrated into the vehicle's structure
SCARF combines two strategic technological areas: high-power supercapacitors and advanced carbon fiber composite structures.
The project explores the integration of energy storage devices into structural components without compromising their performance, reliability, or manufacturing compatibility.
Sustainability and Strategic Impact
Unlike traditional lithium-ion batteries, the architecture of these EDLCs does not rely on critical raw materials (CRMs) making them an intrinsically greener alternative.
The project includes a full environmental and financial analysis, documented in a white paper, to assess its impact on global warming potential (g CO₂eq) and the reduction of normalized costs (€/kWh) for the devices.
Analisi dell’impatto sul riscaldamento globale dei dispositivi sviluppati.
NETWORK
Novac relies on a strategic network to ensure technical excellence and market readiness for the SCARF project
Area Science Park
Area Science Park is the primary partner that funds the project and provides specialized technical services. This includes performing Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM) to analyze device failure modes and electrode morphology, alongside leading the project’s prior art and patent landscape analyses.
Acus Composites
Blacks Advanced Composites and Acus provide essential expertise in carbon fiber prototyping and sustainable reusable mold technology.
MetSuperCap
As a member of the MetSuperCap consortium, we utilize state-of-the-art European measurement standards to benchmark our technology.
Fast Charge Engineering
Fast Charge Engineering assists in developing custom balancing electronics and monitoring PCBs.
Italian Motorsport OEM
A leading Italian Motorsport OEM serves as our primary end-user, providing operational test benches to validate the system in high-performance environments.
