Electric vehicle batteries: what are they and how do they work?

Electric vehicle batteries: what are they and how do they work?

This guide will provide you with all the information about the functions of the battery for electric vehicles (EV), as well as the components and mechanisms that allow efficient operation of electric vehicles.

What is an electric car battery ?

Electric car battery provides electrical energy for the operation of your electric car. She is the heaviest and most expensive part of her car, but the price has dropped significantly in recent years

What is an EV battery made of ?

Batteries for electric vehicles are made of various metals and minerals:

_anode graphite

_ Cathode-Lithium, aluminum, nickel, manganese, iron, cobalt

_ Separator-Polyolefin, a microporous polymer

_ Electrolyte Lithium hexafluorophosphate

_ Pantograph-Aluminum (cathode side) and copper (anode side)

_ Housing - Aluminum, Steel

The most common types of batteries for electric vehicles

Understanding of electric vehicle batteries is not complete without looking at the battery general cellular chemistry of electric vehicle batteries.

Lithium ion

Due to its cost efficiency and excellent energy storage, lithium-ion batteries are the most common and popular batteries for electric vehicles today.

Nickel-Manganese-Cobalt

Nickel-manganese-cobalt batteries provide a more balanced power output and good energy storage.

Nickel-metal hydride

Nickel-metal hydride batteries were often found in the first hybrid vehicles, including the Prius. They are mostly replaced by lithium-ion batteries, but they are still found in Toyota Highlander 2020 and several other hybrids.

Lithium sulfur

These batteries have a large energy storage capacity, but they must be heated first before they can generate enough power to drive an electric car. They are more often seen on electric buses.

Lead acid

Lead-acid batteries were once the preferred type of battery because of their low maintenance and easy replacement. Currently, it is overtaken by lithium-ion batteries and is mainly used in electric vehicles with low power consumption

How does the EV battery work ?

 We deal with each part of an electric car battery and how it works as a whole.

Electric vehicle batteries consist of six main components: anode (negative) and cathode (positive) electrodes, electrolyte, separator, pantograph and housing/casing.

EV batteries have 2 phases, mainly discharge and charging. In the discharge stage of an EV battery, an electrochemical reaction occurs, in which ions flow from the anode through the electrolyte and separator to the cathode, in the process of which they release electrical energy. Pantograph collects this energy and distributes it to external circuits in various subsystems of electric vehicles.

In the charging phase, the opposite happens. The ion flux moves from the cathode to the anode, where electrical energy is stored in the electrodes and current collectors, which can be used in electric vehicles the next day. Future battery technologies for electric vehicles hope to reduce the charging time of battery packs for electric vehicles (usually more than a few hours in one night

How long will the EV battery last ?

The automotive industry estimates the expected life of current battery cells for electric vehicles to be 15 to 20 years (100,000 to 200,000 miles). Despite the aging of the batteries of electric vehicles, the owners may not notice a decrease in power, since the batteries are large from the very beginning, and minor losses are not noticeable.

EV Battery Module and Pack Design

Battery pack for electric vehicles

It consists of modules, which consist of individual battery cells. This allows optimal flexibility in the configuration of different sizes of battery packs.

EV Battery cells, Modules, and Packs: Key Differences

The EV battery consists of the following components and the differences are shown below.

_EV Battery Cell - The basic unit of an EV battery that helps to store and deliver energy.

_EV battery Module - Consists of EV battery cells connected in series or in parallel. Each unit generates a certain voltage and achieves a certain energy capacity.

_EV Battery Pack - Consists of EV battery modules connected in series or in parallel and surrounded by a robust housing. In addition, they include other components for cell monitoring and thermal management.

How are battery packs for electric vehicles manufactured?

The EV battery pack is manufactured according to the EV battery design.

The anode and cathode are first installed in the housing. They are wrapped in a thin metal foil called a pantograph. Subsequently, they are isolated from each other by separators to prevent short circuits. This assembly is then immersed in liquid electrolyte before being sealed in the housing. The cells are then subjected to moisture and leak tests that can lead to corrosion, fire or explosion.

Each individual cell is then assembled into an EV battery module (usually there are 12 battery cells per module, but depending on the brand and model of the EV the modules are then stacked in a strong housing to protect it from physical impact. Just like individual cells, the module is also checked for moisture leakage and leakage.

Finally, the module is manually assembled in a rigid housing to form a battery pack for electric vehicles. This process involves not only stacking the modules, but also ensuring that the electrical connection is performed correctly and fine-tuning is observed

What is Laminate Bus Bar ?

The laminated busbar is a multi-layer and composite structure connected to the platoon. It acts as a distribution system to the main components of electric vehicles.

These offer better individualization, faster installation, lower global system costs and higher efficiency reliability for electric vehicle batteries

Sustainability in Electric Vehicle Battery Design

The future battery technology of electric vehicles focuses on the search for materials that are readily available or reusable from the environment.

1. One of the best sources of material is old batteries. Some are taken to recycling plants where they are shredded and important metals such as lithium, aluminum and copper are extracted from the electrodes. Sustainable batteries for electric vehicles also promise to eliminate cobalt, which is toxic and can only be mined in the Congo