Lithium Iron Phosphate Battery Packs
Lithium iron phosphate (LiFePO4) battery packs offer a number of advantages over other lithium ion chemistries. They have high-cycle life, fast charging and are safe.
However, they are less energy dense than their Nickel Cobalt Manganese Oxide cousins and aren’t able to deliver the same amount of range per cell. This has been one of the major factors that has inhibited widespread adoption of LFP battery chemistry.
Cost
LFP batteries are known for their low cost, which is one of the reasons why Tesla and other EV manufacturers are using them in Powerwalls and entry level models. However, the battery packs don’t offer the same level of efficiency and performance that NMC based battery packs do.
This is due to the fact that lfp batteries have a lower energy density than their NMC counterparts. This results in shorter driving range and a lower capacity for a given size of pack, making them less practical for longer-range EVs.
Although this is a disadvantage, it can be overcome by engineering innovations. For example, battery company Nano One is lowering the cost of cathode production by developing a one-pot process that reduces the complexity of making the cathode material and produces fewer toxic byproducts. It is also reducing the environmental footprint of battery production by avoiding waste and water consumption.
On a more positive note, LFP batteries have also been shown to be safe and durable. This is because they are less prone to thermal runaway. This means that they can be packaged more tightly into a prismatic form factor, which can significantly reduce the weight of the battery pack.
These advancements are paving the way for a wider adoption of LFP battery packs in EVs. In fact, BNEF predicts that average pack prices will drop below $100 per kwh in 2024, which will enable automakers to produce electric cars that achieve price parity with gasoline vehicles.
According to BNEF, the trend is likely to lfp battery packs continue. The organization has been tracking the lithium-ion battery market since 2010 and found that pack prices have dropped 89% in just over a decade.
This is a good thing for the industry, as it means that more consumers will be able to enjoy the benefits of EVs. Moreover, it will help accelerate the development of new battery chemistries, as well.
Another reason that lfp battery packs are cheaper than their NMC counterparts is because they don’t contain nickel or cobalt. These two are price-sensitive raw materials and can cause significant fluctuations in their price. This is why BNEF says that lfp batteries are becoming more and more popular amongst OEMs because they offer a low cost solution with little impact on the environment.
Energy density
Lithium iron phosphate (LFP) battery packs don’t have the same energy density as lithium ion batteries, but they still deliver plenty of range for electric vehicles. The energy density of LFP battery packs is typically 15 to 25 percent lower than other types of EV batteries, but this has started to change thanks to thicker electrodes and cell-to-pack designs, which integrate cells directly into the pack rather than using separate modules.
Another way to increase the energy density of an LFP battery is to use a 3D design. This can increase the number of active material and decrease the inactive materials, thereby increasing the electrical contact between the metal and the active material, which helps to improve battery performance.
A third way to increase the energy density of an LFP is to use a new cathode manufacturing process. One company, Nano One, has developed a one-pot battery cathode production process that reduces the cost and complexity of making cathode material while producing fewer toxic byproducts.
The process also uses less water and energy, which can help reduce the environmental impact of battery manufacturing. The result is an improved cathode quality and a higher-performance battery, which can provide more power and longer cycles than traditional batteries.
Despite these limitations, LFP battery packs are starting to gain popularity in the EV market. Several automakers, including Tesla, Rivian, and SVolt, are already incorporating these battery cells into their vehicles.
Other companies are also developing new EV technologies that will leverage this chemistry. For example, SVOLT recently introduced a new product category called the “short-blade” battery that is based on LiFePO4 chemistry and is expected to be produced by the third quarter of 2022.
This battery is expected to be able to last 4x longer than other EV battery types, which should provide more long-distance range for users. It also comes with a low weight and is more durable, which makes it suitable for applications that require durability and reliability.
While LFP battery packs haven’t reached the same energy density as lithium ion battery packs, they are becoming more popular and more affordable. This may lead to wider adoption in the EV market as more automakers look for ways to reduce the costs of batteries and rethink how they charge them, putting more value into convenience and range rather than price alone.
Safety
Battery packs are a vital part of modern transportation, but they also pose a safety threat. One of the biggest issues is thermal runaway, where one cell heats up so much that it causes a fire in its neighbors. For this reason, large power plants use special fire-safety equipment to prevent thermal runaway. But homes with battery packs — and even some battery-powered cars — aren’t equipped with the same tools.
This is why it’s crucial to understand the underlying working principles of lithium iron phosphate (LFP) batteries. The safety of a LIB is deeply dependent on its chemistry and material properties, the speed at which it generates and dissipates heat, and its tolerance to external forces.
The first level of protection comes from the shell casing, which provides a layer of thermal and mechanical protection that protects the battery cells. In addition, the casing must withstand pressure and vibration.
Another way to keep the cells safe is by designing them with good separators. These are the thin parts of a cell that separate it from other cells, protecting the battery from debris and ensuring that air doesn’t enter the battery system when it gets damaged.
Batteries that have poor separators are prone to internal failures, as the separators can become weakened due to exposure to moisture and rust. This can lead to a dangerous condition called electrolyte stress.
In addition to this, a poor separator can cause the cells to overheat and damage, which can cause fires. This is why it’s important to design a lithium iron phosphate battery with a high-quality separator.
The next level of protection comes from the cathode and anode materials, which protect the battery cells from corrosion. This is why it’s important to select a LIB with the best cathode and anode materials.
Lastly, the outer casing of a LIB is another vital safety component. This is why it’s important to choose a LIB with a durable, long-lasting outer casing.
LFP battery packs are safer than other types of batteries, which is why they’re increasingly popular in electric vehicles. They’re also cheaper and easier to manufacture than NMC batteries, making them a great choice for consumers looking to save money.
Range
There are several factors that impact battery pack range. They include energy density, the number of charge cycles and the ability to be charged to a 100% level regularly. However, the main determinant of a car’s battery pack range is the price per stored kilowatt hour.
The cost of lfp batteries is generally lower than nickel-cobalt chemistries, which is one reason why many automakers are moving to lfp technology. Compared to a NMC battery, a battery pack made with LFP will typically cost around 30% less to produce.
However, this lower cost comes at a price: The battery’s energy density isn’t as high, which translates to a shorter driving range, according to Abuelsamid. The issue is particularly significant in North America, where consumers are often concerned about the range of their electric vehicles.
This is because Americans are used to long road trips and SUVs, which often require large-capacity battery packs. lfp battery packs It’s also important to consider that cold weather affects the battery’s efficiency and performance, which can make it harder to get a long-distance range out of a battery pack.
Fortunately, this can be fixed by redesigning the battery pack to better optimize its energy density. Manufacturers are increasingly adopting prismatic design, which crams cells into a more compact frame. This reduces the amount of space that they take up, while also reducing the weight.
Another way to improve battery capacity is to cram more cathode material into the same volume of space. This can be achieved by using more than one cathode material or by rearranging the cells.
In addition to cramming extra cells, some manufacturers are also developing ways to increase the energy density of their batteries. For example, Nano One has developed a prismatic battery that packs more cells in a smaller volume than a traditional cylindrical battery.
A lot of this work is happening in China, where many of the world’s biggest EV makers are using lfp batteries. The country is a major producer of lithium hydroxide and lithium carbonate, the raw materials for battery production.
This supply deficit has pushed battery prices to record highs. The cost of raw materials for NMC, NMCA and LFP batteries is expected to rise by two-to-threefold over the next year, with a greater gap between the prices of NMC versus LFP chemistries.