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Caption: Jaswinder Sharma makes battery coin cells with a lightweight current collector made of thin layers of aligned carbon fibers in a polymer with carbon nanotubes. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Electric vehicles can drive longer distances if their lithium-ion batteries deliver more energy in a lighter package. A prime weight-loss candidate is the current collector, a component that often adds 10% to the weight of a battery cell without contributing energy.

2023 Battelle Distinguished Inventors

Four scientists affiliated with ORNL were named Battelle Distinguished Inventors during the lab’s annual Innovation Awards on Dec. 1 in recognition of being granted 14 or more United States patents.

ORNL researchers Lu Yu and Yaocai Bai examine vials that contain a chemical solution that causes the cobalt and lithium to separate from a spent battery, followed by a second stage when cobalt precipitates in the bottom. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Used lithium-ion batteries from cell phones, laptops and a growing number of electric vehicles are piling up, but options for recycling them remain limited mostly to burning or chemically dissolving shredded batteries.

An electromagnetic pulse, or EMP, can be triggered by a nuclear explosion in the atmosphere or by an electromagnetic generator in a vehicle or aircraft. Here’s the chain of reactions it could cause to harm electrical equipment on the ground. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

Researchers at ORNL have been leading a project to understand how a high-altitude electromagnetic pulse, or EMP, could threaten power plants.

Sam Hollifield displays a prototype of the Secure Hijack, Intrusion and Exploit Layered Detector, or SHIELD, the device monitoring the cybersecurity of the semi-truck. Credit: Lena Shoemaker/ORNL, U.S. Dept. of Energy

As vehicles gain technological capabilities, car manufacturers are using an increasing number of computers and sensors to improve situational awareness and enhance the driving experience.

ORNL’s additive manufacturing compression molding, or AMCM, technology can produce composite-based, lightweight finished parts for airplanes, drones or vehicles in minutes and could acclerate decarbonization for the automobile and aeropsace industries. 

An Oak Ridge National Laboratory-developed advanced manufacturing technology, AMCM, was recently licensed by Orbital Composites and enables the rapid production of composite-based components, which could accelerate the decarbonization of vehicles

ORNL’s David Sholl is director of the new DOE Energy Earthshot Non-Equilibrium Energy Transfer for Efficient Reactions center to help decarbonize the industrial chemical industry. Credit: Genevieve Martin, ORNL/U.S. Dept. of Energy

ORNL has been selected to lead an Energy Earthshot Research Center, or EERC, focused on developing chemical processes that use sustainable methods instead of burning fossil fuels to radically reduce industrial greenhouse gas emissions to stem climate change and limit the crisis of a rapidly warming planet.
 

Benefit breakdown, 3D printed vs. wood molds

Oak Ridge National Laboratory researchers have conducted a comprehensive life cycle, cost and carbon emissions analysis on 3D-printed molds for precast concrete and determined the method is economically beneficial compared to conventional wood molds.

ORNL researcher Zhijia Du inserts a newly developed liquid electrolyte material into a battery pouch cell. The formulation extends the life of extreme-fast-charging batteries like those used in electric vehicles. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory researchers are taking fast charging for electric vehicles, or EVs, to new extremes. A team of battery scientists recently developed a lithium-ion battery material that not only recharges 80% of its capacity in 10

ZEISS Head of Additive Manufacturing Technology Claus Hermannstaedter, left, and ORNL Interim Associate Laboratory Director for Energy Science and Technology Rick Raines sign a licensing agreement that allows ORNL’s machine-learning algorithm, Simurgh, to be used for rapid evaluations of 3D-printed components with industrial X-ray computed tomography, or CT. Using machine learning in CT scanning is expected to reduce the time and cost of inspections of 3D-printed parts by more than ten times.

A licensing agreement between the Department of Energy’s Oak Ridge National Laboratory and research partner ZEISS will enable industrial X-ray computed tomography, or CT, to perform rapid evaluations of 3D-printed components using ORNL’s machine