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Tag: Tesla News

Tesla’s Upcoming Battery Innovations

https://www.tesla.com/models

Tesla’s Battery Day, where upcoming projects and innovations are announced to investors, was held at the end of September. There were two anticipated announcements: the million-mile battery and a battery price point of $100/kWh, the price at which analysts believe would officially place Electric Vehicles on par with Internal Combustion Engines. 

While no official announcement of a million-mile battery was made, Tesla did announce that the company aims to put out a battery that costs only $60/kWh within the next three years, two years sooner than experts project a battery at this price would be ready to go to market. According to the company, this price would be made possible by reducing battery manufacturing cost. Not only does Tesla intend to eventually move battery production in-house and implement complete vertical integration, but also make use of a newly-patented battery design to bring down costs. 

All in all, Tesla outlined a five step plan to improve batteries.

Cell design

One of the pivotal changes Tesla is making to reach their goal is the design of a tabless battery.

Tesla recently filed a patent for their new battery design that removes the tabs connecting the electrodes to the energy load. This cell structure supposedly has multiple benefits: simpler manufacturing, fewer parts, and a 5x reduction in the electrical path, meaning that energy can flow faster and more efficiently. 

But how would this technology achieve these goals? The current design of a cylindrical battery cell involves layers of cathode and anode material separated by a separator layer and rolled into a cylinder. Tabs are connected to the cathode and anode sheets respectively and stick out to connect to the load.

Tesla’s new battery design takes the cathode and anode foils and arranges them in a shingled spiral pattern. The placement pattern increases the surface area of the active material that it’s touching, facilitating faster movement of ions within the cell. 

In the traditional battery design, the electrode tabs also create a bottleneck problem as ions only have a single path through which to travel to the load. By removing the tab, the ohmic resistance is decreased, allowing energy to travel more efficiently. It also reduces the chances of heat build up in certain areas of the battery due to a concentration of chemical activity. The new design allows these reactions to be spread out evenly within the cell, reducing the possibility of overheating.

Cell manufacturing

The next stage in Tesla’s plan to revamp their batteries is how the cell is manufactured. This means simplifying the process as well as reducing their carbon footprint and energy consumption. 

Currently most battery electrodes are made with a wet process, which entails the electrode powder being mixed with water or another solvent, then placed in an oven to dry. 

Tesla is in the process of perfecting a dry process, which directly converts the electrode powder into film. While Elon Musk stated that this is a much more complex method to master, once perfected it would mean a much simpler manufacturing process and a reduction in energy use in the process.

Anode materials

Tesla, like many battery manufacturers and researchers, is interested in using silicon as a replacement for graphite for the battery anode. Not only is it inexpensive, it is also abundant in the earth’s crust, making it a more sustainable choice in the long-run. Silicon has been found to have 9x the electron capacity compared to graphite, meaning that it has a much higher energy capacity. However, it has been known to expand within the cell and eventually degrade after a number of cycles, rendering the battery obsolete.

To combat this, Tesla stated that it will use raw silicon and an elastic, ion-conductive polymer coating to stabilize the material. Theoretically, this would increase an EV’s range by 20%. 

Cathode materials

Current batteries use cobalt as the cathode material because of its stability and high energy density. However, Tesla had already spoken before on their desire to move away from using this metal due to its toxicity and mining which is often associated with human rights abuses. Instead Musk spoke about turning to focus on nickel as the alternative. Nickel is cheaper and has a high energy density, but by itself is unstable. The company is working on stabilizing the material which would eventually help to bring down battery costs.

Furthermore, Tesla spoke about not wanting to be constrained by the availability of nickel and is planning a flexible approach to the material used in their batteries, using other metals such as iron and magnesium in their energy storage solutions depending on its application.

Cell-Vehicle integration

The final step in Tesla’s plan is to integrate the battery pack directly into the structure of the car itself. Coining the term “structural batteries”, the electric vehicle battery pack is not only storage for energy, but is also an integral part of the vehicle’s structure. This aims to reduce the vehicle's mass and increase range by allowing for cells to be packed more densely without adding extra structure. 

While it will be a few years before we see a fruition of Tesla’s vision, it is exciting to see how these innovations will continue to challenge the EV and energy storage industry as Tesla, and the rest of the world, looks forward to adopting greener and cleaner technologies.

Game-changing Million Mile Electric Vehicle Battery

Chinese car battery manufacturers CALT announced that it is ready to produce a battery that can last for 1.2 million miles across the span of 16 years. This is double the lifespan and eight-times the mileage of current EV batteries, the best of which are typically warrantied for up to 150,000 miles for 8-10 years. This development implies that CATL has figured out a way to reduce battery degradation and loss of capacity -- a process that occurs naturally with batteries over time. 

A battery of this caliber could change the EV industry for the better. It has been long thought that battery technology has yet to reach the capabilities necessary to overtake internal combustion engine (ICE) vehicles for good. While the first generation of fully electric vehicles are still coming to age, there is not yet a comprehensive idea of the impact of long-term consumer use on EVs and batteries. Nonetheless, a battery of this capacity could significantly drive forward EV adoption and provoke larger energy storage solutions.

Declining battery costs

It’s believed that what’s dubbed as the “million-mile battery” could help bring down battery costs. Currently, EV batteries cost around $175 to $300 per kilowatt-hour. Analysts believe that battery costs would need to decline to $100 per kilowatt-hour for the prices of EVs to be comparable to that of ICE vehicles. While it has been projected that this cost could be reached by 2025, researchers at MIT have begged to differ. 

A report published by the MIT Energy Initiative last year states that the $100/kwh price point may not be reached in the next few years if EV manufacturers continue to rely on lithium-ion batteries. Even though the cost has already been on a steady decline, they predict it would slow down as it reaches the limitations of the cost of raw materials. Moreover, as the demand for lithium-ion batteries will continue to increase, they state it would be unlikely that battery prices would decrease significantly.

CATL’s new battery is currently  priced at a 10% premium of their current EV batteries. While the upfront cost is certainly pricier, it makes up for it by its longevity. EV batteries account for a third of the vehicle’s total cost, so the thought of having to replace it if something happens can be daunting for vehicle owners. This is one of the reasons for consumer hesitation towards electric vehicles. Even though most major vehicle manufacturers warranty their batteries for about 8 years, manufacturers and consumers are still waiting to see exactly how long the batteries will last.

The longevity of the battery could even out the overall lifetime cost of ownership by reducing the likelihood that the battery would need to be replaced. The long term durability of the battery could certainly alleviate vehicle owners’ concerns 

Longevity, however, does not denote capacity. The capacity per charge of the EV battery would still be determined by the size of battery that can be placed within the vehicle. So while the million-mile battery may address durability concerns, it may not actually address range anxiety. This is another aspect of the battery that would still need to be improved.

The second life of batteries

An average ICE passenger car lasts about 8-12 years and 150,000 to 200,000 miles. With fewer mechanical parts, EVs could last longer than traditional cars. However, if EVs end up having similar lifespans, the million-mile battery would outlive the rest of the car. This could give rise to battery recycling and repurposing, further decreasing the cost of energy storage. The EV battery pack could be reused in a second vehicle or even in other applications such as grid storage. 

Heavy-duty applications

The million-mile battery could be a significant breakthrough for electric vehicles of all sizes. Commercial or heavy-duty vehicles such as taxis, buses, and trucks would benefit from a durable battery. The batteries of these vehicles typically endure much more stress than private passenger vehicles, with deeper and more frequent discharges and higher power requirements. Again, while it does not necessarily address the energy capacity of the vehicle per charge, it provides a more lasting solution.

With large applications such as grid storage, long-term sustainability is a key concern as frequent maintenance or power-failures could be costly and dangerous. However, a battery of this ability could also be significant to pushing forward this energy storage solution. The CATL packs are estimated to last for 20 years in applications such as energy storage.

The future of EV Batteries

Electrical vehicle battery manufacturers are looking into different ways to further improve battery technology including solid-state electrolytes, heavy-metal free batteries, ultra-fast charging, and higher energy capacity solutions. The EV industry is still finding its footing in the global push towards addressing climate change; a considerable improvement in battery technology would play a huge part in pushing clean energy and a wider acceptance of these solutions. Click the link to see how Arbin is helping to drive the future of EVs.

An Electric Truck? Absolutely! It Might Be Your Perfect Fit

By now, you’re familiar with the wave of electric vehicles (EVs) sweeping across the globe – they’re a forward-thinking, environmentally conscious option that many have come to associate not only with sustainability, but with aesthetics and performance.

But, when you close your eyes and envision the future of our shared roadways, how often do you picture an electric truck?

These new, electric trucks are some of the most exciting innovations to come out of the EV movement – and, apparently, also one of the industry’s best-kept secrets.

It’s time to change that.

Much More Than a Toned-Down Truck

There are many common misconceptions surrounding electric trucks – ideas that they don’t perform the same, aren’t as powerful, don’t elicit the same feeling of a traditional, gas-powered truck, and can’t provide the get-up-and-go when you need it, among other assumptions, keep many away.

However, all of those preconceived notions are inaccurate.

In fact:

  • Electric trucks have comparable strength and power.
    The pickup crowd is often quick to point out that electric vehicles simply don’t have the same muscle as their tried-and-true gas counterparts, though that isn’t the case. Electric motors can provide serious torque and towing capabilities, meaning that owners who leverage their trucks for heavy-duty applications won’t have to miss out on those capabilities.
  • They have long-range batteries and actually promote better handling.
    Trucks can actually better accommodate larger, longer-range batteries than other EVs, meaning that the range on electric trucks is better than most imagine. Also, a lower center of gravity could improve upon one undesirable aspect of traditional trucks – their handling and top-heavy nature.
  • They have sports car-like acceleration.
    Electric truck owners also won’t need to sacrifice a little bit of fun. EVs, in general, get a bad reputation for lacking acceleration, but modern electric motors can deliver the quick acceleration so many seek out in their vehicles.

So, What Options Are Out There?

Currently, there are plans for several legacy carmakers, such as Ford and Chevy, to convert their traditional pickup lines into electric offerings.

However, options from EV mainstay Tesla and an exciting startup in Rivian could reshape the industry.

Let’s take a closer look.

The Tesla Cybertruck

Tesla’s truck offering – which is futuristic looking, to say the least – offers:

  • A durable exoskeleton made from cold-rolled stainless steel and Tesla armor glass
  • Up to 3,500 pounds of payload capacity
  • 100 cubic feet of exterior, lockable storage
  • A towing capacity of over 14,000 pounds
  • Adaptive air suspension
  • 0-60 in as little as 2.9 seconds
  • 500 miles of range

The Rivian R1T

Featuring a more traditional pickup truck aesthetic, the R1T offers:

  • 400+ miles of range
  • 0-60 in three seconds
  • A quad motor system
  • A wading depth of over three feet
  • A towing capacity of 11,000 pounds
  • Up to 750 horsepower
  • Extensive lockable storage

The Future of EVs Keeps on Trucking

It’s clear that electric trucks have a wide variety of benefits and potential applications – from boosts to fleet efficiency and heavy-duty individual applications to luxury lifestyle choices and more, electric trucks are ready to make a big splash in the coming years.

And Arbin’s battery testing capabilities are helping to make that possible, aiding the industry in developing long-lasting, high-performance batteries that help EVs reach their full potential.

To learn more about Arbin’s key role at the forefront of the EV industry, visit arbin.com/battery-test-applications-electric-vehicle/.