RECAP – Recycled Graphite Composites for Enhanced Cooling, Efficiency, and Longevity in Power Electronics

Power electronics are at the heart of electrification, enabling electric vehicles, renewable energy systems, and modern industrial processes. As power levels increase, managing heat efficiently becomes a critical challenge. At the same time, large volumes of graphite from end-of-life lithium-ion batteries remain underutilised.

RECAP addresses both challenges through a single circular solution. The project recovers graphite from spent batteries and integrates it into Heat Node, a Swedish-developed phase change material for thermal management. The resulting composite stabilises temperatures under high and fluctuating loads while efficiently spreading heat.

By replacing conventional silicone-based encapsulation materials, RECAP simplifies manufacturing, removes energy-intensive post-curing steps, and significantly lowers climate impact. The material will be validated in real power converter modules and benchmarked against current industry standards.

Expected results include up to 20 percent lower peak temperatures, a reduction of graphite-related CO₂ emissions by up to 60 percent, and longer lifetime of electronic components.

By connecting battery recycling, advanced materials, and power electronics manufacturing, RECAP demonstrates how circular material flows can strengthen industrial competitiveness while supporting the transition to a net-zero manufacturing industry.