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 Lead acid batteries are less expensive, more recyclable, and better prepared for high-volume production for electric vehicles (EVs), but their relatively short deep life cycle has been the major hurdle for wider use—until now. In 2001, NREL's energy storage team, working with Recombination Technologies and Optima Batteries, was recognized with an R&D 100 Award for developing a current interrupt charging algorithm for lead acid batteries. This breakthrough development extends the cycle life of these batteries by 300% to 400%, which provides an economically rational energy storage device and helps promote EV technologies. This project was funded by the Advanced Lead Acid Battery Consortium.
The charging-interrupt technique equalizes each module to the same state of charge instead of relying on a battery management system that could cost as much as $800. Using the current interrupt charging algorithm with lead acid batteries will cut initial vehicle costs. And there is another benefit—about 95% of all lead acid batteries produced are recycled.
Check out the R&D 100 Award (PDF 180 KB) Download Acrobat Reader.
 Working with Benteler Industries, Inc., NREL's energy storage team received an R&D 100 Award and an Energy@23 Award nomination for inventing the BENCHMARC catalytic converter in 1996. This converter can dramatically reduce automobile emissions and urban air pollution. However, it performs effectively only after reaching operating temperatures of approximately 600°F, so 60% to 80% of all vehicle emissions
occur while the converter is heating up.
NREL's team solved this problem by using variable conductance vacuum insulation and phase-change heat storage on the converter to retain heat from one motor vehicle trip to the next. By staying at an efficient operating temperature for as long as 24 hours after the engine is shut off, the converter eliminates about 80% of "cold-start emissions" to reduce overall automotive emissions by more than half, which also extends the life of the engine. The converter technology was licensed to Benteler Industries, Inc., a major automobile manufacturer supplier, who expects to have its converters ready for installation in model year 2003 cars, pending EPA approval.
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