Where are the battery packs made for electric/hybrid vehicles in the United States?

best electric hybrid cars 2012 image

Many times the car or the design of the battery pack may be in the United States, but the pack itself may be made in some 2nd or 3rd World country like China or somewhere in SE Asia or in some other country without the regulations that the Unites States has. I ask because, as many people know, batteries have toxic chemicals in them and you need these chemicals to make the batteries. Also, what happens when they aren't used anymore? In other words, after the lifespan of the battery pack, what happens to it? Is it recycled or does something else happen to it?

Answer
Each company who makes an electric or hybrid car needs batteries. That component part can be sourced domestically, internationally or some combination. Each company will no doubt be trying to save as much money as possible as they strive for a part that also has a high degree or reliability.

Nissan has chosen to make the batteries for the all electric leaf in the US at a new factory that has been built in Tennessee. http://wheels.blogs.nytimes.com/2012/12/13/nissan-battery-plant-begins-operations-in-tennessee/

What is a "toxic chemical?" You might be surprised that the list includes things we use all the time including:

laundry detergent
gasoline
ammonia
toilet bowl cleaner
motor oil
rubbing alcohol
bleach

http://chemistry.about.com/od/toxicchemicals/f/What-Is-A-Toxic-Chemical.htm Some of the things are only "toxic" if we contact them in a specific way. So just saying something is "toxic" sounds bad but it is really not a complete picture. Lead acid batteries are "toxic" as they contain both lead and acid. But they are also more than 95% recycled. So the overall track record is quite good. And this also has set up an understanding and a formula for dealing with other often "less toxic" chemistry's in batteries with a newer technology intended for electric vehicles.

Such batteries for the EV are expected to last for more than 8 years or 100,000 miles (the warranty) at which time they will be reduced to about 70% to 80% of their like new capacity. There is a potential useful life for the batteries in stationary applications. (computer and telecommunications equipment UPS ) but they may also be recycled depending upon where there is more value. Either way they certainly won't be thrown into any landfill (see below).

Are pure electric cars and plug-in hybrid electric cars easier and cost less to maintain? Do they still have?

Edward

radiators, spark plugs, motor oil? When the battery in a plug-in hybrid electric car runs low, does the car automatically start the onboard generator without the driver doing anything? How long does it take to recharge a electric car to travel 15 miles roundtrip to work?

Answer
Electric cars are operated by electric motors. This is a fundamentally different engine than the heat producing internal combustion engine. They are essentially permanently lubricated and therefore don't require oil changes for the engine. Electric motors do not burn a fuel so do not require spark plugs. They are rotary engines so operate virtually vibration free and silent so do not need tune ups or mufflers. Commercial vehicles like the Nissan Leaf have regenerative braking so they are very light on the traditional brake system causing far less maintenance. One owner of a RAV4ev said that he did not have to perform any vehicle maintenance for over 5 years.

"Pure electric cars" as the term is used are battery electric cars that do not have a traditional engine or a generator. The power is transmitted to the vehicle and stored in batteries. Some electric vehicles may have a radiator that is used for liquid cooling of the battery system. The volt does but the Leaf has an air cooled battery system.

Some vehicles like the Volt are closer to series hybrids than a pure electric car. They have an electric motor that is the primary mover for the vehicle. They also have the traditional engine with all its associated maintenance. They never require charging to operate but the batteries will only last about 40 miles. After this the engine starts a generator automatically to continue the operation of the electric motor.

Parallel hybrids like the Prius are never plugged in and charge the vehicle when less energy is needed to power the vehicle. All energy comes from the fuel. (although the 2012 version can be plugged in for some fuel savings.)

Electric cars economy and charge times will vary. The Nissan Leaf EPA rating is 34 KW-hr to travel 100 miles or .34 kWh /mile. A 15 mile journey would then require (15 x .34=) 5.1 kW hr. You need to add about 5% for charger inefficiency so the total charge required would be approximately 5.36 kWh. If charging from a standard wall outlet (15 amp {1} x 120 volt power supply = 1800 watts or 1.8kW ) then the total charge time should be (5.36/1.8=) approximately 3 hours. If charging from a single phase 220volt x 22.5 {1} amp power supply = 5400 watts or 5.4kW ) then the total charge time should be (5.36/5.4=) approximately 1 hours.

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