New energy vehicles face challenges such as battery warranty expiration, making battery longevity a new industry focus.

As one of the most critical components in new-energy vehicles, the industry's focus on power batteries is shifting—from range, safety, and cost—toward battery lifespan. With the increasing penetration and growing number of new-energy vehicles on the road, a massive fleet of these cars is now approaching the end of their original battery warranties. And once those warranties expire, replacing the batteries will inevitably lead to significant expenses. Currently, the highest replacement costs on the market have already surpassed 230,000 yuan, while even the most affordable options still require nearly 60,000 yuan.
NIO Founder and Chairman William Li, citing data, stated that since 2016, the cumulative number of newly registered new-energy vehicles nationwide has nearly reached 20 million units. Given the standard battery warranty period of eight years, vehicles purchased in 2016 will begin facing battery warranty expiration issues this year. Based on the current stock of new-energy vehicles as of the end of 2023, it is estimated that by 2032, nearly 20 million new-energy vehicles will have reached the end of their battery warranties.
On the other hand, currently the battery cycle life falls short of the vehicle's total drivable mileage—while a vehicle can theoretically travel up to 1 million kilometers, the industry-standard battery cycle life typically reaches only about 240,000 kilometers. Against the backdrop of challenges such as power batteries losing warranty coverage, "different lifespans for vehicle and battery," and the high costs associated with battery replacements, NIO has unveiled a plan for a long-life battery solution and has signed a cooperation agreement with CATL. The goal is to enable batteries to maintain at least 85% of their original health after 15 years of use. This groundbreaking initiative builds on NIO's comprehensive strategies spanning diverse areas, including battery chemistry materials, cell architecture, and cloud-based operational systems.

Extending the lifespan of electric vehicle batteries is hardly a new industry issue. Samsung, along with other leading automakers such as BYD and Mercedes-Benz, are actively investing in the development and application of related technologies. These efforts aim to enhance both the performance and safety of batteries while simultaneously boosting their longevity. BYD’s Blade Battery, for instance, utilizes LFP (lithium iron phosphate) materials and a unique structural design that optimizes heat dissipation and improves battery strength, effectively minimizing degradation caused by overheating. Thanks to this innovative technology, BYD can now offer an impressive warranty of up to 8 years or 125,000 miles for its batteries. Similarly, Mercedes-Benz provides a robust 10-year or 250,000-kilometer warranty on the battery of its EQS model, underscoring the company’s strong confidence in its battery technology. Beyond just extending battery life and performance guarantees, these initiatives also highlight the critical role of the Battery Management System (BMS), as well as the significant impact that user habits and external environmental factors can have on battery longevity.
Furthermore, Toyota Motor Corporation has also made significant progress in solid-state battery technology. The company announced that its solid-state batteries can now be produced at a pace nearly comparable to that of conventional battery manufacturing, marking a critical step toward the commercialization of this groundbreaking technology. Toyota’s collaboration with Japan’s energy giant Idemitsu Kosan is accelerating this advancement even further. One of the most notable advantages of solid-state battery technology over traditional lithium-ion batteries is their exceptionally long lifespan. Thanks to the use of solid electrolytes, solid-state batteries are better equipped to resist battery degradation compared to lithium-ion batteries with liquid electrolytes, ultimately delivering a significantly extended service life.
Stanford University's research reveals that simply adjusting the software of electric vehicles—specifically, allowing the battery to rest for several hours after being fully discharged—can significantly enhance both the range and lifespan of lithium-metal batteries. This discovery requires no additional costs, as it only involves reprogramming the Battery Management System (BMS) software, showcasing the immense potential of intelligent battery management in optimizing battery performance. The study underscores the critical role of the BMS in extending battery life, while also highlighting the importance of maintaining an optimal charging range, avoiding extreme temperatures, adopting moderate charging rates, and conducting regular battery health checks to ensure the battery remains in peak condition. Effective lifecycle management of batteries not only reduces environmental impact but also creates greater value for both businesses and consumers.
Additionally, good usage habits and a relatively mild external environment are equally crucial for extending battery life. Together, these factors play an even more significant role in achieving the goal of long-lasting batteries than the battery technology itself. These advancements highlight the importance of optimizing and prolonging battery life through a comprehensive approach that involves intelligent battery management, adjustments in user behavior, and adaptation to diverse usage environments.

Li Bin stated that battery life is not only an issue that NIO, as an automotive company, needs to address and resolve—it’s also a industry-wide challenge that the entire sector must tackle together. Only by overcoming the battery-life problem can China’s new-energy vehicle industry achieve long-term, healthy, and sustainable growth.

Translated from Sina Auto

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