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Improving Electric Vehicle Batteries with Single-Crystal, High-Energy Nickel-Rich Cathodes

By Oliver Peckham

New Research on Lithium-Ion Battery Manufacturing

New research led by the Department of EnergyÔÇÖs Pacific Northwest National Laboratory has shown that a simple shift in lithium-ion battery manufacturing could have significant benefits for electric vehicles (EVs). This shift could result in improved energy storage per charge and increased durability over more charging cycles for EV batteries, potentially revolutionizing the EV market.

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An EVÔÇÖs mileage relies on the deliverable energy from each cell in its battery pack. For lithium-ion cells, which dominate the EV battery market, the cell-level energy capacity and cost are dependent on the positive electrode, or cathode, making it a critical component.

The Nickel-Rich Battery Vision Unveiled

The research has highlighted the potential of nickel-rich cathodes, such as NMC811 (with 80% nickel), to vastly improve energy storage and range in EV batteries. However, the existing standard method for producing high-nickel NMC cathodes results in rough and lumpy polycrystal structures that are susceptible to cracking and material failure, posing significant challenges to their viability in EV batteries.

An innovative and cost-effective approach for synthesizing single-crystal, high-energy, nickel-rich cathodes has been developed, potentially overcoming these challenges and revolutionizing EV battery technology.

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Overcoming Challenges in Synthesizing Single-Crystal NMC811

To address the issues with the existing production method for high-nickel NMC cathodes, researchers have proposed converting the polycrystal NMC into a smooth, single-crystal form. However, this conversion is complex and challenging, requiring new techniques and approaches for efficient and practical real-world cathode manufacturing.

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PNNLÔÇÖs Innovative Solution

The research team, led by PNNL battery experts, has introduced a pre-heating step to change the structure and chemical properties of the transition metal hydroxide, which results in the production of uniform single-crystal NMC structures. This innovative approach could pave the way for large-scale production of single-crystal NMC materials, potentially transforming the EV battery industry.

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Rapid Deployment of EV Battery Technology

PNNL, along with industry and university partners, aims to realize commercial-scale synthesis and testing of single-crystal NMC materials, with the goal of achieving rapid deployment in the EV battery market. By leveraging conventional manufacturing equipment and techniques, as well as innovative scale-up approaches, the research team plans to accelerate the commercial-scale manufacturing process to meet the increasing demand for high-performance EV batteries.

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This research was sponsored by DOEÔÇÖs Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office, and Vehicle Technologies Office.

About PNNL

Pacific Northwest National Laboratory (PNNL) is a leading research institution that draws on its strengths in chemistry, Earth sciences, biology, and data science to advance scientific knowledge and address key challenges in sustainable energy and national security. PNNLÔÇÖs collaboration with industry and academic partners is paving the way for groundbreaking advancements in energy technology and materials science.

Disclaimer: AAAS and EurekAlert! are not responsible for the accuracy of news releases posted to EurekAlert! by contributing institutions or for the use of any information through the EurekAlert system.

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