Next-gen EV batteries could last decades, researchers show the potential of single-crystal electrode tech

Perspective: Researchers have achieved a breakthrough in extending the life of electric vehicle batteries by adopting a monocrystalline electrode design. This innovation not only has the potential to significantly increase the lifespan and range of electric vehicles, but also paves the way for a smoother integration of renewable energy sources into power grids.

studyfunded by Tesla Canada and the Natural Sciences and Engineering Research Council of Canada, was led by Professor Jeff Dahn of Dalhousie University in Halifax and a team of researchers. Their innovative battery demonstrated exceptional durability, withstanding more than 20,000 charge-discharge cycles before reaching the standard 80 percent capacity threshold.

To put this into perspective, this is equivalent to an electric car driving an incredible 8 million kilometres.

The research focused on understanding how internal damage and fatigue accumulate in batteries over time and developing methods to prevent these problems, explained Dr. Toby Bond, senior scientist at Canadian Light Source. Using advanced synchrotron light technology at the University of Saskatchewan, the team conducted a detailed analysis of the battery’s internal structure.

The new monocrystalline electrode battery was compared to a conventional lithium-ion battery, which typically lasts about 2,400 cycles before reaching 80 percent capacity. Using CLS’ ultra-bright synchrotron light, the researchers were able to study the internal structure of both types of batteries without disassembling them, ensuring the integrity of the long-cycle cells was maintained.

The results were amazing. While conventional batteries showed extensive microscopic cracks in the electrode material after repeated charging and discharging, the battery with monocrystalline electrodes showed almost no signs of degradation. “In our images, it looked very much like a completely new cell,” said Dr. Toby Bond. “We hardly noticed a difference.”

The key to this longevity is the structure of the electrode particles. Traditional batteries use electrodes made of tiny particles made up of smaller crystalline clusters. In contrast, a monocrystalline electrode is one continuous crystal, which makes it much more resistant to mechanical stress and deformation. Bond compared the difference to the difference between a snowball and an ice cube: the latter is much harder to crush.

This breakthrough has far-reaching implications for the electric vehicle industry and beyond. Current US regulations require EV batteries to retain at least 80 percent of their original charging capacity after eight years of use. However, industry experts are pushing for batteries that will last for decades, enabling “second life applications” such as grid-tied energy storage for renewable sources such as wind and solar.

The extended life of these new batteries can exceed that of other electric vehicle components, representing a major milestone in electric vehicle technology. “We really want these cars to last as long as possible because the longer you drive them, the better the carbon emissions are reduced,” Bond explained.

The research team reports that these advanced batteries are already in commercial production and their adoption is expected to increase significantly in the coming years. “I think this kind of work just helps highlight how reliable they are and should help the companies that make and use these batteries plan for the long term,” Bond said.