In the early years of EVs just 15 years ago, the cruising range on a fully charged battery was about 150 to 200 kms. The battery capacities were smaller then and, of course, the technology was still in its infancy. This limited range created ‘range anxiety’ which deterred many people from considering an EV, fearing that they would be unable to find a charging station close enough when the battery pack was low.
Range anxiety is something the industry has worked hard to erase and with improving technologies – for the batteries as well as the vehicles themselves – the range has been getting longer and longer each year. A longer range not only means being able to go further confidently but also having peace of mind with more ‘reserve’ range available.
Recently, CATL (Contemporary Amperex Technology Co., Limited), a world leader in batteries, has come out with the world’s first LFP (lithium iron phosphate) battery that achieves a range above 1,000 kms with 4C superfast charging. The new battery, known as the Shenxing PLUS, is a follow-up to the Shenxing superfast charging battery that was unveiled in August 2023.
The 1,000-km range comes from many technological breakthroughs. The cathode of Shenxing PLUS is made with a granular gradation technology, which places every nanometer particle in the optimal position to achieve ultra-high compact density. The proprietary 3D honeycomb-shaped material is added to the anode, boosting the energy density while effectively controlling the volume expansion during charge and discharge cycles.
The single-piece casing, which is an industry first, optimizes the internal space utilization, allowing the Shenxing PLUS cells to reach an unprecedented energy density level.
At the system level, the Shenxing PLUS battery pack has a topological structure optimized on top of module-free CTP 3.0 technology, enhancing the packing efficiency by 7%. Through breakthroughs in materials and structure, the battery system’s energy density surpasses the 200 Wh/kg threshold for the first time, reaching 205 Wh/kg, making ranges over 1,000 kms a reality.
Aside from offering long range (which means less visits to the charging station), the Shenxing PLUS also recharges very quickly. Within 10 minutes, it is said to be able to take in enough energy for 600 kms of travel – which is just a bit longer than pumping a liquid fuel tank full from almost empty.
To achieve the quick charging speed, CATL engineers have used technologies such as fast lithium-ion conductive coating, the addition of transition metal elements, and new nanometer encapsulation, rendering smoother and more efficient energy transmission between cathode and anode materials.
CATL has expanded the overcurrent area and capacity of the terminals in the battery system to rapidly dissipate heat during high-current charging. In terms of BMS core algorithms, the company’s newly-developed AI polarization model can predict and control the charging current in real time, enabling faster and smarter energy replenishment.
CATL batteries are supplied to many global carmakers, including Tesla, and about half the new EVs sold in China use its batteries. Ford has also signed a licensing agreement with the company to make low-cost lithium-ion batteries by 2026 at its plant in Michigan using CATL technology. The involvement of a ‘foreign entity of concern’ (China being one of them) has caused controversy but CATL says ‘the project is still on track’.