But for Greenhalgh and his collaborators, the more promising approach is to scrap the battery pack and use the vehicle’s body for energy storage instead. Unlike a conventional battery pack embedded in the chassis, these structural batteries are invisible. The electrical storage happens in the thin layers of composite materials that make up the car’s frame. In a sense, they’re weightless because the car is the battery. “It’s making the material do two things simultaneously,” says Greenhalgh. This new way of thinking about EV design can provide huge performance gains and improve safety because there won’t be thousands of energy-dense, flammable cells packed into the car.
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