​​​​​​​Electric Vehicle Battery Cell Types

To help keep up with national and international regulations regarding carbon emissions, automakers are phasing out the use of full internal combustion engines and designing and building electric vehicles (EVs). These vehicles include sedans, SUVs, trucks, and commercial vehicles that are hybrid, plug-in hybrid, or all-electric. A key component of any type of EV is the battery pack. The battery stores power to run the car in an all-electric range, and it's essential that the vehicle has the correct type of battery with the proper battery cell configuration.

At Chalmers Ford in Rio Rancho, New Mexico, we sell several EVs, including the popular all-electric Ford Lightning pickup truck and the Ford Mustang Mach-E SUV. With this comprehensive guide to EV batteries, you'll gain knowledge of the different types of EV batteries used to power these popular cars.

What Is an EV Battery?

An EV battery stores and sends out high-voltage energy required to run an EV. This type of battery is made up of cylindrical cells, pouch cells, and prismatic cells. Each type of cell structure functions differently and is designed for specific driving uses. EV battery cells consist of two main components known as electrodes: the cathode, which is the positive terminal, and the anode, which is the negative terminal. Lithium ions are charged with an electrolyte fluid found within the cell structures and flow back and forth between the electrodes to keep the battery charged. 

Various raw materials, including cobalt, graphite, nickel, and aluminum, make up the base of EV batteries. These minerals need to be mined, treated, and processed correctly, and the remnants must be stored or disposed of properly to create a sustainable EV industry.

Types of EV Batteries and Types of Battery Cells

The most common type of EV battery is the lithium-ion battery used in hybrid, plug-in hybrid, and all-electric vehicles. However, with advancements in EV battery technologies, we're starting to see different types of EV batteries with longer life spans and improved efficiency. 

Lithium-Ion Batteries and Their Cell Structures

Lithium-ion batteries can come with any of the cell structures we discuss in this article, with similarities and differences for specific applications.

Cylindrical Cells

Cylindrical cells make up the majority of battery cell types. They're affordable to make, versatile for various all-electric uses, and have high-energy density for longer all-electric driving ranges. These cylindrical cells are housed in a metal container with the cathode and anode electrodes and filled with lithium-ion electrolytes. Cylindrical cells are best suited for smaller battery applications and use in warmer weather.

Pouch Cells

As the EV industry evolves, designers of battery cells are creating advanced technologies to help increase battery ranges and efficiency. Like cylindrical cells, pouch cells have cathode and anode electrodes, but they also have a soft pouch filled with lithium-ion electrolytes between the cells. The softness and flexibility of pouch cells allow them to be shaped into various sizes, which is particularly beneficial for small EVs and tight spaces. Pouch cells are slightly more expensive to produce and aren't ideal for large vehicles or applications.

Prismatic Cells

Prismatic cell architecture is best for large EVs, such as commercial buses, trucks, and cargo vans. These cells are built larger to scale than pouch or cylindrical cells, and the electrode stack is encased in aluminum. The lithium-ion electrolytes are sealed in the aluminum casing and then shaped into the specific size needed. Prismatic cells have the highest density output for long-range all-electric driving. However, they're more expensive to make.

Nickel-Metal Batteries for Hybrids

Because hybrids use a combination of battery storage, electric motors, and an internal combustion engine, many hybrid and plug-in hybrids use nickel-metal batteries. These batteries generally last longer than lithium-ion ones and are safer to use. Nickel-metal batteries are expensive to make, which is a limiting factor for lower-cost EV manufacturers.

Solid State Batteries

Though still in the early stages of EV battery development, solid-state batteries may replace lithium-ion and nickel-metal batteries in the future. A solid-state battery has no cell structures and uses a solid electrolyte for the charge rather than the liquid found in other types of EV batteries. Due to their design and structure, they're more compact, taking up less room in a vehicle. Solid-state batteries also have longer driving ranges, which is an appealing feature for EV owners who want to drive more before recharging.

Benefits and Considerations of Each EV Battery

EV batteries have a set life expectancy, with lithium-ion ones needing replacement after 10 to 12 years. Where do these old batteries go? Can they be recycled or repurposed? Some components of EV batteries can be recycled by specialized reclaimers, and those metals and parts are often reused. Some EV batteries may not be suitable for long driving ranges needed in an EV, but they could find a new purpose for simple battery storage.

As more companies begin manufacturing EVs, the need for raw materials increases. Mining for minerals is costly, and the mines impact the environment. With advancements in EV batteries extending their life span, there'll be less need to mine raw materials and build recycling centers dedicated to the art of carefully dismantling old batteries.

At this stage, EV owners don't have a choice as to what type of battery their vehicle comes with. It's up to automakers to continue researching and designing more environmentally friendly EV batteries with long driving ranges and life spans to ensure the sustainability of the EV industry.

View Our EV Inventory at Chalmers Ford

We understand the importance of EVs, and we carry the all-electric Ford F-150 Lightning pickup truck, the Mustang Mach-E SUV, and the Ford E-Transit Cargo Van for small business owners. We invite you to view our inventory of EVs and internal combustion engine vehicles and order the one you need. Be sure to check out our vehicle specials for extra savings, apply for financing for your new EV, and schedule auto service to keep your vehicle in top condition. Contact us at Chalmers Ford in Rio Rancho, New Mexico, to learn more about EV battery types.

Image by Roberto Sorin | Licensed with Unsplash License