FAQs

Automotive manufacturers rely on thermal interface materials (TIMs) to prevent overheating in electric vehicle (EV) batteries. TIMs improve thermal regulation across traction packs by optimizing heat transfer between key components and supporting effective dissipation. This article discusses where and how TIMs are applied in EV battery packs to enable faster, safer charging, maximize range, and…

The vast majority, upwards of 80% in recent years, of energy storage installations have used lithium-ion batteries. Lithium-based deployments have continued apace despite supply chain concerns, largely because of lithium batteries’ falling prices and exceptional efficiency. Lithium’s dominance, however, has led to concerns about its continued ability to meet the expected demand for energy storage…

Thermogalvanic energy harvesting (EH) cells use an electrochemical cell that generates electricity directly from heat by maintaining a temperature difference between two electrodes immersed in an electrolyte solution containing a redox chemical couple. In addition to EH, thermogalvanic cells (TGCs) are being proposed for thermal management and cooling applications. A TGC is primarily designed to…

Batteries are a key element in electric vehicles (EVs), and there has been a lot of development in solid-state and other EV battery chemistry. This FAQ will highlight the promising materials that align with solid-state and other EV batteries, making them suitable for EV batteries. Material advances in solid-state batteries In solid-state batteries, sulfide, oxide,…

This final part of the multipart FAQ will explain the mechanical assembly and soldering process used to make joints during electric vehicle (EV) battery production. Although these two mechanisms are somewhat primitive in nature, they still find applications for making low-cost EVs where the makers do not have access to automation and advanced technologies. Mechanical…

This third part of the multipart FAQ will discuss magnetic pulse welding, micro-TIG, and clinching for electric vehicle (EV) battery productions. While the first two mechanisms use high temperatures to make joints, the clinching mechanism is based on applying force to create mechanical interlocking to create joints. All three mechanisms are less popular than the…

Resistance spot welding and wire bonding are popular choices for creating joints during EV battery production. However, every joining technology comes with a trade-off, giving packaging engineers room to select the appropriate one for their battery design. This is the second part of the multipart FAQ on the joining methods for EV battery production and…

Joints are important electrical and mechanical connections in producing electric vehicle (EV) batteries. They link individual battery cells to make a full battery pack. However, the process of making joints has evolved over the years due to various technologies. This first part of the multipart FAQ will discuss ultrasonic welding and laser welding, two commonly…

Samsung recently announced the development of a groundbreaking solid-state electric vehicle (EV) battery (Figure 1), promising a 600-mile range, 9-minute rapid charging, and a 20-year lifespan. In contrast, EVs with conventional lithium-ion (Li-ion) batteries typically offer a 250 to 350-mile range, 25 to 30-minute rapid charging, and an 8 to 15-year lifespan. Although many major…

First-generation solid-state batteries are poised to boost the driving range of electric vehicles (EVs) by 50% to 80%. Solid-state batteries could extend this range even further, with some automotive manufacturers ambitiously targeting 900 to 1,000 miles per charge. This article reviews how solid-state technology increases EV battery capacity and range, discussing lighter and more energy-dense…