The electric vehicle industry is advancing by leaps and bounds, and much of that progress depends on batteries. In recent weeks, three key developments have highlighted concrete improvements: a cooling system manufactured in Spain, a new polymer material that extends cell life, and a Chinese patent that brings solid-state technology closer to reality. These innovations address different but complementary problemsfrom thermal management to durability and energy density.
While Mahle's plant in Tarragona is already mass-producing plates that keep the temperature under control, laboratories in South Korea and China are presenting chemical and structural solutions that promise more efficient batteries. The common denominator is the search for greater autonomy and a longer lifespanThese two factors remain the main obstacles to the mass adoption of electric cars.
Mahle starts production of cooling plates in Montblanc
Mahle's plant in Montblanc (Tarragona) has begun mass production of a critical component: a cooling plate for electric vehicle batteries. The investment of several tens of millions of euros This has allowed for the modernization of the facilities and the achievement of a capacity of 15.000 units per week. The workforce, comprised of 750 employees, has seen an increase in skilled employment in the area.
These plates keep the battery temperature below 40°C and ensure uniform heat distribution between the cells. Precise thermal control is essential for fast charging and longevity of lithium-ion batteriessince overheating accelerates degradation. The manufacturing process is highly automated, with minimal manual intervention, to meet the demanding requirements for corrosion resistance and surface cleanliness. Roger Gombau, the plant manager, emphasized that this project demonstrates Mahle's industrial capabilities in the field of electromobility.
A hybrid polymer doubles the lifespan of the batteries.
A team from Sungkyunkwan University and Seoul National University has developed a new polymer binder that allows for the manufacture of thicker electrodes without losing performance. The material, called DHP, combines elastane and polyacrylic acid, two polymers with complementary properties: the first provides elasticity and the second a strong interaction with the electrode components.
In conventional batteries, the polyvinylidene fluoride (PVDF) binder tends to migrate to the surface during drying when the electrode is thick, causing cracks and peeling. The new polymer avoids this problem and doubles the adhesion strengthMaintaining structural integrity even in thick electrodes, the DHP cells retained 86,8% of their initial capacity after 200 charge and discharge cycles in tests, while conventional cells ceased functioning after approximately 95 cycles. Furthermore, the technology can be integrated into existing production lines without the need for new equipment, facilitating its industrial adoption. The researchers, led by Ki-Jae Kim and Jang Wook Choi, believe this advancement could significantly increase the range of electric vehicles.
BYD patents a composite cathode for solid-state batteries
Chinese manufacturer BYD has registered a patent (CN122474592A) that addresses one of the biggest challenges of solid-state batteries: maintaining intimate contact between solid components as the cell expands and contracts. The solution consists of a composite cathode that mixes two types of solid electrolytes.Small halide particles and larger sulfide particles. When combined, the smaller particles fill microscopic gaps, optimizing ion transfer and reducing mechanical stress.
BYD's chief scientist, Lian Yubo, has pointed out that the stability of the solid-solid interface is the main obstacle to the industrialization of this technology. The company expects to have its first batch of solid-state batteries next year.However, mass adoption is not expected until the next decade. In the laboratory, the use of smaller sulfide particles has improved capacity retention by almost 18%. BYD holds several patents in this field, including a solid electrolyte membrane with polymer fibers and a double-layer cathode coating. Despite this progress, the industry agrees that manufacturing challenges remain before these batteries are used in production cars.
The three developments reflect a clear trend: research into batteries for electric vehicles is advancing on multiple fronts, from cooling to materials chemistry. While Mahle reinforces its industrial commitment in Spain with a state-of-the-art plantLaboratories in Korea and China are proposing solutions that could double battery lifespan and pave the way for solid-state technology. The combination of these innovations, although still at different stages of development, points to a future where electric cars are more autonomous, durable, and safe.
