Electric vehicle (EV) battery technology that can supply range, longevity and power, while also being a more sustainable option than gas powered vehicles, is highly sought after. More and more customers are gradually moving to the EV market, but they are demanding vehicles that perform better and are safer for humans and the environment. Vehicle manufacturers are being put under more pressure by government emission regulations to make more efficient and less harmful vehicles to the environment.
The issue is that making green, safe cars generally means that the vehicle’s performance will suffer. EV’s maximum range and charging times are improving, but they are still nowhere near where they need to be for even more widespread adoption. The average maximum range for EVs in 2020 was 259 miles, and the average charging time for a full charge was from six to eight hours. There are fast charging stations dotted in certain locations, but the infrastructure is not big enough yet for this to make a significant impact.
Improving batteries
As time has passed, battery chemistry has given birth to many new ways of creating cheaper, more powerful EV batteries. However, no particular option has been able to develop a product that is completely equal to an internal combustion engine. Mass-market consumers do not want to compromise on things like range limitation, and this is inhibiting EV adoption.
A new design of battery cell structure that includes 3D smart electrodes shows promise in bridging this gap, as it enhances battery performance in practically every category. This new 3D cell architecture allows for improved surface area and better properties for the battery’s electrodes, which in turn, results in faster charging times and longer driving ranges.
Why not 2D electrodes?
Batteries made from lithium-ion with 2D current collectors are what is currently used across the battery industry. This traditional structure has not changed in over 30 years and has some restrictive limitations. For instance, lithium-ion batteries are severely affected by temperature, and it reduces the longevity and performance of the batteries. This puts a huge emphasis on quick and even heat dissipation and distribution in EVs, or any battery for that matter.
Current collectors allow electrons to pass between the cathode, the anode, and the electrical circuits, accumulating all of the collected energy. Longer range and higher power needs the batteries to give both the power and energy needed. This results in the battery becoming more expensive and heavier. If the current collectors were able to transfer electrons more effectively, this would give the customers what they want without compromising the weight and cost of the batteries.
2D, planar current collectors also have further limitations with uneven heat transfer and excessive heat generation. This is because of the structure of 2D current collectors, as they do not allow heat to quickly and evenly dissipate and can lead to the generation of a thermal runaway. Making the 2D current collectors bigger can help with thermal issues, but this will negatively impact the cycle life and power of the battery. Conversely, if a large amount of material is used with relatively thin current collectors, high energy cells are created but the battery will degrade quickly.
3D electrodes stabilize batteries
Smart 3D current collectors are the solution to creating batteries for EVs that can give long range performance, fast charging and optimum power. Their design/structure allows for more active material to be loaded, allowing for higher energy density, instead of the older 2D planar design that was quite restrictive with regards to the loading of material. The 3D structure makes the contact area between the current collector and electrode much larger, similar to increasing the size of a road for cars, allowing for more accessible energy capacity.
3D electrodes also have a lower resistance internally, which reduces the heat generated and propagated, and improves the transfer of electrons. It features a porous structure that makes up for any significant expansion of battery cells while charging or discharging. Mechanical stability is improved because of this, and due to the buffering properties that the 3D structure possesses it gives a safer way to use promising emerging and existing chemistries. This can include silicon or other materials, in hopes of achieving an even higher energy density.
The combination of improved conductivity, enhanced energy storage, reduced heat generation and material expansion means that these new 3D electrodes can achieve longer ranges, faster charging and improved battery life. All of these advantages are possible without changing the size or components within the battery. Furthermore, any battery system can take advantage of this new technology and integrate 3D electrodes, so the possible applications are vast.
The 3D current collectors actually take up the same amount of space as their 2D counterparts but provide much more power. This results in better performance in many categories for batteries that are constructed with the 3D technology. It also provides may benefits for automotive manufacturers in particular as they will have to use fewer batteries with the 3D technology as they would have had to use with the 2D current collectors. Weight, space and money are all saved, and it also gives more space within the cabin of the vehicle to be used more efficiently.
Increasing EVs battery performance is vital to their success, consumers are demanding longer range, faster charging times and more longevity. The current technology is not satisfying demand, as it is limited by its structure. Smart 3D electrodes are a plug-and-play technology that can give EVs the boost they need to appeal to the mass market.
