Recent reports remind that the electric car batteries we have now are just an intermediary.

WITH electric cars, it all comes down to the battery – and with batteries, it all comes down to what’s next.

In which case, intriguing news from two quarters. First and most recently, there’s James Dyson. In opening up more fully about the promise about the Dyson car we’ll never see, the British magnate leaves impression that while it was doomed on cost, the cancelled seven-seater known only by its codename, N526, was at least showing huge potential in respect to operability. The promise of offering double the range of a Tesla Model X reminds of the potential from solid state battery technology that the car world is aiming to implement.

Speaking of those ‘T’ cars … the other figure of the moment is, of course, Mr Loony Tunes himself.

Accepting that it’s becoming increasingly obvious that not everything Elon Musk says can be trusted as fact, there’s still good reason to take genuine interest what he seems set to have to say on occasion of the ‘Battery Day’ that was supposed to occur today but has now been deferred to some time in June, and might now be staged over several days … and in Texas, rather than California. Welcome to Elon’s world, right?

Much like the “Autonomy Day” that happened last year, Tesla is planning to give presentations to investors, which are livestreamed, about its latest development in powertrain and battery technology. 

What’s getting pundits excited is the realisation of something Musk has long teased rivals and investors about – a low-cost, long-life battery.

Such a device is now said to be developed to the point where it is intended to insert into Tesla’s staple Model 3 sedan, albeit initially just in the cars coming out of the brand’s new plant near Shanghai whose function is to purely build stock for sale in China.

There is emergent evidence to suggest the new battery might be the breakthrough to bringing the cost of EVs in line with petrol cars, and allow EV batteries to have second and third lives in the electric power grid.

Tesla has made clear in the past of its desire to deliver batteries designed to achieve outcomes well beyond the capabilities of today’s types. That conceivably would easily outlast the usable life of a car then, having done so, enter a second-life as a powerwall home installation or integrated into a larger commercial undertaking, to fulfil Tesla's goal to achieve the status of a power company.

Recent reports say this has been jointly developed with China’s Contemporary Amperex Technology and deploys technology developed by Tesla in collaboration with a team of academic battery experts recruited by Musk. 

The batteries differ to today’s types by relying on innovations such as low-cobalt and cobalt-free battery chemistries, and the use of chemical additives, materials and coatings that will reduce internal stress and enable batteries to store more energy for longer periods.

According to reports, Tesla also plans to implement new high-speed, heavily automated battery manufacturing processes designed to reduce labour costs and increase production in massive “terafactories” about 30 times the size of the company’s sprawling Nevada “gigafactory” — a strategy telegraphed in late April to analysts by Musk.

Tesla is working on recycling and recovery of such expensive metals as nickel, cobalt and lithium, through its Redwood Materials affiliate, as well as new “second life” applications of EV batteries in grid storage systems, such as the one Tesla built in South Australia in 2017.

Reuters news agency reported exclusively in February that Tesla was in advanced talks to use CATL’s lithium iron phosphate batteries, which use no cobalt, the most expensive metal in EV batteries and also the most controversial ingredient, due to the associations with child labour being used in cobalt mining in the Congo, a primary source.

CATL also has developed a simpler and less expensive way of packaging battery cells, called cell-to-pack, that eliminates the middle step of bundling cells. Tesla is expected to use the technology to help reduce battery weight and cost.

Reports say CATL also plans to supply Tesla in China next year with an improved long-life nickel-manganese-cobalt battery whose cathode is 50 percent nickel and only 20 percent cobalt.

Tesla now jointly produces nickel-cobalt-aluminum batteries with Panasonic at a “gigafactory” in Nevada, and buys NMC batteries from LG Chem in China. Panasonic has declined to comment.

Taken together, the advances in battery technology, the strategy of expanding the ways in which EV batteries can be used and the manufacturing automation on a huge scale all aim at the same target: Reworking the financial arithmetic that until now has made buying an electric car more expensive for most consumers than sticking with carbon-emitting internal combustion vehicles. 

The cost of CATL's cobalt-free lithium iron phosphate battery packs has fallen below $US80 per kilowatt-hour, with the cost of the battery cells dropping below $US60/kWh, the sources said. CATL’s low-cobalt NMC battery packs are close to $US100/kWh.

The car industry cites that $100/kWh for battery packs is the level at which electric vehicles reach rough parity with internal combustion competitors. 

It was an inability to achieve anything like this that caused Dyson to axe his project. Indeed, in an interview with Britain’s ‘The Times’ newspaper, he was pretty frank about how the only figures that looked good for his car related to performance and range –  the same sort of get-up-and-go of a performance combustion engine SUV of similar size and almost 1000kms on a single charge.

Sounds tasty? Perhaps not so much given the car would have cost well over $300,000, Dyson has admitted. Hence why, after putting around $150 million into the gig – which he could afford (all this information comes from an interview he gave on occasion of topping Britain’s rich list, with an estimated value of $NZ3.2 billion) – he pulled the plug last October, by which stage they’d reached the point of having a running prototype – still unseen - plus styling concepts of the finished interior and Range Rover-ish exterior, both of which were shown off to media.

The whole point of the Dyson car was, of course, to show the potential of the proprietary solid state battery tech that is core to the inventor’s homeware products. The challenge of transferring this to an automotive product was huge, but the tests had been promising.

That range was a huge wow. Website Autoblog says that, assuming that the ultimate figure was based on Europe’s WLTP standards, it would have been an impressive jump from Tesla’s Model S’ 610km and almost doubling the long-range Model X’s 510 km (the latter also a seven-seater). 

There’s more. Current lithium ion batteries lose oomph more quickly when stressed  - which is what high speed driving does – and also operate most effectively in a narrow ambient temperature band; range drops off especially when it get icey outside.

Comment from Dyson suggests his car wasn’t so affected. He told ’The Times’ the model sustained great performance “even on a freezing February night, on the naughty side of 70mph (110kmh) on the motorway, with the heater on and the radio at full blast.”

Even though his batteries are more compact than current lithium ion cells, the weight issue wasn’t resolved: The car had an alloy body, yet still weighed 2.6 tons. Yet it could clock 0-100kmh in 4.8 seconds (about half a second more than the long-range Model X), with its top speed apparently reaching 200kmh (50kmh shy of the Model X’s). This is all coming from the twin 200kW electric motors rated with 400kW and 650Nm of torque.

Even though the Dyson car is no more, its spirit lives on. The founder said the 500-strong team are already working on various other projects, and that he is open to the idea of letting car makers tap into his company’s batteries, He’s not adverse to taking a second look at making cars again some day. But only if it becomes commercially viable.