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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.

ORNL researchers have developed a new pressing method, shown as blue circle on right, that produces a more uniform solid electrolyte than the traditionally processed material with more voids, shown as gray circle on left. The material can be integrated into a battery system, center, for improved stability and rate performance. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

ORNL scientists found that a small tweak created big performance improvements in a type of solid-state battery, a technology considered vital to broader electric vehicle adoption.

Researchers at Oak Ridge National Laboratory discovered a tug-of-war strategy to enhance chemical separations needed to recover critical materials. Credit: Alex Ivanov/ORNL, U.S. Dept. of Energy

ORNL scientists combined two ligands, or metal-binding molecules, to target light and heavy lanthanides simultaneously for exceptionally efficient separation.

Researchers observe T-shaped cluster drives lanthanide separation system during liquid-liquid extraction. Credit: Alex Ivanov/ORNL, U.S. Dept. of Energy

Researchers at ORNL zoomed in on molecules designed to recover critical materials via liquid-liquid extraction — a method used by industry to separate chemically similar elements.

Researchers captured atomic-level insights on the rare-earth mineral monazite to inform future design of flotation collector molecules, illustrated above, that can aid in the recovery of critical materials. Credit: Chad Malone/ORNL, U.S. Dept. of Energy

Critical Materials Institute researchers at Oak Ridge National Laboratory and Arizona State University studied the mineral monazite, an important source of rare-earth elements, to enhance methods of recovering critical materials for energy, defense and manufacturing applications.

Oak Ridge National Laboratory’s Ramesh Bhave partnered with Momentum Technologies to develop a modular, scalable system for recycling scrap permanent magnets in e-waste. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Researchers at Oak Ridge National Laboratory and Momentum Technologies have piloted an industrial-scale process for recycling valuable materials in the millions of tons of e-waste generated annually in the United States.

Oak Ridge National Laboratory scientists are enhancing the performance of polymer materials for next-generation lithium batteries. Credit: Adam Malin/ORNL, U.S. Dept. of Energy

Researchers at Oak Ridge National Laboratory are using state-of-the-art methods to shed light on chemical separations needed to recover rare-earth elements and secure critical materials for clean energy technologies.

Batteries - The 3D connection

Oak Ridge National Laboratory researchers have developed a thin film, highly conductive solid-state electrolyte made of a polymer and ceramic-based composite for lithium metal batteries.

Salting the gears

Researchers at Oak Ridge National Laboratory proved that a certain class of ionic liquids, when mixed with commercially available oils, can make gears run more efficiently with less noise and better durability.

Tungsten tiles for fusion

Using additive manufacturing, scientists experimenting with tungsten at Oak Ridge National Laboratory hope to unlock new potential of the high-performance heat-transferring material used to protect components from the plasma inside a fusion reactor. Fusion requires hydrogen isotopes to reach millions of degrees.