Engineers Garage

  • Electronic Projects & Tutorials
    • Electronic Projects
      • Arduino Projects
      • AVR
      • Raspberry pi
      • ESP8266
      • BeagleBone
      • 8051 Microcontroller
      • ARM
      • PIC Microcontroller
      • STM32
    • Tutorials
      • Audio Electronics
      • Battery Management
      • Brainwave
      • Electric Vehicles
      • EMI/EMC/RFI
      • Hardware Filters
      • IoT tutorials
      • Power Tutorials
      • Python
      • Sensors
      • USB
      • VHDL
    • Circuit Design
    • Project Videos
    • Components
  • Articles
    • Tech Articles
    • Insight
    • Invention Stories
    • How to
    • What Is
  • News
    • Electronic Product News
    • Business News
    • Company/Start-up News
    • DIY Reviews
    • Guest Post
  • Forums
    • EDABoard.com
    • Electro-Tech-Online
    • EG Forum Archive
  • DigiKey Store
    • Cables, Wires
    • Connectors, Interconnect
    • Discrete
    • Electromechanical
    • Embedded Computers
    • Enclosures, Hardware, Office
    • Integrated Circuits (ICs)
    • Isolators
    • LED/Optoelectronics
    • Passive
    • Power, Circuit Protection
    • Programmers
    • RF, Wireless
    • Semiconductors
    • Sensors, Transducers
    • Test Products
    • Tools
  • Learn
    • eBooks/Tech Tips
    • Design Guides
    • Learning Center
    • Tech Toolboxes
    • Webinars & Digital Events
  • Resources
    • Digital Issues
    • EE Training Days
    • LEAP Awards
    • Podcasts
    • Webinars / Digital Events
    • White Papers
    • Engineering Diversity & Inclusion
    • DesignFast
  • Guest Post Guidelines
  • Advertise
  • Subscribe

The challenge of optimizing battery designs

By Eileen Singh March 11, 2020

Battery developers face some difficult challenges when engineering these electrochemical cells. Depending on a battery’s use and application, such challenges include:

  • Energy & power density
  • Battery life
  • Costs
  • Sustainability

Modeling and simulation are two current methods that researchers and developers use to test and improve such issues. Optimization of each component of a battery and battery system — such as electrolyte, electrodes, and separator — can be accelerated using modeling and simulations. For example, Fiat Research Center applies mathematical modeling for studying thermal management of container cells for its hybrid vehicles.

Advancing the battery designs of the future will require a close look at each of these key elements…

Energy density is restricted by a battery’s chemistry and its design. The chemistry is defined by the electrode material and the structure of the electrolyte. For example, lithium-air batteries offer great potential for efficient-energy storage applications because of their extremely high theoretical energy density. However, there are still technical limitations to consider before their safe implementation, such as the components necessary for thermal management and battery weight.

Additionally, the power density of a battery is necessary for some applications, especially for the efficiency of electric vehicles. High-power density is needed when recapturing energy in a short period of time, such as through regenerative braking or fast recharging. This means the battery must cope with high current densities through recharge and relatively low current frequencies during discharge. Battery components, including the electrodes, separator, and electrolytes, are extremely important for power density.

Battery life is critical for optimizing applications and significant where safety and reliability are involved. Ideally, battery discharge, use, and failure should occur slowly and in a controlled and transparent process. Uneven current density distribution and inadequate control of the discharge and recharge cycles, as well as thermal management, may increase wear and increase the risks of failure. Short-circuits created by metal deposition can also decrease in productivity and increased runaway heating.

The operating capacity for a lithium-ion battery storage system, for example, is determined by the type of lithium-ion chemistry being used combined with the number of battery cells in the total battery bank. There are a lot of factors to consider.

Technologies for state-of-health monitoring are needed to continuously evaluate the state of the battery system and the chances of failure.

Costs for batteries have reduced considerably over the last decade. A report published by Bloomberg New Energy Finance (BNEF) late last year indicated that battery prices have dropped from $US1,100/kWh ($A1,609) since 2010, and should reach near $US100/kWh mark ($A146) by 2023. This is good news for the electric vehicle market because it means that EV costs will be on par with internal combustion engine vehicles.

According to Bloomberg, this is largely due to increasing order sizes but also because of the use of high-energy-density cathodes and improved pack designs.

However, manufacturing methods for high-power batteries are still relatively high. So, there is significant potential in productivity gains by large-scale manufacturing processes of the battery elements.

Sustainability has become a critical topic in the design of new batteries. There’s pressure, particularly, on the EV industry to figure out recycling and prevent unnecessary waste of batteries after their useful life. So, it’s important for manufacturers and governments to offer a plan for mining, recycling, producing, and disposing of new battery models where possible.


Filed Under: Batteries, Products, Tech Articles

 

Next Article

← Previous Article
Next Article →

Questions related to this article?
👉Ask and discuss on Electro-Tech-Online.com and EDAboard.com forums.



Tell Us What You Think!! Cancel reply

You must be logged in to post a comment.

EE TECH TOOLBOX

“ee
Tech Toolbox: 5G Technology
This Tech Toolbox covers the basics of 5G technology plus a story about how engineers designed and built a prototype DSL router mostly from old cellphone parts. Download this first 5G/wired/wireless communications Tech Toolbox to learn more!

EE Learning Center

EE Learning Center
“engineers
EXPAND YOUR KNOWLEDGE AND STAY CONNECTED
Get the latest info on technologies, tools and strategies for EE professionals.

HAVE A QUESTION?

Have a technical question about an article or other engineering questions? Check out our engineering forums EDABoard.com and Electro-Tech-Online.com where you can get those questions asked and answered by your peers!


RSS EDABOARD.com Discussions

  • Exporting sensor readings as data...
  • Inconsistent Charge Termination Voltage with battery charger
  • 21V keeps getting shorted to my UART line.
  • Voltage mode pushpull is a nonsense SMPS?
  • Voltage mode push pull with extra DC blocking capacitor

RSS Electro-Tech-Online.com Discussions

  • Is AI making embedded software developers more productive?
  • Why can't I breadboard this oscillator?
  • using a RTC in SF basic
  • Parts required for a personal project
  • Cataract Lens Options?

Featured – RPi Python Programming (27 Part)

  • RPi Python Programming 21: The SIM900A AT commands
  • RPi Python Programming 22: Calls & SMS using a SIM900A GSM-GPRS modem
  • RPi Python Programming 23: Interfacing a NEO-6MV2 GPS module with Raspberry Pi
  • RPi Python Programming 24: I2C explained
  • RPi Python Programming 25 – Synchronous serial communication in Raspberry Pi using I2C protocol
  • RPi Python Programming 26 – Interfacing ADXL345 accelerometer sensor with Raspberry Pi

Recent Articles

  • GigaDevice launches GD32C231 MCU series with 48MHz Cortex-M23 core and 64KB Flash
  • Advanced Energy releases 425 W CF-rated medical power supply in 3.5 x 6 x 1.5-inch format”
  • LEM combines shunt and Hall effect sensing in 2000 A current measurement unit
  • What is AWS IoT Core and when should you use it?
  • AC-DC power supply extends voltage range to 800 V DC

EE ENGINEERING TRAINING DAYS

engineering

Submit a Guest Post

submit a guest post
Engineers Garage
  • Analog IC TIps
  • Connector Tips
  • Battery Power Tips
  • DesignFast
  • EDABoard Forums
  • EE World Online
  • Electro-Tech-Online Forums
  • EV Engineering
  • Microcontroller Tips
  • Power Electronic Tips
  • Sensor Tips
  • Test and Measurement Tips
  • 5G Technology World
  • Subscribe to our newsletter
  • About Us
  • Contact Us
  • Advertise

Copyright © 2025 WTWH Media LLC. All Rights Reserved. The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media
Privacy Policy

Search Engineers Garage

  • Electronic Projects & Tutorials
    • Electronic Projects
      • Arduino Projects
      • AVR
      • Raspberry pi
      • ESP8266
      • BeagleBone
      • 8051 Microcontroller
      • ARM
      • PIC Microcontroller
      • STM32
    • Tutorials
      • Audio Electronics
      • Battery Management
      • Brainwave
      • Electric Vehicles
      • EMI/EMC/RFI
      • Hardware Filters
      • IoT tutorials
      • Power Tutorials
      • Python
      • Sensors
      • USB
      • VHDL
    • Circuit Design
    • Project Videos
    • Components
  • Articles
    • Tech Articles
    • Insight
    • Invention Stories
    • How to
    • What Is
  • News
    • Electronic Product News
    • Business News
    • Company/Start-up News
    • DIY Reviews
    • Guest Post
  • Forums
    • EDABoard.com
    • Electro-Tech-Online
    • EG Forum Archive
  • DigiKey Store
    • Cables, Wires
    • Connectors, Interconnect
    • Discrete
    • Electromechanical
    • Embedded Computers
    • Enclosures, Hardware, Office
    • Integrated Circuits (ICs)
    • Isolators
    • LED/Optoelectronics
    • Passive
    • Power, Circuit Protection
    • Programmers
    • RF, Wireless
    • Semiconductors
    • Sensors, Transducers
    • Test Products
    • Tools
  • Learn
    • eBooks/Tech Tips
    • Design Guides
    • Learning Center
    • Tech Toolboxes
    • Webinars & Digital Events
  • Resources
    • Digital Issues
    • EE Training Days
    • LEAP Awards
    • Podcasts
    • Webinars / Digital Events
    • White Papers
    • Engineering Diversity & Inclusion
    • DesignFast
  • Guest Post Guidelines
  • Advertise
  • Subscribe