Battery technology company 24M Technologies has announced a new packaging system that it claims can increase EV range by up to 50% through improved energy density. The system, called 24M ETOP (Electrode-to-Pack), replaces traditional battery cells by integrating sealed electrodes directly into battery packs.
The technology addresses a fundamental inefficiency in current lithium-ion batteries, where a large proportion of space is occupied by inactive materials such as supporting metals and plastics within cell casings. Traditional battery packs typically contain electrodes comprising 30% to 60% of their volume, with the remainder taken up by structural components.
24M ETOP seals cathode and anode pairs in thin polymer films, eliminating the need for individual cells and modules. This approach allows electrodes to comprise 80% of a pack’s volume, according to the company. The system can work with various battery chemistries including NMC, LFP, NCA, sodium-ion, and others.
The company provides an example of how the technology could work in practice: a 75kWh NMC battery typically used in mid-sized EVs could be increased to over 100kWh using the same chemistry and pack size, representing a 33% range increase. Alternatively, manufacturers could use less expensive LFP chemistry while maintaining the same range as a traditional NMC pack.
Beyond energy density improvements, 24M ETOP offers design flexibility that enables battery packs in different shapes and voltages. The sealed electrodes can be arranged in series and parallel configurations, supporting voltages from 48V up to 400-800V systems.
Manufacturing benefits include relaxed safety tolerances for individual electrodes and reduced equipment investment costs. The company says the system eliminates the need for high-precision manufacturing equipment typically required for traditional battery production.
“24M ETOP brings a step change in performance, replacing traditional cell-to-module-to-pack construction with electrode-to-pack construction, maximising energy density,” said Naoki Ota, President and CEO at 24M Technologies. “24M ETOP makes it easier to build compact, flexible and safe high voltage batteries, presenting a revolutionary opportunity for electric vehicle manufacturers – longer ranges with the same chemistry or the same range with lower cost, safer chemistries, both in the same space.”
The technology can be combined with other 24M products including the company’s Impervio separator and Eternalyte electrolyte systems. 24M Technologies, founded as a spinout from MIT, focuses on battery design and manufacturing innovations.
