The Key Players Overcoming Electric Vehicle Driving Range Limitations

By Owais AliReviewed by Laura ThomsonJul 23 2024

Electric vehicles (EVs) are a vital technology in the global fight against climate change, offering reduced emissions and improved sustainability in transportation. Despite these environmental benefits, the widespread adoption of EVs faces significant challenges, primarily due to their limited driving range. This article examines the current state of EV technology, focusing on range limitations and the key players working to overcome these obstacles.

Image Credit: Owlie Productions/Shutterstock.com

Environmental Challenges and Benefits of Electric Vehicles

Unlike traditional vehicles that burn fossil fuels, EVs operate on electricity, producing zero tailpipe emissions. This significant reduction in emissions helps combat climate change and enhances local air quality, contributing to healthier communities.^1,2

However, EVs also present environmental challenges. The production and disposal of batteries involve extracting raw materials such as lithium, nickel, and cobalt, which can have significant ecological impacts.

For example, lithium mining is a water-intensive activity requiring approximately 2 million tons of water per ton of lithium, and it can cause ground destabilization and biodiversity loss.

Improper recycling and disposal of EV batteries at the end of their lifecycle also harm the environment, with only approximately 5% of lithium-ion batteries being recycled. This highlights the need for improved recycling infrastructure and processes.

Manufacturing EV batteries generates significant CO₂ emissions, ranging from 3 to 16 tons per battery, depending on its size. However, these initial emissions are typically offset over the vehicle's lifetime through reduced operational emissions.³

Current Driving Range Challenges of Electric Vehicles

The driving range of an EV, which refers to the distance it can travel on a single charge, is a critical factor for consumer adoption. Despite advancements, many EVs offer limited ranges compared to traditional internal combustion engine vehicles. This limitation can be particularly challenging for long-distance travel or areas with inadequate charging infrastructure.

Several factors significantly influence EV driving range, including battery capacity, energy density, vehicle weight, efficiency, and extreme weather conditions.

Consumers often expect a driving range between 300 and 450 km, but achieving this consistently in real-world conditions remains a significant challenge. This uncertainty can deter potential buyers and slow market growth.^1,4

Recent Research and Company Developments in Driving Range

Panasonic and Sila Nanotechnologies: Silicon anode batteries

In collaboration with Sila Nanotechnologies, Panasonic is developing silicon anode batteries that could enable electric cars to achieve 500-mile ranges and recharge in just 10 minutes.

Sila has replaced graphite in conventional lithium-ion batteries with its Titan Silicon anode powder, consisting of nanostructured silicon particles. This innovation significantly increases battery energy density without requiring new manufacturing techniques.

Silicon anodes are approximately five times lighter than graphite and occupy about half the space when fully charged, paving the way for extended driving distances and faster charging times in EVs.⁵

BYD's Blade battery

Chinese automotive giant BYD is launching its next-generation Blade battery, developed by its subsidiary FinDreams. This battery promises significant improvements over current power packs.

The new Blade battery offers an energy density of 190 Wh/kg, making it 25% more efficient than existing lithium iron phosphate (LFP) batteries, potentially enabling EVs to reach up to 1000 km on the CLTC cycle with fewer cells or unchanged pack size.⁶

Toyota's advanced battery technology roadmap

Toyota has plans to establish a new battery electric vehicle factory, with production slated to begin in 2026. The company is advancing four next-generation batteries, featuring innovations in liquid and solid electrolytes.

The Performance battery, scheduled for debut in 2026, will extend driving ranges to over 800 km, while the subsequent High-Performance battery, anticipated for 2027/28, aims to achieve ranges exceeding 1000 km.

Toyota's solid-state lithium-ion batteries, targeted for commercial use by 2027/28, promise a 20% increase in driving range compared to the Performance battery and rapid charging times of 10 minutes or less for a 10-80% state-of-charge.⁷

QuantumScape's solid-state batteries

QuantumScape has reached a significant milestone, with its solid-state cell significantly exceeding the requirements in endurance tests. The solid-state cell completed over 1000 charging cycles, corresponding to a total mileage of over half a million kilometers, while retaining 95% of its capacity.

This development suggests that QuantumScape's solid-state cells could enable long ranges, quick charging, and minimal aging.⁸

Improved lithium-sulfur batteries

University of California researchers have innovated a new cathode material for solid-state lithium-sulfur batteries, enhancing self-healing and electrical conductivity capabilities. This breakthrough addresses significant challenges with sulfur cathodes, including structural degradation and poor electron conductivity during operation.

The improved cathode material has the potential to double the energy density of electric vehicles without adding weight, extending battery life and advancing solid-state lithium-sulfur batteries as a more viable and eco-friendly option.⁹

Lithium iron phosphate (LFP) batteries

Lithium iron phosphate (LFP) batteries dominate the Chinese electric vehicle market but have been less popular in North America, primarily due to their limited range. However, this trend is shifting as automakers like Our Next Energy (ONE) and Mitra Chem innovate with new LFP technologies.

Unlike the prevalent nickel-cobalt batteries, LFP batteries offer enhanced safety and durability, albeit with slightly lower energy density. For example, ONE's Aries II battery pack has achieved energy density parity with nickel-manganese-cobalt packs but at a 25% lower cost and without nickel or cobalt.

In collaboration with General Motors, Mitra Chem has refined LFP chemistries like lithium manganese iron phosphate (LMFP) using advanced simulations to optimize performance and reduce costs.

These developments signal a potential shift toward iron-based batteries in North American EVs by the mid-2020s, offering improved affordability and performance with technologies like cell-to-pack (C2P) architecture.¹⁰

Further Research Needed in Driving Ranges

Despite these advancements, further research is essential to overcome existing limitations in EV technology, including solid-state battery commercialization, improved fast-charging thermal management, efficient recycling methods, enhanced cold weather performance, cost reduction, long-term durability testing, increased energy density, and exploration of alternative materials like graphene and polymers for enhanced energy density.

Addressing these challenges demands ongoing interdisciplinary research combining materials science, chemistry, and engineering to push the boundaries of battery performance, sustainability, and affordability for widespread EV adoption.¹¹

Alternatives to Electric Vehicles

In addition to EVs, alternative clean transportation technologies also show promising advancements.

Hydrogen fuel cells, for instance, provide long ranges and quick refueling times, producing only water vapor as emissions. However, they face challenges in infrastructure development and overall energy efficiency. Hybrid vehicles combine the benefits of electric and conventional powertrains, offering improved fuel efficiency without range anxiety. However, they rely partially on fossil fuels and have more complex systems.

Advanced biofuels present an option that can utilize existing infrastructure while potentially being carbon-neutral. However, they face limitations in availability and may compete with food production.

While these technologies have merits, EVs offer a more practical and widely applicable solution for achieving sustainable transportation. Therefore, overcoming EV driving range limitations will be crucial for decarbonizing the transportation industry and transitioning to sustainable mobility.¹²

References and Further Reading

1. KV, S., Michael, L. K., Hungund, S. S., & Fernandes, M. (2022). Factors influencing adoption of electric vehicles–A case in India. Cogent Engineering, 9(1), 2085375. https://doi.org/10.1080/23311916.2022.2085375
2. Ramachandaran, S. D., Ng, H., Rajermani, R., & Raman, A. (2023). Factor Influencing Consumer's Adoption of Electric Car in Malaysia. TEM Journal, 12(4), 2603. https://doi.org/10.18421/TEM124-72
3. Martina Igini. (2023). Why Electric Cars Are Better for the Environment. https://earth.org/electric-cars-environment/
4. EVMarketsReports. (2023). Driving Range Is A Key Factor in Electric Vehicle Adoption. https://evmarketsreports.com/driving-range-is-a-key-factor-in-electric-vehicle-adoption/
5. Carlton Reid. (2023). Panasonic's New Powder-Powered Batteries Will Supercharge EVs. https://www.wired.com/story/panasonic-powder-powered-silicone-ev-batteries/
6. Mark Andrews. (2024). BYD's 2nd generation blade battery to launch this year. https://carnewschina.com/2024/04/08/byds-2nd-generation-blade-battery-to-launch-this-year/
7. Toyota. (2023). Toyota sets out advanced battery technology roadmap. https://media.toyota.co.uk/toyota-sets-out-advanced-battery-technology-roadmap/
8. Andreas Groß. (2024). PowerCo confirms results: QuantumScape's solid-state cell passes first endurance test. https://www.volkswagen-group.com/en/press-releases/powerco-confirms-results-quantumscapes-solid-state-cell-passes-first-endurance-test-18031
9. Zhou, J., Holekevi Chandrappa, M. L., Tan, S., Wang, S., Wu, C., Nguyen, H., ... & Liu, P. (2024). Healable and conductive sulfur iodide for solid-state Li–S batteries. Nature, 627(8003), 301-305. https://doi.org/10.1038/s41586-024-07101-z
10. Sam Abuelsamid. (2023). Lithium Iron Phosphate Set To Be The Next Big Thing In EV Batteries. https://www.forbes.com/sites/samabuelsamid/2023/08/16/lithium-iron-phosphate-set-to-be-the-next-big-thing-in-ev-batteries/
11. Raja, V. B., Raja, I., & Kavvampally, R. (2021, December). Advancements in battery technologies of electric vehicle. In Journal of Physics: Conference Series (Vol. 2129, No. 1, p. 012011). IOP Publishing. https://doi.org/10.1088/1742-6596/2129/1/012011
12. Shafiei, E., Davidsdottir, B., Leaver, J., Stefansson, H., & Asgeirsson, E. I. (2015). Comparative analysis of hydrogen, biofuels and electricity transitional pathways to sustainable transport in a renewable-based energy system. Energy, 83, 614-627. https://doi.org/10.1016/j.energy.2015.02.071

Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.