Transportation Storage

EnZinc is developing a low-cost battery using 3D zinc microstructured sponge technology that could dramatically improve the rechargeability of zinc-based EV batteries. As a battery material, zinc is inexpensive and readily available, but presently unsuitable for long-term use in EVs. Current zinc based batteries offer limited cycle life due to the formation of tree-like internal structures (dendrites) that can short out the battery. To address this, EnZinc, in collaboration with the U.S.

The National Renewable Energy Laboratory (NREL) is developing a low-cost battery system that uses safe and inexpensive organic energy storage materials that can be pumped in and out of the system. NREL’s battery, known as a “liquid-phase organic redox system,” uses newly developed non-flammable compounds from biological sources to reduce cost while improving the amount of energy that can be stored. The battery’s unique construction will enable a 5-minute “fast-charge” and promote long life by allowing for the rapid replacement of liquid electrodes.

Illinois Institute of Technology (IIT) is collaborating with Argonne National Laboratory to develop a rechargeable flow battery for EVs that uses a nanotechnology-based electrochemical liquid fuel that offers over 30 times the energy density of traditional electrolytes. Flow batteries, which store chemical energy in external tanks instead of within the battery container, are typically low in energy density and therefore not well suited for transportation.

BASF is developing metal hydride alloys using new, low-cost metals for use in high-energy nickel-metal hydride (NiMH) batteries. Although NiMH batteries have been used in over 5 million vehicles with a proven record of long service life and abuse tolerance, their storage capacity is limited, which restricts driving range. BASF looks to develop a new NiMH design that will improve storage capacity and reduce fabrication costs through the use of inexpensive components. BASF will select new metals with a high energy storage capacity, then modify and optimize battery cell design.

Oak Ridge National Laboratory (ORNL) is developing an electrolyte for use in EV batteries that changes from liquid to solid during collisions, eliminating the need for many of the safety components found in today’s batteries. Today’s batteries contain a flammable electrolyte and an expensive polymer separator to prevent electrical shorts—in an accident, the separator must prevent the battery positive and negative ends of the battery from touching each other and causing fires or other safety problems.

Pennsylvania State University (Penn State) is using a new fabrication process to build load-bearing lithium-ion batteries that could be used as structural components of electric vehicles. Conventional batteries remain independent of a vehicle’s structure and require heavy protective components that reduce the energy to weight ratio of a vehicle. PowerPanels combine the structural components with a functional battery for an overall reduction in weight.

Bettergy is developing an inexpensive battery that uses a novel combination of solid, non-flammable materials to hold a greater amount of energy for use in EVs. Conventional EV batteries are typically constructed using costly materials and require heavy, protective components to ensure safety. Consequently, these heavy battery systems require the car to expend more energy, leading to reduced driving range. Bettergy will research a battery design that utilizes low-cost energy storage materials to reduce costs, and solid, non-flammable components that will not leak to improve battery safety.

General Electric (GE) Power & Water is developing an innovative, high-energy chemistry for a water-based flow battery. A flow battery is an easily rechargeable system that stores its electrode--the material that provides energy--as liquid in external tanks. Flow batteries have typically been used in grid-scale storage applications, but their flexible design architecture could enable their use in vehicles. To create a flow battery suitable for EVs, GE will test new chemistries with improved energy storage capabilities and built a working prototype.

The University of California, San Diego (UC San Diego) is developing a new battery that can be built into a vehicle frame. Conventional electric vehicle batteries are constructed independently of chassis, which results in a heavier, more inefficient vehicle. By rethinking auto frame design and incorporating the battery into the frame, vehicles can be cheaper and lighter vehicle. Since conventional batteries require potentially flammable materials, UC San Diego will also explore new chemistries to make this multifunctional battery safe in the event of a collision.

Arizona State University (ASU) is developing an innovative, formable battery that can be incorporated as a structural element in the vehicle. This battery would replace structural elements such as roof and side panels that previously remained passive, and incapable of storing energy. Unlike today’s batteries that require significant packaging and protection, ASU’s non-volatile chemistry could better withstand collision on its own because the battery would be more widely distributed throughout the vehicle so less electricity would be stored in any single area.