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New 3D Technology to Make EV Batteries Safer

New 3D Technology Claims To Make EV Batteries Safer

With the advent of extensive R&D in EV battery technology, new methods are being developed to address safety issues pertaining to EVs. It is becoming a trend for companies to keep devising modern methods leveraging technology to make EV batteries safer. In the last few years, many cases of terrible incidents regarding electric cars have surfaced. Unfortunately, most of these highlight some sort of battery issue as the root cause. With reports suggesting around 100 million EVs on roads worldwide by 2030, it becomes crucial to come up with solutions to make electric car batteries safer. Hence, battery companies are not just focusing on increasing range and reducing charging times, but also making them more resistant to fire and thermal runaway. We know that the latter is the biggest cause of worry. Once an EV battery catches fire, it is excruciatingly difficult to douse it. The reason is the availability of toxic and explosive chemicals in the battery construction itself. Essentially, that is a constant fuel to keep the fire going. As a result, we have had situations where the batteries kept burning for upto 48-72 hours. You might also like: Which is Better EV Battery Cooling System – Liquid or Air? You might also like: Top 5 Tips To Save / Earn Money From EV Charging 3D Thermal Barriers Technology to Make EV Batteries Safer Freudenberg Sealing Technologies, a tech company, has introduced an advanced solution to address a critical concern in the rapidly growing field of electric vehicles (EVs). The company has developed 3D thermal barriers aimed at mitigating the risk of thermal runaway in high-energy-density lithium-ion batteries, which are becoming increasingly common in modern EVs. You might also like: 5 New EV Battery Technologies – Aluminium-ion to Niobium The 3D thermal barriers mark a departure from conventional two-dimensional options like flat mats and thermal blankets. These barriers are custom, flexible, and can fit in various positions within the battery structure, allowing for easy integration of additional components. The novel 3D geometries come from injection moulding and continuous extrusion. This adaptability also offers a noteworthy advantage – the resulting intricate 3D geometries are lightweight and exert minimal impact on the overall battery weight. Freudenberg makes heat-resistant, electrical, and thermal insulating materials. Thorough in-house testing demonstrates that these materials can endure temperatures of up to 1,200°C. This resilience is due to the specific composition of the compounded polymers This renders them impervious to both extreme heat and particle impacts, such as those that occur during cell venting. The 3D thermal barriers use elastomer solutions in solid and foam forms. Additionally, they can also be plastic components like Quantix Ultra® for intricate geometric patterns. You might also like: Top Solid-State Battery Companies For EVs Learn Electric Cars Says There are new EV technologies coming about quite frequently. That is normal with so much research going on about EV batteries in various parts of the world. This may just be one of many potent ways to make EV batteries safer. With time, we expect more such breakthroughs which will have safety at its core. Not to mention, longer range and shorter charging times will still be the main parameters while designing new solutions.

How to Maximize EV Driving Range – Tips & Strategies

17 Comments / Featured / By LEC Team

Electric cars look to be the norm going forward which is why it makes sense to acquaint ourselves with their behaviours and idiosyncrasies. Arguably the most common question among future EV owners is how to maximize EV driving range. As more vehicles get electrified, this is a valid question. Extending the distance an EV can travel on a single charge is critical for mass adoption and to appease range anxiety. In this blog, we shall explore several tips and strategies to improve electric driving range. This would range from optimizing driving habits and maximizing battery efficiency to utilizing charging infrastructure effectively. You might also like: Wireless Charging For EVs Could Be Revolutionary Technology How to Maximize EV Range? Regenerative Braking Firstly, let us commence by discussing a built-in feature that most EVs inherently possess – Regenerative Braking. During acceleration, the electric motor takes power from the battery to power the wheels. However, during braking, the kinetic and heat energy can be used in the reverse direction to get stored back into the battery. When the driver lifts his/her foot off the gas pedal, this reverse circulation of energy can bring the car to a complete stop. This is called energy recuperation or regenerative braking. This is a great feature that could be used on downhill slopes to get some juice back into the battery. Reducing Energy Consumption in the Cabin You might know that it is nigh impossible to get the exact driving range that is claimed by the company as per the WLTP or any other standardized test cycle. This is because the range depends on various factors including driving mannerisms and the use of energy-sucking components like HVAC, heated and ventilated seats, auxiliary audio systems, etc. Now we understand that you can’t switch off the AC when it’s scorching hot, but in the case of an emergency, you must know that turning all these functions off can help maximize the range. You might also like: Are Stricter Emission Norms Right to Push Mass EV Adoption? Battery Management and Maintenance An eminent aspect of electric cars is their battery management system. In fact, carmakers are burning a lot of cash in the development of the BMS for EVs. This takes into account how well the cooling system is, how will the battery perform outside the ideal temperature range, how often does a battery need maintenance, etc. Regularly monitoring the battery’s state of charge (SoC) and avoiding extremely high or low levels can help prolong battery life. Sticking to manufacturer-recommended maintenance schedules, including software updates and battery health checks, helps maintain optimal performance. Using Charging Infrastructure Prudently You would think what role can the charging infrastructure play in maximizing range, right? Well, it is well-known that prolonged fast charging of any Li-ion battery can reduce its life. Sure, it doesn’t degrade the battery too much too rapidly. But if you are planning to own an EV for 8-10 years or even beyond that, making a conscious decision of using DC rapid charging minimally can make a lot of difference. For this, proper planning is needed. You must develop the habit of charging your EV at your home or work using an AC charger. Restrict the usage of DC rapid charging for long journeys on highways. Driving Mannerisms Finally, the most effective way to maximize the driving range of an EV depends on the way you drive it. Now, this is true even to sequester the maximum fuel economy from your ICE-powered vehicle and this law holds true even in the EV world. As opposed to ICE cars, EVs are more suited for city driving and not high-speed scenarios on highways. Higher energy gets consumed in the latter case. Traditional cars are more efficient on the highways but consume a lot of fuel in bumper-to-bumper traffic. To squeeze the maximum range though, simple habits like using the throttle and brake pedal gently and not flooring it is the way to go. You might also like: Here’s How Ferrari May Still Sell ICE Cars Post EU Ban of 2035 Learn Electric Cars Says These are some tips and strategies that one could incorporate in everyday life, as well as from a long-term perspective to ensure that the health of the battery is great and you are able to get the maximum range out of every charging cycle. We must also add that the R&D on batteries is still ongoing and ways to increase range and reduce charging times are surfacing every day. Hence, we might get more efficient batteries going forward.

5 New EV Battery Technologies – Aluminium-ion to Niobium

28 Comments / Battery / By LEC Team

New EV battery technologies are being developed vehemently all across the globe. The traditional and upcoming electric carmakers and traditional battery and tech companies are collaborating to develop future batteries as the electrification wave grips the mobility industry. The need for zero tailpipe pollution-emitting vehicles is a priority as the warnings from the scientific community about environmental degradation are unequivocal. As a result, R&D in battery technology has been underway for almost a decade now. Here are the top 5 relatively viable options that might make it into mass-production before the decade-end (some of these are already being tested in production vehicles starting this year (2023)). You might also like: Top Solid-State Battery Companies For EVs You might also like: Does the Future of EVs Rest on Sodium Ion Batteries? 5 New EV Battery Technologies Sodium-Ion Batteries We have already covered the details of the principle, advantages and disadvantages of Sodium-ion batteries previously. Just for recap, this battery type uses Sodium (instead of Lithium) to carry ions from the cathode to the anode and vice versa enabling the charge and discharge process. Sodium is the 6th most abundant element found in the earth’s crust, is non-inflammable, has a wider temperature range of operation, has low production cost, etc. These are the benefits over the existing Li-ion batteries. However, the issue is their low energy density and almost equal charge-discharge cycle counts compared to the Li-ion batteries. Also, mass production has only just commenced by CATL and BYD. You might also like: Are Chargers at DC Fast Charging Stations Bad For EVs? Solid State Batteries The next crucial and interesting EV technology is called a solid-state battery. As the name reflects, the electrolyte solution that is found between the cathode and anode of an electric car battery (or any other Li-ion battery used in other electronic gadgets) is in solid/gel form. In Li-ion batteries, this is in a liquid state which is what causes fire. But with solid-state technology, this electrolyte is in solid or gel form. Hence, the size and weight of the battery are reduced leading to increased range and faster charging times. However, more research is needed to produce these on a large scale. Lithium Sulfur Batteries Lithium Sulfur (Li-S) batteries use sulfur instead of complex, toxic, fast-diminishing and difficult-to-source elements like Cobalt or Nickel in their construction. This makes the batteries slightly lighter increasing their energy density which could be as high as around 500 Wh/kg compared to around 300 Wh/kg for regular Li-ion batteries. These can have around 1,500 charging cycles. However, the issues with these include polysulfide “shuttle” resulting in leakage of cathode material. You might also like: Tesla Battery (4680) vs BYD Blade Battery – Comparison Aluminium Ion Batteries Another interesting and potentially disruptive EV battery technology is the use of Al-ion. In this construction, Aluminium ions are used as charge carriers between the cathode and anode. Aluminium can exchange 3 electrons per ion which makes its energy density around 50 times higher than Li. Having 3 electrons has its advantages and disadvantages. The latter include relatively short shelf life and issues with heat, rate of charge, overall electrical behaviour and energy capacity. Niobium Batteries Finally, there are the exciting Niobium batteries that take 1 minute to recharge due to their layered molecular structure. Cambridge-based Nyobolt is working on this unique technology that uses Niobium anode reducing the charging time drastically. Even under severe temperatures, these batteries are less prone to catching fire. Their temperature gradient is just 8 degrees Celsius compared to around 27 degrees Celsius for regular batteries. While there has been significant development in the first two technologies with BYD and CATL having commenced the production of Sodium-ion batteries in mass-market EVs, the others still are in various stages of development and testing. It would be interesting to see which out of these (if any) dominates the space by the end of this decade. Also, chances are that these might co-exist or new technologies might also crop up.

Why Electric Cars Catching Fire Must Concern You

22 Comments / Featured / By LEC Team

While industry experts and new car buyers are beginning to jump on the EV bandwagon, we must also acquaint ourselves with the issue of electric cars catching fire. Now, before we go any further, we must mention that this is not an EV-bashing blog or creating fear among potential buyers, but a rather factual piece of content which talks about why EV fires are different and worse than fire in ICE-powered vehicles. Also, for the record, USA Today shows data highlighting that the number of EVs catching fire out of 100,000 vehicles is just 25 compared to gas cars (1,530). So, EVs are clearly much safer when it comes to fire explosions. Furthermore, most fires occur when vehicles get crashed which may necessarily not be due to any defect in the battery or construction. With that out of the way, let us discuss the chemistry of an EV fire. You might also like: Does the Future of EVs Rest on Sodium Ion Batteries? Chemistry of Electric Cars Catching Fire When a traditional gas-powered vehicle gets engulfed in flames, standard procedures like putting water into the fire to cut the oxygen supply works adequately. Additionally, fire extinguishers can control the situation and people are aware of what to do in such situations. However, that is the most terrifying aspect of EVs catching fire. We know that most EV batteries use Lithium-ion chemistry with Nickel, Cobalt, Manganese metals and liquid electrolytes. Generally, the battery is sealed off securely and it is meant to stay that way even during unfortunate cases. However, if the battery catches fire once, most standard procedures won’t be effective in dousing it out. The reason behind that is simple. The EV battery components become the fuel themselves causing a thermal runaway. This is due to the electrolyte decomposing and releasing Oxygen among other toxic gases including Carbon Monoxide, Hydrogen Cyanide, Hydrofluoric Acid and Cobalt. You might also like: Top Solid-State Battery Companies For EVs You don’t need to get in contact with these gases to get affected negatively. Some of these gases could get absorbed by your skin. That is the reason why people have lost their lives in such fires. There have also been cases reported where the fire kept on going for hours despite being tried to control it using conventional water and fire extinguishers. Hence, if such a fire breaks out in a parking lot where multiple EVs are parked, we could have a serious problem on our hands. Since most people charge their EVs at their homes, this issue becomes more pertinent. Overnight charging is the most common and practical way of charging EVs across the world. In fact, some people, due to a lack of space around the house, end up installing charging equipment inside the house. In countries like Australia, solar charging and storage devices are quite common. But these must be away from the house, at least outside the building so that even if there are such terrible situations, lives are not at stake. That is the reason why EV fires are extremely perilous and we must be informed about such things. As mentioned previously, the chances of EVs catching fire are still a lot lesser compared to traditional gas-powered vehicles. Nevertheless, proper safety measures and procedures must be in place as EVs get more popular than ever. The concerned authorities must come up with safety protocols about what must be done in such situations so that people are able to deal with these scenarios in the best possible way.

Sodium Ion Battery - Representational Image

Does the Future of EVs Rest on Sodium Ion Batteries?

18 Comments / Battery / By LEC Team

Sodium Ion batteries are emerging as a viable solution for EVs but there are pros and cons to them. Currently, almost all EV batteries are constructed using Lithium Ion chemistry. In addition to that, the other elements used in Li-ion configuration include Nickel, Copper, Manganese, Cobalt, etc. Now, all these (including Lithium) are limited resources found in a handful of areas around the globe. Not only that, there are environmental challenges associated with the mining of most of these elements. For instance, the Democratic Republic of the Congo sits on the largest Cobalt reserves in the world. There are numerous and frequent cases of child labour being used to extract Cobalt which raises human rights concerns in addition to the limited amount of such rare elements. Also, Lithium is primarily used in consumer electronics like smartphones, tablets, laptops, etc. Hence, the automobile industry will always be the second recipient of it. You might also like: Are Chargers at DC Fast Charging Stations Bad For EVs? Sodium Ion Batteries for EVs That is where Sodium comes into the picture. Sodium is the 6th most abundant element in earth’s crust. More importantly, it sits right next to Lithium on the periodic table which lends almost similar properties compared to Lithium. Being abundantly available means that the cost of the element is significantly lower than Lithium. At present, the cost of EVs is what is the biggest hurdle in mass adoption apart from the charging infrastructure. Advantages of Sodium Ion Batteries in EVs Disadvantages You might also like: Tesla Battery (4680) vs BYD Blade Battery – Comparison Could Sodium-Ion Batteries Replace Lithium-Ion in EVs? Well, it is that classic case of yes and no. Better put, there is a chance that both could co-exist depending on the use case and market. Markets, where cost is the driving factor for EV sales, could go for Sodium-Ion batteries. In fact, China has already started experimenting with these in their EVs that are on sale like Hina Battery in Sehol E10X compact EV. BYD and CATL are about to join the fray soon. For other markets and carmakers where affordability is not the issue and performance takes the front seat, Lithium-Ion batteries will continue. With the amount of R&D going into battery development in various parts of the world, there might be better alternatives or favourable modifications to Lithium-Ion batteries too.

Factors on Which Energy Consumption of an EV Depends

30 Comments / Featured / By LEC Team

With electric mobility taking its roots as the future solution, it becomes critical to acquaint ourselves with the factors on which the energy consumption of an EV depends. Now, everyone is concerned about the range of electric cars which is also the last remaining major issue with electric mobility in conjunction with charging infrastructure. But it looks like if EVs start offering really high range, people might get encouraged to take the plunge. For this blog post, we shall take into account the incredible feat achieved by the Mercedes VISION EQXX, where it was able to travel over 1,200 km on a single charge with an impressive energy consumption of just 8.3 kWh per 100 km. It completed this journey of 1,202 km from Stuttgart (Germany) to Silverstone (UK) in 14 hours and 30 minutes. You might also like: GAC Aion Hyper GT to be the Most Efficient Production Car Ever Key Figures for this Journey Value Distance Travelled 1,202 km Time Taken (over two days) 14 hours 30 minutes Drag Coefficient (Cd) 0.17 Energy Consumption 8.3 kWh per 100 km Weight (unladen) 1,755 kg Battery < 100 kWh Voltage > 900 V Key Values Energy Consumption of an EV Aerodynamics Now, it is not that difficult to understand that aerodynamics can greatly affect the energy consumption of an EV. In fact, that is the reason why the shapes of Formula 1 cars are so distinct. They focus on optimizing the body design to achieve the best aerodynamic efficiency. Essentially, it refers to how efficiently the body of the vehicle is able to cut through wind resulting in the lowest wind resistance. This becomes important with increased speeds. At high speeds. wind resistance poses the greatest hurdle to the acceleration of any vehicle. In the case of the Mercedes VISION EQXX, its body curves and a retractable rear diffuser aid the aerodynamics tremendously. This allows an overall value to be just 0.17 Cd, which will be the best on any production car when it officially launches beating its own kin, the EQS (which has a Cd value of 0.20 currently). Also, there are additional aero-shutters that open up below the front bumper further contributing to the aerodynamic efficiency at high speeds. You might also like: 2023 Hyundai KONA Electric vs 2023 Kia Niro EV – Specs, Range and Price Comparison Energy Consumption of an EV Depends on Wheels You might have noticed that the tyres of most EVs are very specifically designed. While it is an attempt to distinguish EVs from traditional ICE-powered cars, there is a deeper meaning hidden there as well. There is a way of making a car more aerodynamically efficient but that might make less aesthetic and practical sense. For instance, Mercedes says that they could bring the Cd value down to 0.16 if they cover the rear wheels. In fact, we see something like that on the Lightyear 0 solar EV. So, while that might theoretically be possible, EV makers also need to consider the fact that the final product must look like a car for them to actually sell as it might not go down too well with the potential customers for whom the looks and design play a key role. The EQXX has a Crr (Coefficient of Rolling Resistance for Tires of 0.0047). You might also like: Are Chargers at DC Fast Charging Stations Bad For EVs? Rolling Resistance and Weight Now, the total resistance to the motion of any vehicle takes into account the frontal area of the car, its weight, the rolling resistance of the tires, its velocity, air density and acceleration due to gravity. Out of these, automobile designers can vastly control the frontal area and the weight of the car. For this example, the frontal area of the EQXX is 2.12 m2 and its weight is 1,755 kg (3,869 lbs). In comparison, the weight of the EQS is around 2,500 kg. The frontal area of the Telsa Model 3 and Toyota Prius is 2.20 m2. The weight of the battery of the EQXX is just 495 kg compared to 537 kg for the 100 kWh battery of the Tesla Model S. Hence, Mercedes has improved on these aspects without compromising the shape of the vehicle too much. Energy Consumption of an EV Depends on Powertrain and Packaging Finally, energy consumption is a factor of the efficiency of the powertrain. While the aforementioned factors were a part of the design, the efficiency of the powertrain is what engineers are most engrossed in. That is where the EQXX shines. It has a cell-to-body construction and a passive cooling system for the battery. Note that the motor and inverter have active cooling. Mercedes also says that the powertrain efficiency during highway runs is around 95%. Also, the peak DC charging capacity is limited to 120 kW. Both these figures inform that the battery heating is not a problem which is why the engineers have decided to go with an air-cooled battery system rather than the more common liquid-cooled ones that we see in most cars. Hence, these are the most prominent factors that determine the overall efficiency and energy consumption rate of an EV. Mercedes VISION EQXX is an attempt to showcase just how far we can stretch the boundaries with the existing technology without making too many changes to the general aesthetics of a car. We are certain that more carmakers will pursue this method of making cars more efficient rather than slapping them with large batteries. We would love to hear your opinions about this.

Electric Car Batteries Swapped or Replaced

Can Electric Car Batteries Be Replaced or Swapped?

23 Comments / Battery / By LEC Team

With the EV trend becoming a reality, it becomes critical to know the basics of maintenance related to your electric cars. Is it possible for the electric car batteries to be replaced or swapped? Since the adoption rate of electric cars is still minuscule compared to their internal combustion engine-powered counterparts, there are myriad queries related to them. The batteries, charging characteristics, and range anxiety continue to pose hurdles in the mass adoption of EVs. While the benefits of shifting to EVs might be quite understandable and logical, the actual implementation is enveloped in quandary and uncertainty. The aim of this article is to dispel some myths surrounding electric car batteries. You might also like: Tesla Battery (4680) vs BYD Blade Battery – Comparison Can The Electric Car Batteries Be Swapped or Replaced? Let us try to understand this by using a familiar analogy. In the case of traditional vehicles, the engines and their components are fixed, while the fuel is needed to be filled regularly. Similarly, the electric motors on the electric cars are fixed, but the batteries that feed power to those motors could be removed or swapped, if need be, Generally, the batteries are placed underneath the floor of the vehicle and charged on a regular basis just like your smartphones, tablets or laptops. However, with the limited charging infrastructure available in most countries and high charging times associated with EVs, people always have this range anxiety about what would happen if their EVs run out of charge on a highway. But there is a solution that might not be widespread in the personal mobility space. In the commercial electric vehicle fleet across various markets, there is the practice of swapping the batteries of the car. You might also like: Is Electric Car Battery Safe, Fireproof, Waterproof and Short Circuit Proof? How Is It Achieved? The delivery companies, for instance, have huge warehouses where the entire fleet of their delivery vehicles is parked. There is sufficient charging infrastructure there too where the vehicles could even be charged using the regular AC chargers overnight. There is a provision for removing batteries from electric vehicles, especially commercial vans. The battery that has been charged overnight is used in the morning. It could suffice the entire day while the other battery is being charged in the meanwhile. You might also like: What Is Vehicle To Load (V2L) & Which EVs Have This Feature? If there is an issue with the battery that is being operated or it runs out of juice, one could simply visit the warehouse and swap the discharged battery for a recharged one in a matter of minutes. The battery packs are compact and could be easily placed in their designated slot in the EV. The battery that is taken out could directly be taken to the charging station and the refuelling time (essentially) be reduced to the time taken to replace the two batteries. This would ensure that the operations are not halted because of charging times and productivity will enhance due to the element of predictability that is achieved by this method. Slowly and steadily, with the prices of batteries coming down in the future, this solution could be utilised for personal use too. This technique is being practised even today by big companies that use electric vehicles for commercial purposes.

Is Electric Car Battery Safe, Fireproof, Waterproof and Short Circuit Proof?

31 Comments / Battery / By LEC Team

The electric car battery is the most crucial component of any EV and hence, its safe, fireproof, waterproof and short circuit proof nature needs to be ascertained. How safe, fireproof, waterproof and short circuit proof is the battery of your electric car? Well, it is a pressing issue that a ton of potential electric car buyers struggle with. And it is a valid concern too. With the immediate future of mobility belonging to electric cars alone, one must be aware of the strength and behaviour of batteries to establish a smooth ownership experience of an electric car. Is Your Electric Car Battery Safe, Fireproof, Waterproof and Short Circuit Proof? While the battery technology in automobiles may be new, the R&D by the giant automakers regarding every single aspect of a vehicle is not. Hence, they have taken into consideration all the aspects of battery usage. This includes rigorous and thorough testing under all weather conditions, across various terrains, in different driving and traffic conditions, in battery charging scenarios, etc. While designing the battery, the strength is taken into account. The placement of the battery is also done in such a way that during unfortunate incidents, it doesn’t get destroyed hurting the passengers. There is an imminent danger of a short circuit since a battery is nothing but a group of cells placed together. But there are fireproof materials placed between the cells to prevent that from happening. Also, the battery pack is concealed in a fireproof and waterproof cover/module. On the outside where the charging socket of a car is located, the charging doesn’t begin until a few internal tests have been done to ensure that no water, moisture or dirt is detected in the socket or the charger. Once it is established that everything is in order, the charging of a car commences. Such basic procedure has been followed extensively by all carmakers. Nail Penetration Test The nail penetration test is done to stimulate an internal short circuit in the battery of an electric vehicle. It measures the temperature rise within the battery when a nail is penetrated through the battery surface, simulating damage in the event of deformation due to a crash. Batteries that pass that test prove that even in case of emergencies, the battery will not explode. Just like the safety ratings of a regular car, this test is the benchmark to rate the safety of the battery pack of an EV. With time, more such tests will become standardised to ensure homologation and road legality. With the constant advancement and research in battery technology, things are only bound to improve further. As a matter of fact, there are plenty of new materials, techniques, and processes that would come up as every automaker shifts toward electrification. Then we would witness even more modern solutions to battery-related issues. So, to answer the question, the batteries in EVs ARE waterproof, fireproof, short circuit proof and safe.

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