Carmakers race to develop ultra-fast EV batteries as charging times remain key barrier

The electric vehicle (EV) industry is poised for a major breakthrough as carmakers and startups accelerate efforts to develop ultra-fast-charging batteries, addressing one of the key obstacles to widespread EV adoption: long charging times.

Currently, charging an EV in the US can take anywhere from 20 minutes to over 50 hours, significantly longer than refuelling a petrol car, Caliber.Az reports via foreign media.

As a result, many potential buyers remain hesitant to switch to electric vehicles.

But recent developments in battery technology suggest that charging times could soon be slashed to under 10 minutes. Ramesh Narasimhan, Executive Vice President at battery startup Nyobolt, said such advancements could transform the customer experience, making EV charging as fast and convenient as refuelling a traditional vehicle.

"The transition from a 40-minute or hour-long charging session to one lasting just minutes will revolutionize the experience," Narasimhan told Business Insider.

In August, Chinese startup Zeekr unveiled new batteries for its 007 sedan, claiming they were the fastest-charging batteries in the world, able to reach 80% charge from 10% in just over 10 minutes. Meanwhile, Chinese battery giant CATL introduced its Shenxing Plus battery in April, which reportedly provides 600 kilometres of range after just 10 minutes of charging.

According to Rory McNulty, product director at Benchmark Mineral Intelligence, recent advances in battery chemistry and software design have enabled manufacturers like CATL to optimize their batteries for faster charging without compromising safety. "We are on the verge of introducing new materials that will charge even quicker," McNulty said.

Nyobolt, based in the UK, demonstrated its own prototype EV in June, where its battery charged to 80% in just 4 minutes and 37 seconds, providing a range of around 120 miles. Narasimhan expressed hopes that this technology will be integrated into passenger vehicles by the end of the decade.

Despite the promise of faster charging, challenges remain. Carmakers face a difficult choice between large, long-range batteries and smaller, fast-charging batteries with less range. Narasimhan highlighted the ongoing dilemma of balancing charging speed and energy density, with smaller batteries potentially lowering EV prices, which could increase affordability and drive adoption.

Charging infrastructure is another significant hurdle. To achieve the rapid charging speeds promised by new battery technologies, high-powered 350-kilowatt chargers are required. Currently, the US has approximately 30,000 charging ports capable of delivering such speeds. According to a study from the National Renewable Energy Laboratory, this number will need to grow to around 182,000 by 2030 to support the increasing demand for EVs.

"Charging infrastructure is the next frontier," McNulty said, warning that without an accompanying upgrade to charging networks, even the most advanced batteries will face limitations.

China, however, is leading the charge. The country dominates the global battery industry, with companies like CATL, BYD, and Zeekr at the forefront of developing batteries with faster charging times and longer ranges. Andy Palmer, former executive at Aston Martin and Nissan, described China’s battery industry as "10 years ahead" of its Western competitors, aided by government subsidies and a robust manufacturing infrastructure.

The rapid expansion of China's EV market and charging infrastructure is seen as a key factor in its dominance. Cosimo Ries, analyst at Trivium China, noted that fast chargers are now ubiquitous across major cities. "The charging-infrastructure bottlenecks that were a problem a couple of years ago are no longer an issue," Ries said.

As competition intensifies in China’s EV market, manufacturers are under pressure to reduce charging times and lower prices. Ries believes that faster charging will soon become standard in even mid-tier and lower-end models, bringing the industry closer to the long-awaited goal of five-minute charging.

With China leading the charge, the global shift toward ultrafast EV batteries appears imminent, but the race to build a fast-charging network capable of supporting them is only just beginning.

By Aghakazim Guliyev