US-based 24M Technologies introduced its ETOP technology, which integrates electrodes directly into the battery pack. The technology, which increases energy density by 50%, could enable cars with a 1,600 km range.
US-based 24M Technologies announced that its new battery design could allow electric vehicles to achieve 50% more range on a single charge without increasing the battery size.
ETOP Technology Increases Energy Density
The company introduced its “cell-free” Electrode-to-Pack (ETOP) technology, aiming to provide manufacturers with stronger, more cost-effective, and domestically produced batteries. This solution is being developed not only for electric vehicles but also for eVTOL aircraft and energy storage systems.
The ETOP technology, first announced in October 2023, eliminates the limitations of traditional cell and module designs by integrating electrodes directly into the battery pack.
In current manufacturing processes, battery packs and modules are created by assembling individual cells. However, this method introduces “inactive” materials that do not carry energy, such as the metal and plastic used in the cell casings. This older approach leads to wasted space, reduces energy efficiency, increases costs, and limits design flexibility.
24M’s ETOP technology fundamentally changes the battery production process and eliminates these issues. The technology completely removes the need for separate cells, modules, and unnecessary materials by integrating sealed anode/cathode pairs directly into the battery pack. This innovation enables the complete bypass of traditional cell structures in high-voltage systems and allows manufacturers to achieve the highest possible pack-level energy density across any chemistry type. This is because a larger portion of the battery consists only of active materials (the electrodes) that carry energy. In a traditional battery pack, electrodes occupy 30-60% of the volume, whereas with ETOP, this ratio can increase up to 80%.
The company states that this method greatly simplifies the production process and allows for manufacturing to begin with low capital investment. The sealing of the electrodes, stacking, connection, and closing of the pack can be integrated into the production line with a single machine.
24M claims that when the ETOP technology is combined with its other proprietary technologies—such as the Impervio separator for safety and the Eternalyte electrolyte which allows for fast charging down to -40 degrees Celsius—manufacturers can create cost-effective batteries capable of delivering a 1,600 km range.
The potential for a 1,600 km range in a car is a massive leap forward. Do you think a high range like this will soon become the new standard for premium electric vehicles?
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