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What are electric vehicle batteries made of?

What are electric vehicle batteries made of?

During the late 19th century, a few electric vehicles were already rolling through the streets of the U.S. However, their popularity was short-lived because the manufacturing of cars with gasoline-fueled internal combustion engines proved cheaper. General Motors tried to bring the electric car back in 1996 with a thousand units of the EV1, but these models were ultimately scrapped.

Now, decades later, thanks to innovations made in the battery industry, EVs are on the rise and show no signs of stopping. With the cleaner energy and sustainability guaranteed by electric vehicle batteries, major automobile companies have promised to replace their current fleet of traditional cars with EVs by the 2030s.

Despite the EV’s popularity, car owners are still mystified by the EV batteries in their cars. Some even believe that their cars are running on a single battery and not a large number of EV battery cells contained in heavy battery packs.

For this article, let us direct our focus on the humble but innovative EV battery, its inner workings, and why they are the best choices for a better driving experience and a cleaner environment.

EV battery components: what you need to know

While an EV battery pack is composed of a number of components, let us first take a closer look at a single battery cell contained within the pack.

Within the metal housing of a cell, you have four major EV battery components: the cathode, anode, separator, and electrolyte. The cathode is the POSITIVE electrode and the anode is the NEGATIVE electrode.

EV batteries are named after the chemical/metal materials that are found in the cathode and anode. For example, nickel-cadmium batteries have cathodes of nickel hydroxide and anodes of cadmium hydroxide.

On the other hand, cathodes of nickel-metal hydride batteries have nickel oxy-hydroxide as the active material while hydrogen-absorbing alloy is found in the anode. Lead-acid batteries are named for their lead electrodes immersed in mild sulfuric acid.

Solid batteries are so-named because, instead of a liquid or non-aqueous electrolyte, they have solid materials, like powders, ceramic, or glass, between the electrodes. We shall be discussing lithium ion batteries in a section below.

How do electric vehicle batteries work?

The cathode contains positively charged particles called ions. When you turn your EV on (“Discharge”), these ions flow through the electrolyte and separator from the cathode to the anode. It is this chemical reaction or flow of ions that generates the electrical power for your car to run.

Now, when you turn off your car and plug the battery into an electrical outlet (“Charge”), the reverse happens. The ions now flow from the anode to the cathode. This chemical reaction transforms power back into electrical energy which is stored in the cathode.

How are EV batteries manufactured?

Electric vehicle batteries are manufactured based on an EV battery design that meets the dimensions (size, frame, etc.) and power requirements of the car model.

To answer the question how are EV batteries manufactured, let us look at the current workflow being followed.

The EV battery cells are the first to be assembled. Inside a cell, the anode and cathode are inserted or arranged into sheets (depending upon the type of cell) and kept apart by the separator. This set-up is then immersed in an electrolyte fluid. This assembly is enclosed in a housing to form the individual cells.

EV batteries can be cylindrical (the most common), prismatic (seen more often in Chinese-made EVs), or pouch forms. These cells are subjected to two tests: the “leak check” to ensure that the electrolyte is not leaking from the cell (which can cause fire) and the “moisture check” to ensure that moisture from the environment doesn’t seep into the cell.

Next, these cells are assembled into battery modules, usually at 12 cells per module, but it would depend upon the car model. These modules also come with a sturdy metal housing to protect the cells. The modules are later stacked together in a metal frame to protect them from physical shocks and vibrations.

Finally, the models are assembled into the battery pack housing, which is further tested and fine-tuned for safety. All connections to the battery pack – including a cooling system – are done manually by an automotive technician. Robotic arms insert and tighten the screws of the pack securely to the car itself.

Lithium ion EV batteries: way to the future

Among the EV batteries in the market today, lithium ion EV batteries are considered the dominant technology at present and in the coming future.

Since their introduction in the EV market, the cost of lithium ion EV battery packs have dropped dramatically and are projected to cost below US$100 per kWh in 2023.

Lithium EV battery components are the same as other batteries, having an anode, cathode, separator, and electrolyte. The difference lies in the materials contained therein. Both the anode and cathode contain lithium. In addition to lithium, the cathode also has a mix of nickel, cobalt, and manganese, while the anode is made out of graphite.

Future EV battery technology is presently concentrated on recycling valuable metal components of lithium ion EV batteries, particularly lithium, nickel, and cobalt. It is because of the recyclability of these types of batteries that lithium ion EV batteries are being touted as the ËV Battery Technology for the Future.

What happens to electric car batteries after they’re no longer usable? Are they recyclable?

Through proper care and usage, especially in terms of measured charging cycles, electric vehicle batteries may last between 10 and 20 years. While EV batteries are built for durability, they won’t last forever. The EV battery cells degrade and lose their capacity over time. EV battery packs are said to be “dying” when the car’s driving range grows shorter and shorter.

EV batteries may be returned to the manufacturer for a replacement. Because of the EV battery pack design, these batteries are ideally shredded at a recycling plant. The result is a powdered mixture of all the materials used in their manufacture. This mixture is further broken down to its elemental composition through acid dissolution (a process known as “hydrometallurgy”) or smelter liquefaction (“pyrometallurgy’). The solution produced is sieved, with the metals like lithium, cobalt, and nickel precipitated out as salts to be used in the manufacture of new EV batteries.

Since some so-called “dead” EV batteries may still have a capacity of around 20% to as much as 50%, they can be given new life by using them as a secondary storage system for homes and establishments utilizing alternative power sources, such as solar and wind energy.

Electric vehicle batteries not only enable us to have “clean and green” means of personal mobility. They are also becoming the ultimate sources for recyclable materials for batteries that will be used in cars and other functions for the future.

Discover how our battery interconnect system helped a leading EV manufacturer overcome design challenges

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