Popular Mechanics: Inside Plug-in Car Tech's Race to Production (and Top 10 Rides)

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Inside Plug-in Car Tech's Race to Production (and Top 10 Rides)

Big automakers and promising startups say electric vehicles are coming as soon as next year, but there's a lot of work to be done—by scientists—before lithium-ion batteries are ready for mainstream hybrids.

By Chuck Tannert
Published on: February 6, 2008

The future of American motoring will be—at least in part—battery-powered. Now, from unveilings at last month’s Detroit auto show to updates from plug-in startups and entries for the Automotive X Prize, it’s becoming increasingly clear that the lithium-ion pack is what will get us there. Almost every top-tier carmaker has announced plans to use the technology, but they haven’t exactly said when we might see roadworthy li-ion-powered vehicles. The consensus is that they’ll probably start to appear in the 2010 to 2012 time frame—though no one’s promising anything.

Even though lithium-ion already runs everything from laptops to screwdrivers, the reality remains that only a handful of smaller companies actually make these electric cars for production (or soon will). And whether it’s AC Propulsion (a converted Scion xB), Aptera (a sleek three-wheeler), HST (a plug-in Shelby Cobra), Hybrid Technologies (an all-electric Mini Cooper) or even Tesla (a high-performance sports car), none of these startups put out large quantities, and the vehicles they do make are pricey. It all comes down to that battery.

So what’s up with the final push before li-ion is finally ready for prime time? We checked in with the lab rats from Detroit to Silicon Valley to find out when emissions-free driving will switch from dream to dealership.

Issue No. 1: Battery Chemistry

Sounds simple, right? Pick a chemical makeup and run with it. Not so fast. “There are as many, if not more, recipes for these batteries as there are companies that supply them,” says Denise Gray, director of hybrid energy storage systems for General Motors (click here for our full interview). “Automakers need to experiment to find which works best for them. That takes time. We need them to perform as a function of driving style, location and climate. They need to deliver both power and range when needed, every time it’s needed.”

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