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MagyarCALB unveils U-shape EV battery structure for higher 4680 or LFP cells energy density and 10-minute charging
The world's top EV battery makers have introduced innovative cell-to-pack (CTP) technologies that use the shells as part of the chassis structure. Tesla utilizes such a structural 4680 battery pack on the Texas-made Model Y in order to significantly cut costs with better volumetric energy density and way fewer welding points. The downside is that such CTP batteries are nearly impossible to repair, yet the production savings sees them installed in more and more vehicles.
The battery cell packaging innovations will continue, it seems, as the world's top 7 manufacturer of electric vehicle batteries - CALB - today announced another breakthrough for a further increase in energy density and charging speeds. CALB uses a new U-shape structure of cylindrical cells that increases shell conductivity by 50%.
"We have made a disruptive innovation to the structure of the cylindrical battery by introducing the 'U' type structure," said CALB's VP, and added that the reasons for the research were the longer flow path and poorer conductivity of current tabless batteries' steel shells.
The decrease in resistance and shorter flow path bring faster 6C charging speeds, or 10-minute sessions on a suitable charger.
The typical energy density of performance nickel batteries also increases to 300 Wh/kg, while that of affordable LFP cells goes up to 200 Wh/kg. For comparison, the tested energy density of Tesla's 4680 cells in the Model Y is 244 Wh/kg, while the Model 3's LFP battery made by CATL can reach about 160 Wh/kg.
CALB's new battery structure breakthrough would thus allow for a roughly 20% bump in energy density at the same footprint. What's equally important is that the U-style structure will be much cheaper to manufacture with 70% reduction in welding stations compared to the current tabless solutions.
CALB counts Honda and others among its EV battery clients, but it remains to be seen which makes and models will benefit from the new pack system first. CATL's cell-to-pack Quilin battery is already in mass production and will be launched on retail EVs this current quarter.
