Electric vehicle batteries, or EV batteries, are increasingly available in the market. These are replacing traditional internal combustion engines, focusing on enhancing specific energy, cycle life, and efficiency. As per IEA reports,

The need for electric vehicle (EV) batteries increased by 40% from 2022 to 2023, reaching over 750 GWh. 

This demand is higher in the United States and Europe. However, their cost is high, accounting for approximately 50% of the total cost of an EV. 

Reducing costs by using cheap materials or recycling wastes and using them with EV batteries can bring down the cost. This is where experimenting with materials comes into play.

Researchers are exploring many options, including cobalt-free batteries, graphite, and other options beyond lithium-ion. These options can address environmental and geopolitical issues relating to the extraction and use of materials like lithium and cobalt.

In this article, we will learn more about alternative materials and their potential to reduce the cost of EV batteries. 

The Cost Factor in Current EV Batteries 

The cost of the components of EV batteries determines whether the battery will be cheap or not. This is because there are multiple interconnected modules inside each EV battery pack. The nodes are made up of tens to hundreds of rechargeable lithium-ion cells. 

Collectively, these cells make up roughly 77% of the total cost of an average battery pack, or about $101/kWh.

The cathodes used in lithium-ion batteries for EVs account for the largest share of a cell’s cost. Commonly used cathode materials are lithium, cobalt, manganese, and nickel. Meanwhile, the anode – frequently made of graphite – accounted for 12% of costs that year.

Role of Lithium and Cobalt in the Cost 

Lithium and cobalt are important factors for the cost of EV batteries.

In 2023, cobalt and nickel supply increased by 6.5% and 8%. On the other hand, lithium supply increased by 10%, reducing battery costs. 

Low critical mineral costs help bring battery costs down significantly. However, they also imply lower cash flows and narrower margins for mining companies.

Environmental and Geopolitical Issues 

Around 70% of the world’s cobalt is mined in the Democratic Republic of Congo.

This has led to a geo-strategic rivalry between the world’s biggest economies over this crucial resource.

As for lithium, around one-third of the world’s lithium comes from salt flats in Argentina and Chile. 

This has raised concerns about the sustainability of lithium extraction, particularly in regions where water is scarce.

Case Studies of Promising Alternatives for EV Batteries

Some of the case studies conducted on alternatives for EV batteries are as follows:

Sodium-Ion Batteries 

Sodium-ion (Na-ion) batteries are better alternatives as sodium is significantly more abundant than lithium. This makes it cheaper and more sustainable to produce. 

A new type of hybrid sodium-ion battery offers both high capacity and rapid-charging capabilities. However, current sodium-ion batteries deliver lower power output and storage capacity than lithium-ion batteries and take longer to charge. Researchers are working on overcoming these limitations.

Cobalt-Free Batteries 

Researchers at MIT have designed a cobalt-free battery that could offer a more sustainable way to power electric cars. The new lithium-ion battery includes a cathode based on organic materials instead of cobalt or nickel. 

This material can conduct electricity at the same rates as cobalt batteries for EVs. The new battery also has a better storage capacity and can be charged up faster than cobalt batteries. 

Lamborghini has already licensed the patent and is moving ahead with this technology.

Graphene-Based Batteries 

Graphene is a single layer of carbon atoms stacked in a two-dimensional honeycomb lattice that has exceptional properties. It’s highly conductive, has a large surface area, and is incredibly strong and light. These properties could potentially improve energy storage, flow, and charging/discharge rates.

Lithium Iron Phosphate (LFP) Batteries 

This year, one alternative that could be a player in the EV batteries field is lithium iron phosphate. (LFP). It is a low-cost cathode material sometimes used for lithium-ion batteries. 

LFP batteries use lithium iron phosphate as the cathode material, offering high energy density and long life under high temperatures. They are known for their safety, low toxicity, and long cycle life. Their flat discharge curve makes them stable and reliable. 

LFP batteries can withstand up to 3,000 cycles under most conditions and over 10,000 cycles under optimal conditions. 

Review of Existing Patents/Startups on EV Batteries

Companies often file patents for the same invention in multiple countries to protect their intellectual property rights globally. Here are some examples of patents related to alternative materials for EV batteries:

Solid-State Batteries 

While lithium-ion batteries may be perfect for EV batteries, the high number of patents for solid-state batteries may be feasible. 

The USPTO database indicates a total of 1,302 U.S. patent applications related to solid-state batteries were filed. Nearly 74% of those filed during the last five years.

Companies like Meta Materials have been granted patents for second and third-generation nanoporous ceramic battery separators. This is said to enhance battery safety, lifetime, energy, and power density. 

Battery Assembly for Electric Vehicles 

A comprehensive patent analysis was performed on 6 popular cathode materials. This considered performance comparison, development trend, annual installed capacity, technology life cycle, and distribution among regions and patent assignees. 

The study obtained the number of patents for cells (23,178), modules (6711), and packs (13,488).

Toyota’s Solid-State Battery Patents 

Toyota has 1,331 solid-state battery patents covering solid-state batteries or solid electrolytes, charging and charge protection, coatings, etc.

Biodegradable Batteries

In India, startups are harnessing biodegradable waste to power up EV batteries. For instance, 

• Nexus Power is developing biodegradable batteries using abundantly available materials in India. 
• Another startup, Hop Charge, aims to provide door-to-door charging services for EV owners. 
• Exponent Energy is providing rapid charging from 0-100% within 15 minutes through its batteries. 
• Cancrie, a four-year-old startup, is using coconut shell powder to enhance the efficiency of lithium-ion batteries.

End Note

Cobalt-free batteries present a promising solution for the future of electric vehicles. Tesla’s move towards lithium iron phosphate (LFP) batteries reflects a broader industry trend away from cobalt reliance. 

For example, Elon Musk’s commitment to eliminating cobalt further highlights the importance of this shift. Despite its utility in EV batteries, cobalt’s associated geopolitical and ethical challenges highlight the need for alternative solutions.