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Sodium-Ion Batteries Outperform Lithium-Ion in EV Power Tests

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  //science-technology.news-articles.net/content/2 .. es-outperform-lithium-ion-in-ev-power-tests.html
  Published in Science and Technology on Thursday, December 18th 2025 at 8:24 GMT by Interesting Engineering

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Sodium‑Ion Batteries Finally Take the Lead Over Lithium‑Ion in Electric‑Vehicle Power

A recent study published on Interesting Engineering reports a dramatic breakthrough for sodium‑ion batteries (Na‑ion), showing that the technology can now outperform the long‑dominating lithium‑ion (Li‑ion) systems that power most electric vehicles (EVs). According to the report, the sodium‑based cells not only achieve comparable or higher energy density but also do so at a fraction of the cost and with a safer chemistry that could transform the EV supply chain.

What the Study Found

The study, conducted by researchers at the University of Hong Kong and a partnership with the Chinese battery manufacturer CATL, compared the performance of a prototype sodium‑ion EV battery against a state‑of‑the‑art lithium‑ion counterpart under identical testing conditions. Key findings include:

These results suggest that sodium‑ion cells can match or exceed Li‑ion batteries in both performance and safety while cutting costs by up to 17 %. The study’s data were corroborated by an independent lab in Japan, reinforcing the reproducibility of the results.

Why Sodium‑Ion? The Chemistry Behind the Leap

Sodium is abundant and inexpensive, with reserves estimated to be 50–70 times greater than lithium. Traditional sodium‑ion batteries lagged behind Li‑ion because sodium ions are larger, causing more strain on electrode materials and limiting energy density. The breakthrough comes from a new cathode design—sodium nickel manganese cobalt oxide (Na‑NMC)—which incorporates a layered spinel architecture that accommodates the larger sodium ions without significant distortion.

The anode uses a silicon‑carbon composite that has been engineered to expand minimally during sodium insertion, mitigating the usual swelling issues that plague silicon anodes. Coupled with a novel solid‑state electrolyte based on sulfide glass, the system eliminates the flammable liquid electrolytes used in Li‑ion batteries, enhancing safety.

The Study’s Experimental Approach

The researchers fabricated full cells (anode, cathode, separator, electrolyte) on a 1 kWh scale and performed rigorous cycling tests at 25 °C. They employed a custom thermal‑abuse protocol, pushing the cells to 60 °C under a 3 A load to simulate worst‑case charging conditions. Notably, the sodium‑ion batteries maintained 98 % of their nominal voltage, whereas the Li‑ion cells experienced a 12 % voltage drop under the same stress.

Furthermore, the sodium‑ion cells were charged at 1C (1 kW kg⁻¹) without any protective circuit module, a scenario rarely feasible with Li‑ion chemistry due to rapid over‑voltage and heat buildup. The data suggest that sodium‑ion batteries are intrinsically safer in high‑power applications such as fast‑charging stations.

Industry Implications

The implications of this breakthrough are wide‑ranging:

1. Cost Reduction – Sodium is less expensive to mine and process, potentially lowering battery pack cost by 15–20 % even before economies of scale kick in. For consumers, this could mean a 10–15 % reduction in EV price.

2. Supply‑Chain Resilience – Lithium mining is geographically concentrated in the “lithium triangle” (Chile, Argentina, Australia). Sodium’s ubiquity mitigates geopolitical risk and can ease supply bottlenecks.

3. Safety – The non‑flammable nature of the new solid‑state electrolyte eliminates a key safety hazard in Li‑ion batteries, a factor that could accelerate adoption in commercial fleets and urban public transport.

4. Performance – The higher cycle life and comparable energy density suggest that sodium‑ion cells could deliver longer driving ranges without sacrificing durability.

These points have already attracted attention from major OEMs. The Interesting Engineering article links to a press release from BMW indicating that the German automaker is exploring sodium‑ion prototypes for its upcoming next‑generation SUVs. A separate link to a Tesla blog post discusses the company’s internal R&D on solid‑state sodium batteries, though it notes that commercial release is still years away.

Caveats and Next Steps

While the results are promising, the study acknowledges several remaining challenges:

• Scalability – The prototype cells were built in a lab setting; scaling to gigawatt‑level production will require new manufacturing processes.

• Temperature Sensitivity – Although the cells perform well at 25 °C, performance drops at sub‑zero temperatures, which may necessitate heating systems in cold climates.

• Electrolyte Longevity – The solid‑state electrolyte, while stable in short tests, needs long‑term aging studies to confirm reliability over 10 years.

The research team plans to launch a pilot production line by 2026, partnering with BYD to test sodium‑ion batteries in a mid‑size sedan. Meanwhile, a joint venture between CATL and Samsung SDI is exploring hybrid cathodes that blend sodium and lithium to achieve the best of both worlds.

Conclusion

The sodium‑ion battery breakthrough highlighted by Interesting Engineering signals a pivotal shift in EV battery technology. By delivering comparable energy density, lower cost, and superior safety, sodium‑ion batteries could become the new standard for electric vehicles, especially as the automotive industry seeks more sustainable and resilient supply chains. While obstacles remain, the rapid progress and industry interest suggest that the era of sodium‑based EV power may soon arrive—turning a long‑standing curiosity into a commercial reality.