ORNL Unveils Ultra-Fast Charging, Long-Life EV Battery with Critical Material Reduction
Key Insights
Researchers at Oak Ridge National Laboratory have engineered an electric vehicle battery capable of achieving an 80% charge in just ten minutes.
The innovative design significantly reduces the reliance on critical materials like copper and aluminum, bolstering domestic supply chains.
Utilizing a novel polymer-metal current collector, the battery maintains high energy density and performance over 1,000 charge cycles.
Enhanced safety features, including a circuit-breaker-like polymer, mitigate fire risks and improve overall battery reliability.
In a significant advancement for the electric vehicle (EV) sector, researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have unveiled a novel battery technology poised to redefine EV performance and sustainability. This innovative lightweight battery is capable of recharging to 80% capacity in a mere 10 minutes, a speed that dramatically mitigates range anxiety and enhances the practicality of electric mobility. Crucially, the design also substantially reduces the reliance on high-demand critical materials, addressing key supply chain vulnerabilities.
The core of this breakthrough lies in a newly developed current collector, a polymer material sandwiched between ultra-thin layers of copper or aluminum. This advanced component, a result of collaboration between ORNL and industry partner Soteria Battery Innovation Group, allows for superior energy density and exceptional fast-charging capabilities. According to Georgios Polyzos, a lead researcher on the project, the design significantly curtails the use of near-critical materials, particularly copper, which directly supports U.S. efforts to bolster domestic EV battery production and reduce dependence on foreign sources.
Beyond its rapid charging speed, the new current collector boasts a remarkable weight reduction, being only a quarter of the mass of conventional designs. This lighter construction contributes to an extended driving range for EVs, a vital factor for consumer acceptance. Despite the stresses associated with extremely fast charging, the battery has demonstrated robust performance, maintaining high energy density even after 1,000 charge cycles. Optimized processing parameters during manufacturing have successfully prevented the wrinkling of the thin polymer, ensuring the commercial viability of this innovative design.
Safety, a paramount concern in battery technology, is also significantly enhanced by ORNL’s innovation. Brian Morin, CEO of Soteria Battery Innovation Group, emphasized that the polymer within the current collector acts as an intrinsic circuit breaker. By removing 80% of the metal, the design inherently reduces the risk of fires caused by internal short circuits. Morin further explained that the plastic film is engineered to degrade and pull away the metal if an incorrect circuit produces an electric shock, thereby preventing potential hazards. This dual benefit of performance and safety positions the technology as a potential game-changer for lithium-ion battery applications.
Supported by the Department of Energy’s Advanced Materials and Manufacturing Technologies Office, this project marks a pivotal step towards more sustainable and affordable EV solutions. As global demand for electric vehicles continues its upward trajectory, innovations like the ORNL battery offer a compelling pathway to meet this growth while simultaneously improving supply chain resilience and environmental footprints. The detailed findings of this research have been published in the journal Energy & Environmental Materials, underscoring its scientific rigor and profound implications for the future of clean transportation.