New Battery Packs Save Money by Eliminating Cells and Modules

­A new technology from the Massachusetts-based 24M could dramatically lower the cost of battery packs by eliminating individual cells and modules.

By far, the most expensive single component of electric vehicles is the battery pack, and having to purchase a replacement can push the “break even point”, relative to gas-powered vehicles, much further out or make it a net loss.

So OEMs and automakers are constantly on the lookout for ways to reduce battery overhead, whether it’s bringing more of the production process under their own umbrella, sourcing cheaper key minerals, or changing the very structure of the batteries, themselves.

And 24M, backed by auto giant Volkswagen, is taking the latter approach.

At last week’s Japan Mobility Show in Toyko, 24M showed off what it deemed ETOP (Electrode-to-Pack) with electrodes packaged directly into the battery pack.

As 24M points out, “current lithium-ion battery cells have a large fraction of inactive, non-charge-carrying materials — supporting metals and plastics — within a cell’s casing. These inactive materials reduce module and energy density and add unnecessary expense and waste.”

But by eliminating unnecessary cell materials, 24M is able to achieve high energy density and save costs.

“24M ETOP will be a game-changer for electric mobility and energy storage systems because it delivers unmatched energy density,” said Naoki Ota, 24M President and CEO. “This innovative new battery technology is enabled by our Unit Cell technology and is reflective of what’s yet to come from 24M.”

And of course, Volkswagen recently took a 25% stake in 24M, giving Volkswagen access to 24M’s SemiSolid technology for its next-gen lithium-ion batteries.