A car battery is made from a combination of chemical, metal, and plastic components, and the exact composition depends on the type of battery – most commonly lead-acid for traditional vehicles and lithium-ion (Li-ion) for electric vehicles (EVs).

🔋 For Traditional Vehicles: Lead-Acid Battery

These are the most common in petrol/diesel cars.

Main components:

• Lead dioxide (PbO₂): Positive plate.

• Spongy lead (Pb): Negative plate.

• Diluted sulfuric acid (H₂SO₄): Electrolyte, which facilitates the flow of electrons.

• Plastic casing (usually polypropylene): Strong, acid-resistant outer shell.

• Separators: Thin insulators (made of fiberglass or polyethylene) between the plates to prevent short circuits.

Environmental note: Lead-acid batteries are heavy and contain toxic materials but are highly recyclable – over 95% of the battery can be reused.

⚡ For Electric Vehicles: Lithium-Ion Battery

Used in most EVs and hybrids.

Key materials:

• Lithium compounds (e.g., lithium cobalt oxide, lithium iron phosphate): Used in the cathode.

• Graphite: Used in the anode.

• Electrolyte: Often a lithium salt (like LiPF6) in an organic solvent (like ethylene carbonate).

• Aluminum and copper foils: Conductive layers supporting the anode and cathode.

• Battery management system (BMS): Electronics controlling temperature, charge/discharge, and safety.

• Casing: Usually aluminum or steel housing with internal protective modules.

Other materials in the cathode depending on chemistry:

• Nickel

• Cobalt

• Manganese

Environmental note: Lithium-ion batteries are lighter and more efficient but less recyclable at present (though this is improving rapidly).

To concentrate only on lithium-ion batteries what components are required to make one of these?

🔋 Core Components of a Lithium-Ion Battery

1. Cathode (Positive Electrode)

   • Made from lithium metal oxides, typically:

     • Lithium Cobalt Oxide (LiCoO₂) – phones, laptops

     • Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO₂ or NMC) – EVs

     • Lithium Iron Phosphate (LiFePO₄ or LFP) – low-cost EVs, energy storage

   • Key raw materials:

     • Lithium

     • Nickel

     • Cobalt

     • Manganese

     • Iron (in LFP variants)

     • Aluminum (as a current collector)

2. Anode (Negative Electrode)

   • Typically made of graphite (carbon in crystalline form)

   • Future tech may use silicon or lithium metal

   • Key raw materials:

     • Graphite

     • Copper (as a current collector)

3. Electrolyte

   • A lithium salt dissolved in a solvent (usually organic)

     • Common salts: LiPF₆, LiBF₄, LiClO₄

     • Solvents: Ethylene carbonate, dimethyl carbonate

   • Function: Allows lithium ions to flow between the cathode and anode

4. Separator

   • A thin, porous film (often polyethylene (PE) or polypropylene (PP))

   • Keeps the anode and cathode apart but lets lithium ions pass through

5. Battery Management System (BMS)

   • Not part of the chemistry but essential

   • Includes temperature sensors, charge controllers, balancing circuits

6. Packaging

   • Pouch, cylindrical, or prismatic casing

   • Usually made from aluminum, steel, or laminated plastics

🧪 Summary of Key Raw Materials

If you’re looking at this from a business or supply chain angle, the critical raw materials to watch are: lithium, nickel, cobalt, and graphite. These are the ones facing global demand surges and sometimes geopolitical supply issues.