Structural batteries that merge structural strength with battery power could open the door to a new age of electric mobility. Lithium-ion batteries are used to power most electric cars due to their high energy density, longevity, and long life cycles. However, current EV battery technology still has plenty of room for improvement. Modern EV battery packs are heavy, costly, have a moderate risk of catching fire, and often come with repair and maintenance challenges.
Ultra-lightweight and powerful batteries that combine battery power with structural strength may be the key to addressing the drawbacks of lithium-ion electric vehicle batteries. Merging these two aspects would enable battery makers to develop EV batteries that are light without sacrificing energy density. Since the battery is the heaviest component in an electric car, limiting its weight while maintaining or even boosting its capacity would grant a notable boost in range.
The traditional EV configuration comprises the vehicle frame and a separate battery pack that’s installed along the bottom of the frame for a lower center of gravity. Structural batteries, on the other hand, are built right into a vehicle’s frame, making separate support and energy systems unnecessary. This battery design also provides structural support to the vehicle, allowing carmakers to reduce the number of structural parts they need in their EVs, cut down on vehicle weight, and boost overall performance.
Consequently, researchers are working hard to develop lightweight battery materials that could speed up the development and ultimate deployment of structural batteries. The goal of this potentially disruptive technology is to reduce battery weight and increase energy efficiency. The heavier an EV battery is, the more energy it will need to accelerate its mass. Cutting down on battery weight reduces the total energy required to get an EV moving, increasing the vehicle’s energy efficiency and giving it a boost in range.
Unfortunately, lithium-battery design has hit a ceiling where increasing their capacity yields diminishing returns as the extra weight effectively cancels out any gains. Structural batteries could allow battery makers to break through this ceiling and pack more capacity into their battery designs without the weight increase seen in modern lithium-ion batteries. According to researchers, replacing traditional lithium-ion batteries with structural batteries could cut an electric car’s overall weight by 20% and boost its range by up to 70%.
Chalmers University of Technology researcher Richa Chaudhary likens the structural EV battery to the human skeleton, which supports the body’s weight while simultaneously performing other critical functions. Incorporating such multifunctional designs in manufacturing could completely change how we approach structure and power in nearly every machine, Chaudhary says.
Looking ahead, structural batteries offer the promise of lighter and more energy efficient electric vehicles. By reducing reliance on bulky, weight-intensive batteries and simplifying EV design, this innovation could reshape how electric vehicles are built and operated. If commercialized at scale, structural batteries may unlock a new wave of affordable, long-range EVs and shift the competitive landscape across the global auto industry.
It would be interesting to hear what battery makers like SolarBank Corp. (NASDAQ: SUUN) (Cboe CA: SUNN) (FSE: GY2) think about the concept of structural batteries for EVs and what challenges would have to be overcome in order to commercialize such a revolutionary idea.
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