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Power Transportation Technology

New Research Promises Electric Car Batteries That Last For a Million Miles (gizmodo.com) 159

A team of battery researchers from Halifax, Nova Scotia's Dalhousie University believes it has come up with a recipe that can make electric car batteries last for a million miles. Gizmodo reports: In a paper published in the The Journal of the Electrochemical Society earlier this month, battery researchers describe a new lithium-ion battery that could potentially power an electric vehicle for over one million miles and over 4,000 charging cycles while only losing about 10 percent of its charging capacity (and vehicle range) as it reaches the end of its lifespan. Most drivers upgrade their rides well before the odometer rolls over to one million, but the new battery tech could be especially useful in vehicles that are on the road around the clock like taxis, shuttles, and even delivery trucks.

Since 2016, the Dalhousie team has actually been conducting its research on improving lithium-ion batteries exclusively for Tesla, but this paper divulges exactly how they came up with a recipe for a million-mile electric car battery by optimizing all of the ingredients, which includes artificial graphite, and then improving the nanostructure of the lithium nickel manganese cobalt oxide to create a crystal structure that's less likely to crack and degrade performance. According to Wired, who spoke to former researchers who worked in the Dalhousie lab, by publishing the most important details of this research, it provides a new performance benchmark for all of the other R&D labs working on improving battery tech, so, ideally, a million miles of battery life is just the beginning.
Wired points out that just days after this paper was published, Tesla was awarded a patent for a new electric vehicle battery featuring nearly the exact same chemical makeup as the ones detailed in the research paper.
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New Research Promises Electric Car Batteries That Last For a Million Miles

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  • by BitterOak ( 537666 ) on Monday September 23, 2019 @09:22PM (#59229352)
    The headline really caught my attention. Then as I read more, I see that isn't a million miles on a single charge, but rather that's total battery life! Still impressive, but not as mind blowing as I first thought.
    • It is an impressive feat but not the breakthrough things like cars need. We need more energy density so cars can go further between charges. Something that would double or triple the current standards would be a good step forward.

      • by Kobun ( 668169 )
        I'm hoping that Dr. Goodenough's solid battery makes it over the finish line - https://hardware.slashdot.org/... [slashdot.org]
      • by phantomfive ( 622387 ) on Monday September 23, 2019 @10:54PM (#59229552) Journal
        Extending the range will get some more sales, but getting the price down will get a lot of sales.

        That is where the future lies: in cheaper batteries. A cheap car with a 120mile range will sell like hotcakes.
        • by Rei ( 128717 ) on Tuesday September 24, 2019 @05:25AM (#59230132) Homepage

          Bingo.

          The #1 effort by the major manufacturers has been getting price down. Thus you get the push to eliminate cobalt from the cathodes, dry electrode manufacturing to eliminate the massive/expensive/energy-sucking vacuum ovens and solvent recovery systems, "gigafactory"-sized plants for economies of scale, etc etc. Getting costs down per kWh is the key.

        • If 120 miles is the maximum optimum mileage, it might be on the edge of useful for many people in more extreme climates where cold might run that down to 80 miles. I mean if you have a simple daily commute, that might be good enough. But if you've got a more complex routine, you're kind of at the outer limit for other trips.

          I kind of feel like for electric cars to take off the power train has to get to be half of what a ICE power train is so the rest of the car has enough amenities to be appealing to peop

        • by kenh ( 9056 )

          A cheap car with a 120mile range will sell like hotcakes.

          Like the 150 mile range Nissan Leaf [nissanguam.com]? Is that selling "like hotcakes" [extremetech.com]? Fifteen thousand Nissan Leafs were sold in the US in 2018, compared with 146,000 of the Tesla Model 3.

          • The Nissan Leaf is not cheap. Although it looks like a cheap car from the outside, the actual price is rather high.
          • The $30,000 MSRP for a new Nissan Leaf is $10,000 or more higher than budget compact cars. You can buy a lot of gas for ten thousand dollars -- enough to take your car well over 100k miles.

            Maybe it's worth the money, but it currently doesn't meet the criteria of "cheap car with a 120 mile range."

      • Lets hope it comes to Phone, Laptop etc batteries too
        • by Rei ( 128717 ) on Tuesday September 24, 2019 @05:29AM (#59230136) Homepage

          They could easily get longer lifespans today if they wanted to. They're prioritizing initial capacity over longevity. It's a conscious decision.

          The best thing that could be done without any chemistry changes would be to let people set finer charge controls on their phone. The worst way to abuse a li-ion battery is to charge it to 100% and then leave it sitting around at 100% for long periods of time. Yet that's exactly how almost everyone charges their phone every night. Being able to say, for example, "Bring it up to 85%, then right before my alarm goes off, bring it up to 95%" would greatly increase cellphone battery longevity.

          Some laptops (including mine) have something like this, thankfully. When you're at home, you can leave it set to keep the charge level at 50% (optimum). But before you go on a trip, you up it to as high as you want (incl. 100% if you prefer).

      • by Rei ( 128717 ) on Tuesday September 24, 2019 @05:22AM (#59230124) Homepage

        We need more energy density so cars can go further between charges.

        For long-haul air travel and transoceanic shipping, yes - energy density is king. For electric cars, no - they're currently limited by cost rather than weight. The Model 3 variants are roughly equivalent in weight to their performance and class equivalents from BMW with a full tank. The main thing that prevents using, say, two-cell-thick packs** is not mass - yes, people will still buy the cars if they're somewhat heavier, especially since doubling the cells doubles the power and charge rate (and the cell life, by halving the number of cycles per cell)***. It's cost.

        For mainstreaming EVs, cost is king at present. That may change in the future, esp. at the high end (keeping weight down for cornering performance), but for now, it's all about the race to make cells and packs as cheaply as possible per kWh.

        ** - Two-cell-thick packs, like the upcoming Tesla Roadster, aren't actually double the thickness. The pack itself also adds some thickness overhead regardless of how many cells you stack inside, so it's only a ~60-80% increase in effective thickness. And regardless, most people these days prefer to ride higher off the ground (so long as the ceiling height is also increased to match. There's a small drag area penalty, but it's quite insignificant vs. the pack energy increase. All this said, a given vehicle has to be designed for a pack of a given thickness - you can't just retrofit it after the fact.

        *** - It's not exactly "doubling" for any of these, since you are somewhat increasing the energy per unit distance. But it's close to doubling.

  • by Streetlight ( 1102081 ) on Monday September 23, 2019 @09:23PM (#59229356) Journal
    I'm not sure what the current life span is for the battery in the typical cell phone or other portable device under normal use, but if this technology can be used on a small form scale, it would be great.

    And of cource, the improved lifespan would also be very useful for home and grid size electric energy storage systems.
    • every battery is a compromise between various parameters including single charge capacity, life-time number of charges, size aand safety.

      every type of device needs a different compromise point.

      car batteries optimise as much as possible for life-time (because nobody needs to buy a car every year oor ssoso) but can afford a little bit more room (there's a whole car floor's worth of space) and in Tesla's case also packs more cooling tech affording safety closer to laptops than industrial power tools (though o

    • No phone manufacturer wants their battery to last forever. They would be shooting themselves in the dick.
      • by sad_ ( 7868 )

        nah, they would just raise the price to, say $1000, to compensate for lost sales.
        oh, wait...

      • No phone manufacturer wants their battery to last forever.

        Phone manufacturers really don't think that far ahead, except maybe Apple, which has a more locked-in customer base. Android phone manufacturers are too focused on their competition, and anything that gives a short-term competitive edge will be aggressively pursued. So if long-life batteries are available, some phone manufacturer will adopt them for the competitive edge, and that will force everyone else to adopt them, too. Which will actually force Apple to adopt them as well, because their customer base

  • What about rates? (Score:4, Informative)

    by LynnwoodRooster ( 966895 ) on Monday September 23, 2019 @09:29PM (#59229374) Journal
    In pretty much every case to-date, higher charge cycles comes at the expense of charge/discharge rates. Fast charging/discharging kills your cycle count. Some technologies that have high cycle counts have high series resistance that keep the anodes from degrading.
    • Re:What about rates? (Score:5, Informative)

      by ras ( 84108 ) < ... > <stuart.id.au>> on Tuesday September 24, 2019 @12:26AM (#59229638) Homepage

      Re:What about rates?

      Performance at various rates is spelled out in the paper.

      higher charge cycles comes at the expense of charge/discharge rates

      But not this case.

      As the paper says, they charged and discharged at 1C. Nor did they limit the capacity. Each charge was 0%..100%. Capacity drop at 20C after 3,000 cycles was 5% and was linear, meaning if you use the convention "its dead at 80%" the battery lasts 12,000 cycles or over 30 years if deep cycles once per day.

      They did a test at 3C [ecsdl.org] too. It appears to show the battery capacity was less at 3C (heat loss maybe?), but if anything degraded less after 3000 cycles.

    • Fast charging/discharging kills your cycle count.

      I don't think this is true. I think fast charging/discharging generates a lot of heat, which kills your cycle count, if not removed. Good thermal management seems to eliminate most, if not all, of the fast charge/discharge damage. This is why a Tesla charging at 120 kW sounds like a jet engine, because the car is working really hard to move the heat out as it moves the juice in.

  • by hcs_$reboot ( 1536101 ) on Monday September 23, 2019 @11:13PM (#59229588)
    Marty, we did it! [slashdot.org]
  • Another day, another $SUPERBATTERY article! I'm loving it!

    I also get paid $1 per article on $FUTURISTICSTORAGEMEDIUM-HUGE as well, it's pretty great. I've been retired for 10 years . . . .

  • Don't need a car battery that lasts 10x longer than the car. But one that lasts would be great for a house battery.
    • The battery can be taken out of the car and put into a house any time. In fact that was the business plan for powerwall but Tesla can't get enough used packs because the enthusiast scene is consuming them all. A model S pack for example breaks up into multiple (5?) 24v lithium packs around 5 kWh (about 4.4 usable.) So they are being used in vehicle solar systems. They cost about $1100-1250 which makes them by far the cheapest thing worth using. Even cheaper than leaf packs, and you don't have to dick with c

  • Not the Answer (Score:3, Insightful)

    by rally2xs ( 1093023 ) on Tuesday September 24, 2019 @06:11AM (#59230218)

    Tesla S battery, the big one, about $90K, powers car 300 miles which is marginally competitive with a gasoline car.

    Battery lasts 1,000,000 miles.

    9 cents per mile to replace the battery.

    100 miles of driving is then $9 toward battery replacement.

    30 mpg car burning $2.10 / gallon regular gas costs $6.99 to drive the 100 miles.

    Gasoline car still cheaper to drive than just the replacement costs for the battery. Add in the 100 KwH for a charge that will last 300 miles at 12 1/2 cents per KwH (around here) and that is $12.50 / 300 miles or $4.17 / 100 miles or 4.17 cents per mile on top of the 9 cents per mile to replace the battery. 13.17 cents per mile for electric, 6.99 cents per mile for gasoline. Hmmmm....

    Still need much cheaper battery.

    Of course, the electric car doesn't need, in say 200,000 miles of ownership, 2 brake pad changes, just one at $400 / axle for a $800 charge or 0.4 cents per mile, 20 oil changes at $65 / change for synthetic that will last 10K miles for $1,300 or 0.65 cents per mile, 2 timing belt changes at $1,300 per change for $2,600 or 1.3 cents per mile, no engine replacement after rings / pistons become loose in their bores from wear, maybe 300K miles for that, at - what? - $5K for the exchange for 1.66 cents per mile. So, ICE engined car adds 4 cents per mile for routine maintenance items to add to its approximately 7 cents per mile for a total cost of 11 cents per mile, still cheaper than electric's 13.77 cents per mile. 2.77 cents per mile difference for 200,000 miles is $5,540 more for electric over 200,000 mile life of the car, or at least where I usually trade cars at 200,000 miles usually 'cuz everything else is falling apart - new shocks, new power steering pump, hoses, brake pads, water pump, alternator, etc. At least the electric won't have an alternator or water pump, costs I didn't factor into the equation above. The electric MIGHT rival the 30 mpg car if those expenses are factored in, I'm not going to calculate it. Its close, with the big benefits of driving the electric being the head-snapping acceleration and reliability - it won't lunch the MAF sensor and be down for a week that it took the mechanics to get a new one and install it on my last car. But cheaper? Not quite. A bit more expensive.

    Yeah, I'd buy it. But if you're looking for frugal, it won't be achieved by this battery unless the price of the battery comes down. A lot.

    • by lurcher ( 88082 )

      Out of interest, in the UK, that comes out as

      45 mpg car burning $6.00 / gallon regular gas costs $13.33 to drive the 100 miles.

    • by kenh ( 9056 )

      You were wrong before you finished your first sentence.

      The Tesla Model S sedan is $75K, the battery pack is (obviously) cheaper than that.

      The Tesla Model 3 battery pack costs $3-6K and last 300,000-500,000 miles. [interestin...eering.com]

      I look forward to your revised calculation based on real numbers - you know what, I'll just do it for you, you're probably very busy:

      Tesla Model 3 battery, the big one, about $6K, powers car 300 miles which is marginally competitive with a gasoline car.

      Battery lasts 500,000 miles.

      1.2 cents per mile to replace the battery.

      100 miles of driving is then $1.20 toward battery replacement.

      There, that makes more sense.

    • Going up to $3.337/gal on the West Coast. [eia.gov]

      I.e. That calculation of "30 mpg car burning $2.10 / gallon regular gas" is actually somewhere between $7.84 and $11.12 per 100 miles.
      Or between 7.84 and 11.12 cents per mile.
      So that estimate is between 12% and 59% lower than the actual costs.

      Being generous and applying the same error to the other estimates above, makes that 4 cents per mile estimate more like between 4.48 and 6.36 cents per mile.
      Which ads up to between 12.32 and 17.48 cents per mile. Or 14.9 cents p

  • I thought Tesla was talking about going up to 1 million miles and beyond and 20 years and beyond? Well for me sitting around with a Nissan Leaf with only 40,000 miles on it and an effective range that has dropped to ~25 miles while Nissan corporate stonewalls on replacing the battery even though it should be covered under their warranty and long after the documentary on the Leaf had the CEO of Nissan being told up front the specs on the battery don't go the distance, so what did Nissan do to extend the lif
  • Sure, it'll be a great battery upgrade for Tesla's electric vehicles. But the place I see the longer life battery pack really being useful is for the PowerWall battery storage units Tesla sells.

    Right now, a PowerWall isn't really a cost-effective option to keep a house powered throughout a power outage because not only is the up-front cost high, but then you're looking at the whole question of how many years they'll last before they start losing charging capacity. (A mortgage on a new house is typically 3

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