New Technology Drives Start-Stop Battery Innovation

The Rise of Start-Stop Systems

Automakers have rapidly adopted start-stop systems in recent years as a way to improve vehicle fuel efficiency and reduce emissions. This technology automatically shuts off the engine when the vehicle comes to a complete stop, such as at a red light or stop sign, and instantly restarts it when the brake is released or the clutch is engaged. It can deliver fuel savings of 5-10% for typical daily driving patterns according to the U.S. Department of Energy. As the systems have become more widely used, it has driven new innovation in starter battery technology to meet more stringent performance demands.

Meeting Higher Performance Requirements

Start-Stop Battery Technology is used for start-stop applications have much higher performance requirements compared to conventional starter batteries. They must be able to reliably deliver short bursts of very high current upwards of 400-800 amps around town driving, as well as withstand frequent charge-discharge cycling that occurs with each automatic engine start and shutoff. Lead-acid batteries were initially used but have limitations for this application. Advanced flooded and absorbed glass mat (AGM) lead-acid batteries addressed some issues but still fall short of ideal characteristics. New lithium-ion battery designs are emerging as a promising alternative able to meet stringent OEM technical specifications.

Lithium-Ion Batteries Gain Traction

Lithium-ion battery technology has seen rapid gains in popularity for use in start-stop systems due to its superior power handling capability and cycle life performance compared to lead-acid options. It can deliver and sustain very high currents over 1,000 amps required for robust engine cranking. Lithium batteries also have a flat discharge voltage profile, maintaining power right until they are almost drained unlike lead-acid which suffers from output dropoff as it discharges. This translates to consistent starting ability even late in the battery’s life. Cycle life tests have shown some lithium designs can withstand over 3,000 charge-discharge cycles which exceeds typical lead-acid battery lifespan.

Factors Affecting Battery Selection

When automakers are choosing a starter battery technology for forthcoming vehicle platforms with start-stop, there are several factors under consideration. Upfront battery cost is important but longer-term total cost of ownership including maintenance and replacement costs over the life of the vehicle also figure prominently. Battery weight is another factor – lithium types can be up to 40% lighter than equivalent lead-acid reducing vehicle curb weight. The fit and packaging advantages of different battery designs must align with available under-hood space constraints. And robust R&D testing is done to fully validate a technology can reliably meet OEM durability and lifetime drive cycle requirements under all operating conditions.

Lead-Acid Holds Share But Faces Pressure

Despite lithium-ion’s growing appeal, flooded lead-acid batteries from major suppliers like Johnson Controls, Exide, East Penn and others still dominate the starter battery arena holding around 80% global market share according to data sources. However their share is projected to erode as more automakers adopt start-stop and lithium technology gains wider acceptance. Lead-acid suppliers are striving to squeeze more performance out of Advanced Lead Acid designs through ongoing product innovation but face an uphill battle against lithium’s compelling attributes. Many expect the transition will be gradual with dual chemistry strategies also emerging in the coming years.

Tailored Lithium Designs Emerge

Rather than a one-size-fits-all solution, lithium battery innovators are crafting tailored designs optimized for specific vehicle applications and manufacturers’ needs. Suppliers like GS Yuasa, Clarios, Samsung SDI and others offer multiple lithium-ion chemistries including lithium iron phosphate (LFP), lithium nickel manganese cobalt oxide (NMC) and newer lithium nickel cobalt aluminum oxide (NCA). These different active materials offer varying balances of performance attributes like power, energy density, cycle life and thermal stability. Custom pack configurations with different cell and module arrangements as well as Battery Management Systems (BMS) ensure each system delivers the required power profile while achieving optimal volume, weight and cost targets.

New Factory Tooling Investments

As projected demand for lithium starter batteries ramps up driven by government fuel efficiency mandates and the trend toward hybridization, suppliers are making big bets on production capacity expansion. Major players like GS Yuasa, CATL and Samsung SDI have pioneered dedicated lithium-ion automotive battery manufacturing facilities. GS Yuasa recently invested $100 million to establish a new lithium-ion battery plant in Hungary. CATL is putting $2 billion toward battery facilities in Germany. And Samsung SDI broke ground on a $1.3 billion lithium-ion battery gigafactory in Taylor, Texas. With these new factories coming online in 2023-2024 timeframe, lithium battery availability issues should ease as OEMs adopt the technology more broadly across their lineups in the latter half of this decade.

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About Author:

Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. (https://www.linkedin.com/in/ravina-pandya-1a3984191)