Are Solid-State the EV Batteries of the Future?
Lithium-ion (Li-ion) has been — and remains — the leading technology for electric vehicle (EV) batteries due to its high energy density, affordability, reliability, and safety. However, various challenges associated with Li-ion batteries, such as limited charging cycles, energy density constraints, degradation, and potential environmental impacts, are driving engineers worldwide to develop new technologies.
One of these alternative technologies could be solid-state batteries, which have the potential to offer even higher energy densities and faster charging times once manufacturing challenges are addressed. Nevertheless, there are still several obstacles to overcome before solid-state EV batteries can become mainstream. In this article, we’ll examine the current state of solid-state EV batteries, the challenges they face, and how innovative foam and tape solutions can help address them.
The name “solid state” is derived from the electrolytes used to transfer ions between the cathode and anode, as they are solid. These electrolytes are typically made from ceramics, glasses, or polymers. Thanks to their high ionic conductivity, ions can be transferred without the need for a liquid or gel electrolyte, as is the case with Li-Ion batteries.
These solid electrolytes are generally thinner than liquid or gel electrolytes, which enables a more compact and slimmer battery design. As a result, the difference between solid-state and Li-Ion technology is often immediately noticeable when the two types are compared.
Now that we have looked at general technological differences, let us take a closer look at why solid-state technology can be an interesting alternative.
Energy density and more lightweight, compact, and powerful battery designs are key factors engineers are striving to improve. Here, solid-state technology, with potentially higher energy densities in thinner designs, can be advantageous for certain applications where space is limited.
Additionally, solid electrolytes can operate at higher voltages, enabling faster charging times and a longer lifespan. The materials used in solid-state electrolytes are less flammable and can enhance safety by reducing the risks of thermal runaway and battery fires.
Although this sounds like an ideal solution — more power in the same or less space, faster charging, and improved safety — this and other technologies are still in the development and testing phase. It will take time before they may be widely commercialised as true alternatives. In the following paragraph, let us explore the main challenges currently limiting a solid-state technology breakthrough and commercialisation.
With today’s technologies, solid-state batteries are more challenging to manufacture compared to other designs. This increased complexity in manufacturing requires different equipment and expertise than traditional battery technologies, which can drive up costs. New and improved manufacturing processes for solid-state batteries will be needed before the technology can progress to become a price-competitive alternative. At present, there are a few companies working hard to find a way to scale solid-state battery manufacturing at a market price. They often collaborate with a large OEM automotive sponsor that, interestingly, invests in more than one solid-state technology.
Due to their high energy density, solid-state battery designs also face challenges with thermal stress, even though the materials used offer higher thermal stability compared to other technologies. Innovative foam solutions can help mitigate risks and enhance safety and performance.
Another challenge of solid-state EV battery design is mechanical stress or even cracking during operation or assembly due to their higher rigidity compared to traditional designs. Innovative adhesive tapes can not only streamline the complex manufacturing process but also help to mechanically stabilise the battery cells and distribute stress evenly across the battery pack. As process aids, adhesive tapes can significantly reduce the risk of cracking or damage during assembly or operation, leading to improved output, quality, and reductions in manufacturing costs.
The EV battery technology landscape is varied and fast-changing, with all the ups and downs that different solutions provide. There is no ideal or one-size-fits-all solution, but we have learned that solid-state EV battery technology can be an intriguing path towards the electrified mobility of the future. Let your tape experts know where you would like to go so they can help guide you on your way and support you in reaching your final destinations more quickly.