In a surprising twist that challenges conventional wisdom, researchers have uncovered a novel approach to electric vehicle (EV) battery manufacturing that could significantly extend battery lifespan and reduce production time. This breakthrough, funded by the Toyota Research Institute, has the potential to revolutionize the EV industry and accelerate the transition to electric mobility.

A study published in the scientific journal Joule by researchers from the SLAC-Stanford Battery Center, in collaboration with scientists from the Massachusetts Institute of Technology (MIT) and the University of Washington, has revealed that charging lithium-ion batteries at unusually high currents during their initial formation phase can increase their average lifespan by a staggering 50%.

“This is an excellent example of how SLAC is doing manufacturing science to make critical technologies for the energy transition more affordable,” stated Professor Will Chueh, who led the research team. “We’re solving a real challenge that industry is facing.”

Traditionally, EV battery manufacturers have used low currents for the initial charging cycles, believing this method created the most robust solid electrolyte interphase (SEI) layer, which is a crucial component for battery longevity. However, this process is time-consuming, often taking up to 10 hours.

The new research turns this conventional wisdom on its head. By applying high currents during the first charge, researchers could reduce the initial charging time from 10 hours to just 20 minutes while simultaneously improving the battery’s lifespan.

In detail, charging a new lithium-ion battery at high currents during the factory process significantly depletes its lithium supply but extends the battery’s lifespan, according to research from the SLAC-Stanford Battery Center.

Consequently, the key to this improvement lies in the formation of the SEI layer, where during the first charge, lithium ions are deliberately “lost” to form this protective layer on the negative electrode. Counterintuitively, losing more lithium initially — about 30% compared to the traditional 9% — leads to better long-term performance.

Xiao Cui, the lead researcher for the battery informatics team, explained the phenomenon using an analogy stating, “It’s like making a small investment that yields good returns down the road.”

As a result, this discovery could have far-reaching implications for the EV industry. Steven Torrisi, a senior research scientist at the Toyota Research Institute, highlighted the potential impact stating, “Battery manufacturing is extremely capital, energy, and time-intensive. This study demonstrates a generalizable approach for understanding and optimizing this crucial step in battery manufacturing.”

Notably, the U.S. Department of Energy (DOE) recently revealed a new $43 million funding initiative aimed at propelling research, development, demonstration, and deployment (RDD&D) in key areas of advanced EV battery technology. In response, the continued investment in EV battery research and innovative development is noticeably inputted with effort for industry and market purposes.

Read More: U.S. DOE Launches $43 Million Initiative To Further Advance EV Battery Technology

While the results are promising, translating this research into real-world manufacturing processes will be the next challenge. However, if successful, it could lead to EVs with batteries that maintain good performance for much longer periods, addressing one of the key concerns of potential EV buyers.

Moreover, the study showcases the power of scientific machine learning in battery research. By using advanced algorithms, the team was able to identify the most critical factors in battery formation out of dozens of variables, streamlining the research process and potentially accelerating future innovations for EVs.

With breakthroughs like this serving as crucial stepping stones, and the potential to extend battery life by up to 70% in some cases, this discovery may well be the key to unlocking the next generation of EVs that are capable of driving further, lasting longer, and cost less to produce. With this in mind, the road to widespread EV adoption may have just gotten a little shorter, thanks to an unexpected jolt of high-current innovation.

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