Building Batteries that don't Break in the Cold

­Extreme winter weather can strain power systems, stall electric vehicles and leave backup batteries unable to deliver energy when it is most needed. Researchers at Texas A&M University have developed a battery design that continues operating through the coldest conditions.

The team, led by Dr. Jodie Lutkenhaus, professor of chemical engineering and associate dean for research in the College of Engineering, published findings on a polymer-based battery in the Journal of Materials Chemistry A.

A battery designed for subzero conditions

Lutkenhaus said battery performance suffers in cold weather because conventional batteries contain a liquid electrolyte that transports the charge. “If that electrolyte freezes, then charge can no longer be transported. Hence, the battery will not charge or discharge.

“We saw exactly this issue in the cold snap in Chicago in 2024, where electric vehicle batteries were so cold and frozen that they did not charge at their powering stations,” she said.

The team’s new battery design is capable of maintaining functionality in temperatures as low as 40 degrees below zero.

“We’re able to do this because we replace the liquid electrolyte that freezes with a different electrolyte that does not. We also replace the hard inorganic materials that are sluggish at low temperatures with soft polymer materials that are a bit faster,” Lutkenhaus said.

The researchers created an organic dual‑ion battery that uses redox‑active polymers instead of the inorganic electrode materials found in most commercial batteries. They combined these polymer electrodes with a diglyme‑based low‑temperature electrolyte, which remains fluid and conductive at temperatures where conventional electrolytes begin to crystallize.

As a result, the battery maintained 85% of its capacity at 0 degrees C (32 F) and 55% at minus 40 C (minus 40 F), while sustaining high specific power rates.

Why batteries fail in the cold

Battery chemistry relies on the movement of ions through an electrolyte; as temperatures drop, this motion slows dramatically.

With their new battery design, the team avoided such collapse by pairing the low‑temperature electrolyte with soft polymer electrodes, which remain flexible and maintain electrochemical activity even as the system cools. “Hard inorganic materials are often slow at low temperatures, but soft polymer materials can move ions more easily,” she said.

“When you use materials that naturally tolerate the cold, the battery doesn’t have to fight its own chemistry.”

Carbon fiber boosts strength and stability

The researchers also tackled mechanical durability, another factor that limits battery performance in demanding environments. Instead of using metal current collectors — which can add weight and crack under stress — the team incorporated carbon‑fiber weaves. These reinforced the battery while still conducting charge effectively.

The result is a “structural battery,” one that stores energy and simultaneously provides mechanical strength. Such dual‑function designs can be advantageous in electric vehicles, drones or any system where weight and structural integrity matter. “Mechanical stress can damage a battery over time,” Lutkenhaus said. “By building batteries that act as part of the structure, we can reduce weight and improve durability at once.”

A step toward cold‑resistant energy storage

Reliable, low‑temperature performance could impact systems from personal electronics to critical infrastructure.

“With a massive storm or cold snap, electrical grids can go down. Batteries can cover those outages and gaps,” Lutkenhaus said. “If we want an energy system that’s resilient in all seasons, we need storage that isn’t vulnerable to temperature swings.”

While still in the research stage, the battery demonstrates how material innovation can overcome longstanding performance limits.

Lutkenhaus said the work points toward a future where energy storage is more dependable during extreme weather. In the meantime, she provides some practical advice: “If you’re concerned about your electric vehicle or your off-grid battery, I suggest moving it inside, keeping it a little warmer in your garage and not exposing it to the elements, so it won’t freeze.”