In search of the perfect battery

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: When General Motors (GM) launched the EV1, a sleek electric vehicle, with much fanfare in 1996, it was supposed to herald a revolution—the start of the modern mass-production of electric cars. At the heart of the two-seater sat a massive 533 kg lead-acid battery, providing the EV1 with a range of about 110 km. Many people who leased the car were enthusiastic, but its limited range, and the fact that it took many hours to recharge, among other reasons, convinced GM and other carmakers that had launched all-electric models to abandon their efforts a few years later.

Yet today about a dozen firms are once again developing all-electric or plug-in hybrid vehicles capable of running on batteries for short trips. Toyota’s popular Prius hybrid, by contrast, can travel less than a mile on battery power alone. Tesla Motors of San Carlos, California, recently delivered its first Roadster, an all-electric two-seater with a 450 kg battery pack and a range of 350 km between charges. And both Toyota and GM hope to start selling plug-in hybrids as soon as 2010.

So what has changed? Aside from growing concern about climate change and a surge in the oil price, the big difference is that battery technology is getting a lot better. Rechargeable lithium-ion batteries, which helped to make the mobile-phone revolution possible in the past decade, are now expected to power the increasing electrification of the car. “They are clearly the next step,” says Mary Ann Wright, the boss of Johnson Controls-Saft Advanced Power Solutions, a joint venture that recently opened a factory in France to produce lithium-ion batteries for hybrid vehicles.

According to Menahem Anderman, a consultant based in California who specialises in the automotive-battery market, more money is being spent on research into lithium-ion batteries than all other battery chemistries combined. A big market awaits the firms that manage to adapt lithium-ion batteries for cars. Between now and 2015, Anderman estimates, the worldwide market for hybrid-vehicle batteries will more than triple, to $2.3 billion. Lithium-ion batteries, the first of which should appear in hybrid cars in 2009, could make up as much as half of that, he predicts.