Batteries that are more compact, more powerful and longer lasting promise to reduce the cost and increase the practicality of tomorrow’s hybrid-electric vehicles.

Researchers at Argonne National Laboratory (Argonne) near Chicago, Illinois, have for decades envisioned the car of the future, one that is fuel-efficient, high-performing, safe and affordable. Such advancements will be aided by patented innovations and ongoing work by scientists and engineers at Argonne, who are revolutionizing the lithium-ion batteries used in hybrid-electric vehicles. Argonne researchers are zeroing in on the materials used in electrodes, where fundamental improvements can make a significant impact. “Our research is addressing limitations of commercial lithium-ion materials on the market,” said Gary Henriksen, manager of Argonne’s Electrochemical Energy Storage Department, citing the relatively short life, high cost and safety issues associated with the current generation of batteries.

One new approach, patented by Argonne, involves a new family of composite cathode materials for lithium-ion batteries. Its research was funded by the U.S. Department of Energy’s (DOE) Vehicle Technology Program. The technology replaces a lithium cobalt oxide electrode with a new electrode that consists of a combination of lithium and manganese-rich mixed-metal oxides. The new composite electrodes are more stable and can be charged to higher voltages. “We can almost double the amount of energy out of the same volume or weight of cathode material,” Henriksen explained. These high-energy materials are being developed for use in plug-in hybrid-electric vehicles. Batteries that use these more stable composites are less prone to safety concerns, such as overheating and fires, which plague current lithium-ion batteries.

Argonne has developed different electrode materials for use in high-power batteries for conventional hybrid-electric cars. This technology promises to make the batteries more compact, more powerful, longer-lasting and safer. It also could drastically cut the cost of hybrid-electric vehicles for consumers.

Hybrid-electric vehicles currently on the market cost more than their gas-only counterparts. Plus, if gasoline prices are high, it would take years for consumers to recoup their extra investment. “If you can replace the battery with one that does the same job—but is smaller, more lightweight and less expensive—you can get your return on investment much more quickly,” Henriksen said.

Argonne’s patented work with composite cathode materials should hit the marketplace soon. In early 2008, Japan’s Toda Kogyo Corp. entered into an agreement with the lab to take the technology to Detroit, Michigan. Toda is gearing up to start production at a manufacturing facility not far from the auto hub.

Argonne licenses its advanced battery technologies on a nonexclusive basis. While it charges for these licensing rights, it’s a good deal for industry. Argonne has been working on advanced battery R&D for about 40 years and on advanced lithium-ion batteries for about 10 years. “About 10 or 15 years ago, Argonne started to grow a really strong team of people from whom this success has been derived,” said Mike Thackeray, group leader and Argonne Distinguished Fellow in the lab’s Battery Technology Department..

Currently, a team of about 35 scientists and engineers is spearheading the effort to build a better battery. Its lithium-ion battery research is funded by the DOE’s Vehicle Technology Program. Argonne’s approach is holistic, from basic research through engineering to testing complete battery systems. “We’re trying to cover the breadth—to take materials from their infancy to prototype production and into industry much faster,” Henriksen said.

Each time the United States faces an energy crisis, such as in the 1970s and more recently when gasoline prices topped $4 a gallon nationally, Argonne’s work receives new emphasis and attention. “Our number one goal is to reduce our dependence on oil,” said David Howell, acting team leader for Hybrid Electric Systems at DOE headquarters in Washington, D.C.

But the technologies developed at Argonne are positioned to spread beyond automotive batteries to consumer electronics such as cell phones and laptops, and the aerospace, defense and medical sectors. For example, more energy is needed for the ever-increasing array of features packed in sleek, lightweight cell phones. Argonne’s battery technology may help electronics makers meet those demands.

Argonne scientists predict their technology could migrate into broader electronics applications quickly. “We believe our materials could be available within the next couple of years,” Henriksen predicted. “Then it’s basically up to the industrial battery community to introduce them into their products.”