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What are electric car batteries made of?
Electric vehicle (EV) batteries are complex systems made up of thousands of rechargeable lithium-ion cells interconnected to form a single battery pack. Among the various types of cells available, lithium-ion cells are the most widely used due to their cost-effectiveness and ability to provide the best balance between energy storage capacity and price.
The rapid expansion of electric mobility has led to a surge in demand for EVs and, consequently, their batteries. This raises critical questions about how manufacturers can meet this escalating need and what materials are essential for EV battery production.
In this article, we delve into the materials utilized in EV batteries and the intricate process of manufacturing them. We will also highlight the leading EV battery manufacturers and discuss the implications of the growing supply-demand gap for the future of EV batteries.
EV batteries come in various shapes and sizes, depending on the type of cells used and their chemical composition. Understanding the different physical cell structures is crucial before exploring the materials that go into making these batteries.
There are three primary types of battery cells used in electric vehicles: cylindrical cells, prismatic cells, and pouch cells. Although coin cells exist, they are mainly used for research and development purposes and have not yet been adopted for commercial EV applications.
Cylindrical cells are perhaps the most common, named after their cylindrical shape, which provides excellent shock resistance. They are cost-effective and easy to produce, though they may have limitations in power output, particularly in smaller EV batteries where prismatic or pouch cells are preferred.
Prismatic cells, unlike their cylindrical counterparts, can be significantly larger, storing more energy and delivering higher power while managing heat more effectively. Despite being less popular, their usage has been increasing and may capture a significant portion of the market in the near future.
Pouch cells, as their name suggests, are housed in a flexible plastic casing, making them highly space-efficient. However, their delicate casings necessitate additional protection to prevent mechanical damage.
Beyond their structural differences, EV battery cells vary in chemistry, determining the materials used to store electricity. Lithium-ion (Li-ion) batteries are the most prevalent due to their affordability and high energy storage capacity. Other popular chemistries include Nickel Manganese Cobalt (NMC) and Nickel Metal Hydride (Ni-MH), which were favored in earlier EV models for their affordability and longevity.
Lead-acid cells, one of the oldest battery types, are still used in traditional gasoline-powered vehicles for ignition purposes. Although they are repairable and low-maintenance, they lack the energy density required for modern EVs.
Lithium-ion batteries, in particular, require several key materials, including lithium, nickel, cobalt, manganese, and graphite. These materials are arranged in layers, with the cathode typically made from a mix of lithium, nickel, cobalt, and manganese, while the anode is primarily composed of graphite. Aluminum or steel casings enclose the cells, providing structural integrity and protection.
In addition to raw materials, EV batteries rely on numerous hardware and software components to function properly. Key components include the battery module array, battery management system (BMS), battery electrical system, battery cooling system, and battery protection case. Each plays a vital role in ensuring the battery operates safely and efficiently.
Major players in EV battery manufacturing include CATL, LG Energy Solution, and BYD. CATL leads the global market with approximately 34% share, leveraging China's dominance in cathode and anode production. LG Energy Solution ranks second with 14%, recently partnering with Honda to establish a U.S.-based production facility. BYD, another Chinese giant, holds 12% of the market and uniquely serves as both a battery manufacturer and EV producer.
Despite the progress, the EV industry faces challenges in securing raw materials, particularly lithium and graphite. Shortages and rising costs threaten the sustainability of battery production. Recycling old batteries and advancing research in battery efficiency offer promising solutions to these issues.
Looking ahead, the future of EV batteries hinges on innovation in recycling, improved performance, and increased global production capacity. With continued advancements, EV batteries are poised to remain a viable and sustainable energy solution for the foreseeable future.