Engineers at RWTH Aachen University in Germany performed detailed disassembly of Tesla and BYD batteries for studying their structural elements and performance characteristics. The research team works to complete the understanding of EV battery technology, which current public information fails to provide.
Electric vehicles depend on EV batteries as their most crucial and costliest component. Manufacturers reveal partial information about these critical battery characteristics even though they determine range, charging speed, and lifespan. The battery suppliers aim to restrict their design details from reaching competitors, according to Jonas Gorsch, who works as a research associate at RWTH Aachen.
The researchers analyzed the 4680 cell from Tesla alongside the Blade Cell from BYD because these companies lead the EV market across North America, Europe, and China and directly manufacture their battery cells. Their complete control enables them to enhance battery design for perfect vehicle integration.
The researchers discovered that both batteries lacked silicon anodes even though silicon has proven to enhance energy density. The companies employed laser welding to join thin electrode foils, as this manufacturing approach improves scalability while simplifying production.
The thermal characteristics of both batteries showed fundamental variations. BYD’s cells demonstrated better thermal management during identical charging sessions because they generated only half the heat output per volume compared to Tesla’s cells. The brands implemented different approaches to electrode sheet attachment, with BYD using laminated separator edges and Tesla utilizing a new material to bind electrode materials.
The research findings serve as an essential reference point for developing improved battery designs, according to Gorsch. The researchers have not examined mechanical stress on battery longevity but plan future studies on upcoming EV cell designs. The research efforts will likely produce EV batteries that are more efficient and have increased lifespan duration.
