Ford Claims Breakthrough in Battery Tech for More Affordable, Longer-Range Electric Vehicles

Ford Motor Company stated they are nearing the ability to provide consumers with more cost-effective and higher-mileage electric cars due to an advancement in their battery tech. However, the statement provided few specifics, causing skepticism among several industry analysts.

On April 23, Charles Poon, who leads electrified propulsion engineering at Ford, revealed that the company based in Dearborn intends to introduce more affordable electric vehicles with extended range per charge by the end of this decade due to advancements in their new battery cell technology.

"This day represents a crucial point in Ford’s path toward electrification and the broader future of electric vehicles," as stated by Poon. LinkedIn post After extensive research and development at our advanced Battery Center of Excellence located in Ion Park (Romulus), I am excited to announce that the Ford team is introducing an innovative battery chemistry: Lithium Manganese Rich (LMR). This breakthrough is not confined to laboratory settings; we are currently focused on scaling up the production of LMR cells with plans to incorporate them into our upcoming vehicle models before the end of the decade.

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Poon mentioned that the Ford team has already started manufacturing its second-generation LMR cells at their pilot facility.

However, experts noted that lithium manganese batteries aren't novel. The initial model of the Chevrolet Volt utilized cells featuring manganese spinel cathodes, as stated by Sam Abuelsamid, who serves as the vice president for market research at Telemetry Insights. He explained that "spinel" denotes a particular kind of three-dimensional molecular arrangement.

Abuelsamid mentioned that there are also other types of battery constructions, adding further clarification. Our Next Energy A battery start-up located in Novi is working on manganese-based cells along with the Gemini hybrid battery pack. The Gemini system, which aims to extend the range of electric vehicles twofold, utilizes dual-cell technology—employing a lithium iron phosphate cell for regular use and an anode-free cell for extended journeys.

The significant benefit of manganese lies in its abundance, affordability, and stability (unlike nickel compounds, it does not easily undergo thermal runaway)," Abuelsamid stated via email to the Free Press. "However, certain types of manganese-based cells may have a shorter lifespan," he added.

LMR is an answer

A representative from Ford, Emma Bergg, explained to the Free Press that although numerous firms have explored Lithium-Metal-Replacement (LMR) technology, this approach faces hurdles related to voltage decline and gas production. The distinctive aspect of Ford’s LMR advancement lies in tackling these problems without compromising energy density, as stated in her emailed response.

Abuelsamid mentioned that manganese batteries exhibit a limited lifespan when charging cycles are considered. However, Ford hinted at having discovered a potential solution for this issue; nonetheless, Ford refrained from elaborating on the specifics of their method.

Sam Fiorani believed that the clarification indicated advancement rather than a significant breakthrough.

"Addressing the issue head-on doesn’t seem like they've discovered a final answer, but instead indicates progress and efforts moving towards a potential future resolution,” said Fiorani, who serves as the vice president of global vehicle forecasting at AutoForecast Solutions, to the Free Press.

In his posting, Poon mentioned that Ford’s LMR battery technology could bring about a "significant improvement" by offering EVs increased safety and stability similar to what lithium iron phosphate batteries provide, along with greater energy density compared to advanced high-nickel batteries, thus enabling a longer driving range per charge.

Poon mentioned that Ford aims for a considerably reduced cost compared to today’s mid-nickel batteries, aiming to make electric vehicles more affordable. Since batteries account for at least one-third of an EV's total cost, Ford sees decreasing these expenses as essential to reaching price equality with conventional gas cars.

Poon noted that Ford initially provided nickel cobalt manganese batteries before introducing lithium iron phosphate batteries in 2023. LMR represents the response to 'what comes after?'

But battery technology for EVs is in its infancy compared with the development of internal combustion engines, said Fiorani.

Fiorani stated that we can expect numerous enhancements over the next few years and decades as the automotive sector is now concentrating on this technology.

He mentioned that initiatives like LMR batteries should not be dismissed since they indicate potential in establishing electric vehicles as viable alternatives to gas-powered cars, which could result in widespread acceptance of EVs. However, he remains cautious until more information is provided by Ford.

As with many of the advancements reported over recent years, LMR still has limitations and doesn't seem to be the ultimate solution we're hoping for right now," Fiorani stated. "Overcoming issues related to voltage decline and limited battery lifespan are significant obstacles to tackle.

Reducing cobalt usage lowers expenses, involves child labor

Currently, Ford’s electric vehicle range encompasses the Mustang Mach-E, the F-150 Lightning pickup, and the E-Transit van. During the initial three months of the year, Ford reported It sold 22,550 all-electric vehicles, marking an 11.5% rise compared to the same time last year.

Bill Ford, who leads the chairmanship of Ford, has consistently promoted the idea of making electric vehicles more affordable. In January at the Detroit Auto Show, Bill Ford stated that the company is putting significant effort into reducing the cost of electric vehicles since increasing their affordability will act as "a key driver for broader acceptance."

Ford's announcement follows this. New York Times reported On Monday, China's CATL — the leading provider of batteries for electric vehicles globally — announced significant advancements enabling them to produce cost-effective, lightweight batteries that can recharge rapidly and withstand colder temperatures, all while enhancing driving distance. According to CATL, these improvements won’t be broadly implemented in upcoming electric vehicles for another few years. However, their innovative system promises drivers could soon achieve a charging time as short as five minutes, yielding sufficient power for up to 320 miles of travel.

David Whiston, an auto industry analyst atMorningstar, informed the Free Press that Ford’s recently disclosed advances in battery cell technology could diminish or remove the necessity for cobalt—a costly mineral frequently extracted through child labor, thereby raising ethical concerns.

Whiston acknowledged that he isn't a specialist in battery chemistry, yet he mentioned that LMR batteries utilize more common elements instead of cobalt for their cathodes, making it simpler and less expensive to obtain LMR materials.

Jamie L. LaReau serves as the senior automotive journalist covering Ford Motor Company for the Detroit Free Press. You can reach Jamie at jlareau@freepress.com . Keep up with her on Twitter @ jlareauan . To register for our service autos newsletter . Become a subscriber .

The article initially appeared in theDetroit Free Press. Ford said it's made a breakthrough in battery tech to make cheaper EVs with longer range