Feature: Batteries
Understanding today’s diverse battery landscape
By Joseph Notaro, Chief Revenue Officer, Dukosi W
ith the rapid evolution of battery technology, what is the current landscape of
battery cell design, application, and next- generation innovations? Te battery landscape today is
exceptionally diverse, driven by the specific needs of a wide variety of applications across automotive, industrial and consumer markets. From the compact cylindrical cells used in power tools and smaller vehicles like e-bikes, to larger prismatic and pouch cells found in consumer electric vehicles (EVs), industrial vehicles, and stationary battery energy storage systems (BESS). Each application today has specific cell requirements, and yet there’s still many more to come that can benefit from electrification. Broadly speaking, cylindrical cells are
oſten used in batteries for their ease of manufacturing, cost, and mechanical robustness, while pouch cells can offer superior energy density for applications with strict weight and size constraints. However, an application not only impacts
the preferred cell type but also the areas of performance that battery designers prioritize. Automotive batteries for consumer EVs generally need to find a balance between range, safety, and cost, but some applications, such as the newer EV variants that are appearing in agricultural and mining operations, will need to bias towards peak robustness due to the usage patterns and harsh environments they experience. Alternatively, BESS installations supporting renewable energy production will prioritize long life cycles, cost-efficiency, and ease of
maintenance over compactness or weight. New battery designs are also transforming
the vehicle-cell dynamic. Tese include innovative architectures such as cell-to- pack (CTP), which removes the need for intermediate modules, and cell-to-chassis (CTC), which embeds cells directly into the vehicle’s core chassis for even further space and weight optimisation. In both cases, the aim is to increase design flexibility, integration, energy density, and potentially simplify production.
Could you compare how the specific requirements of different applications influence the design and management of high-voltage batteries in automotive and industrial settings? High-voltage, high-power batteries are
central to electrification in both automotive and industrial settings, but their design and management do differ due to the unique requirements of each sector. As mentioned before, automotive
applications balance efficiency, safety, and range, necessitating batteries that can support long-distance travel and fast charging, with battery weight being a key consideration. To streamline production and manage costs, passenger EVs require modular battery platforms capable of capacities ranging typically from around 40 kWh to 100 kWh. However, the ongoing trend of upgrading battery system voltage from 400V to 800V to enhance charging speeds and reduce energy losses is introducing new design complexities. In automotive battery management, safety is of utmost importance, but factors like streamlined integration and enhanced operation efficiency are also critical.
Larger industrial and commercial EV
applications, however, must manage higher peak loads and more sustained operation, while frequently operating in challenging environments with high temperatures or continuous vibrations. Terefore, battery robustness and overall capacity are key. Tis second element is especially crucial and affects the applications that can currently be addressed by industrial EVs. For example, while the world’s biggest electric construction excavators weigh around 26 tons and use batteries of around 300 kWh, large mining vehicles can easily reach up to 1000 tons, far beyond the limits of today’s batteries. In order to meet the demands of vehicles working in harsh environments as well as larger vehicle types, the manufacturing of larger batteries needs to be simplified, while energy density and efficiency optimised. In BESS applications, like those
supporting renewable energy deployments, high-power batteries prioritise energy density, longevity and thermal stability. Unlike automotive or industrial systems, BESS designs are less constrained by weight or size, enabling the use of larger-format prismatic cells, which can help to reduce design complexity and enhance durability. Nevertheless, challenges persist in guaranteeing the safety and maintainability of the system, mandating comprehensive sensing and battery monitoring to identify issues such as cell-level imbalances and to optimize energy distribution across battery packs for enhanced longevity and reliability. Despite their differences, all three
markets will benefit from any technology that can enhance key performance metrics while improving production
www.electronicsworld.co.uk June 2025 15
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