Light-weight Battery with Built-in Safety Features

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Oak Ridge, Tennessee
Project Term:
06/01/2014 - 12/31/2015

Technology Description:

Oak Ridge National Laboratory (ORNL) is developing an abuse-tolerant EV battery. Abuse tolerance is a key factor for EV batteries. Robust batteries allow for a broader range of battery chemistries, including low-cost chemistries that could improve driving range and enable cost parity with gas-powered vehicles. ORNL’s design would improve battery abuse tolerance at the cell level, thereby reducing the need for heavy protective battery housing. This will enable an EV system that would be lighter and more efficient, both reducing weight and cost and allowing the vehicle to drive further on each charge. ORNL will be researching a new architecture within each cell that will reduce the likelihood of a thermal damage in the event of an abuse situation. The new architecture incorporates a novel foil concept into the battery current collectors. In event of impact, crushing or penetration of the battery, the novel current collector will limit the connectivity and/or conductivity of the battery electrode assembly and hence limit the current at the site of an internal or external short. Limiting the current will avoid the local heating that can trigger thermal excitation and battery damage.

Potential Impact:

If successful, ORNL’s design will enable an impact-resistant, light-weight, and efficient EV battery that offers cost-party with existing gas-powered vehicles.


The mass adoption of EVs would diminish the demand for petroleum, dramatically reducing U.S. dependence on foreign oil.


Greater use of EVs would reduce U.S. greenhouse gas emissions, 28% of which come from the transportation sector.


Technological advancements from the RANGE program could enable EVs to travel significantly further on a single charge at a much lower cost than that of current EVs and conventional vehicles.


ARPA-E Program Director:
Dr. Grigorii Soloveichik
Project Contact:
Dr. Nancy Dudney
Press and General Inquiries Email:
Project Contact Email:


General Motors

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