New battery types

Picture of a sunset with the shadow of a battery in the middle

Source: sommart - stock.adobe.com

Batteries, which may be single-use or rechargeable, use an electrochemical process to store electrical energy. Non-rechargeable and rechargeable batteries are termed "primary batteries" and "secondary batteries" respectively. In a rechargeable battery, a capacitor stores electrical energy in an electric field, enabling the battery to be charged and discharged much more quickly, but not to maintain a constant voltage during discharge [1].

Solid-state batteries (SSBs) are a particular form of rechargeable battery in which solid material is used for the two electrodes and the electrolyte [2]. Short-duration energy storage devices, such as conventional lithium-ion rechargeable batteries, can store power for a maximum of four to six hours. Energy storage durations of eight hours or more are referred to as long-duration energy storage (LDES) [3]. Conversely, fuel cells are not energy storage devices, but energy converters [4].

The preferred rechargeable battery type for numerous applications, from smartphones to solar storage and electric cars, continues to be the lithium-ion battery. The nickel manganese cobalt (NMC) form of lithium-ion battery is now complemented by cheaper but less powerful lithium ferrophosphate (LFP) batteries.

New rechargeable types of another class of battery, the lithium metal battery, are also currently under development [5]. In this type of battery, metallic lithium acts as the anode, making these batteries less stable and less safe. One new type of rechargeable lithium metal battery is claimed to have reached over 2,200 charge cycles with short charging rates, with a charge capacity of over 80% being maintained [6].

In pouch cells, a form of construction for lithium-ion rechargeable batteries that is widely used, including in electric cars, the aim is to extend the battery life by up to 10% by means of mechanical compression [7].

Other new rechargeable battery types and developments include the following:

  • Solid-state batteries: All-solid-state batteries (ASSBs) have a longer service life, permit new, space-saving and weight-saving cell concepts, and offer safety benefits, as the risk of leakage and fire is reduced to a minimum. A wide range of solid materials can be used as the electrolytes: polymers/organic electrolytes, sulphides/thiophosphates and oxides [8].
  • Metal-air batteries: Lithium-oxygen (LiO2) batteries in particular, are considered to have considerable potential, owing to their ability to store large quantities of energy and their relatively low overall weight. The use of 1,3-dimethylimidazolium iodide (DMII), a salt, as an additive can improve both performance and service life of lithium-air batteries [9].
  • Lithium-sulphur batteries: in 2025 Researchers achieved a breakthrough with the production of a lithium-sulphur battery capable of withstanding around 25,000 charge cycles (at least in the laboratory). To do so, they developed a solid electrolyte from a glass-like mixture of boron, sulphur, lithium, phosphorus and iodine, which evidently increases the reaction rate at the electrodes [10].
  • Aluminium-ion batteries: A new battery type, developed in 2024 with the addition of aluminium fluoride and fluoroethylene carbonate, lost less than 1% of its charging capacity over more than 10,000 charge cycles [11].
  • Sodium-ion batteries: Use of a new type of cathode material (sodium vanadium phosphate (NaxV2(PO4)3) is expected to increase the theoretical energy density of these batteries by over 15%, thereby greatly improving efficiency [12].
  • Redox flow batteries: These batteries are suitable for storing electricity from wind turbines and photovoltaic systems, thereby increasing the proportion of renewable energies in the electricity supply. They are safe to operate, non-flammable and have a service life of up to 20 years. Machine learning and generative artificial intelligence methods are among those being used in the search for new electrolyte materials to replace vanadium, which is an environmentally harmful and critical raw material [13].
  • Hybrid flow systems: A demonstrator was developed in 2024 that combines a powerful vanadium redox flow battery with a supercapacitor with aqueous electrolytes. This will enable large consumers to compensate flexibly for critical grid conditions [14].
  • Ultracapacitors/supercapacitors: These provide an instant energy boost and are suitable energy storage devices for all applications requiring high performance and numerous cycles. They are also easy to recycle and cannot explode in the event of an accident. The SuperBattery is a hybrid solution that combines the storage mechanisms of lithium-ion batteries and supercapacitors within the battery cell to attain both fast charging capability and high energy density [15].
  • Organic SolidFlow batteries: These batteries are based on readily available, recyclable organic material, are non-flammable and guarantee safe operation. They are suitable for a wide range of applications and constitute an alternative to lithium-ion technology [16; 17].
  • Proton batteries: This new organic battery type, with a cathode made of tetraamino-benzoquinone (TABQ), delivers good performance and long service life and, unlike lithium batteries, is non-flammable. Because it uses a water solution as the electrolyte, it is lightweight, inexpensive, and presents a sustainable alternative to the current lithium standard [18].
  • Carbon as the battery cathode: Acetylene black, which can be produced with lower CO2 emissions, is a suitable substitute for standard carbon black. In addition, the existing commercially available standard carbon nanotubes (CNTs) are being replaced by new, significantly thinner CNTs. This reduces the quantities of carbon materials and thus improves the energy efficiency [19].

  • What is accelerating the trend, and what is slowing it down?

    Technological progress, new materials and improved manufacturing processes are accelerating battery development and resulting in more powerful and longer-lasting batteries. For example, advances in solid-state battery technology are making higher energy densities and safer batteries possible. Sodium-ion-based battery storage systems have increasingly been attaining market maturity since 2024. Their use will continue to increase in the future, albeit initially in China [20].

    In electric vehicles, the use of lightweight materials can promote battery development. Fibre-plastic composites in the housings of lithium-ion batteries reduce battery weight and provide better protection for the battery core in the event of an accident [21]. In the future, electric cars could also become an integral part of the power grid and help to stabilise it, for example during peak loads. Bidirectional charging and drive modules ensure that the battery is not only charged quickly, but also feeds excess energy back into the grid [22].

    New mathematical models can yield a better understanding of processes inside batteries and help to improve them. Approximation methods, computer-aided simulations and machine learning are used to describe all processes at the microscopic and macroscopic level and to develop battery models that are as precise as possible. This allows manufacturing processes to be improved and the service life of the batteries to be extended [23].

    The political will to develop more environmentally responsible and sustainable energy storage solutions and the need to reduce dependency on fossil fuels and increase energy security are driving research and development in the battery sector. Efficient, long-term storage is essential for solar and wind energy, and also for the stabilisation of power grids and for decentralised energy storage for private households. Funding schemes and government support for the development and production of new battery technologies can facilitate their introduction on the market [24]. By the same token, the loss of financial resources slows down innovation.

    Economic policy factors also have an influence on battery development. Efforts are being made to reduce dependency on rare, imported raw materials and critical substances. Lithium-ion batteries contain a range of metals (lithium, cobalt, nickel, manganese) that are considered critical. Limitation of their availability to a small number of countries and the geopolitical control of these raw materials make battery production vulnerable to market distortions and supply bottlenecks.

    The high demand for powerful batteries for electric mobility and use in the transport sector is driving innovation and investment in battery technology. The focus lies on faster charging times and greater energy density to increase range, reduce production costs and therefore total vehicle costs. Similarly, the demand for more efficient and cheaper batteries for smartphones, laptops, wearables, drones, medical technology and many other applications is also a significant factor.

    Many new battery technologies are at the development stage and still have numerous technical hurdles to overcome before they are ready for the market. Research and development present challenges and can be delayed by the widespread shortage of skilled workers, particularly in the sector of science, technology, engineering, and mathematics (STEM). Material and production process costs alike are high, and the battery market is highly competitive. In addition, unfavourable market conditions, high import tariffs, limited availability of raw materials and high raw material prices may reduce willingness to invest.

    Environmental and sustainability requirements [26] and strict safety standards [27] can delay the development and market launch of new batteries, as regulations on the carbon footprint and material use require extensive testing and certification. The development of suitable recycling methods with a low environmental impact is also an important challenge. Current recycling processes in many cases inefficient and expensive.

  • Who is affected?

    The power generation industry, skilled trades, the electrical engineering industry, the raw materials and construction materials industry, civil engineering, waste management, the chemical industry, vehicle maintenance, transport, agriculture, the fire services, the ambulance services, research institutions

  • Examples (in German only)
  • What do these developments mean for workers’ safety and health?

    The hazards associated with the development, manufacture, use, disposal and recycling of lithium-ion rechargeable batteries are well known. These particularly include the handling of high-voltage batteries in electric vehicles, including in the event of accidents. Mechanical damage and electrical or thermal stress resulting in leaking electrolyte fluid can cause chemical burns. The main danger, however, is posed by fires, or even explosions, resulting from thermal runaway (uncontrolled overheating). Fires involving lithium batteries are particularly dangerous and difficult to extinguish, owing to the batteries having a high energy density and generating the oxygen needed for combustion themselves.

    The electrolytes in lithium batteries are often irritating or toxic and can release dangerous gases such as hydrogen fluoride (HF). Active materials are often processed in powder form and require respiratory protection during filling, transfer and mixing operations and during recycling. Since process steps often take place in an oxygen-reduced environment due to the risk of fire, oxygen monitoring is also of key importance for safety.

    New research aims to make lithium-ion batteries safer. Crash tests, for example, can be used to determine the conditions under which thermal runaway occurs, in which the cells fail in a chemical chain reaction, accompanied by the development of intense heat and gas, possibly with the generation of flames or even explosions [7]. An innovative gas and thermal management system with valve control is intended to reduce the temperature and concentration of the escaping gases to below the limits at which self-ignition or spontaneous gas explosion can occur [28].

    Contamination of the environment caused by lithium-ion battery fires is also the subject of more detailed study. Test fires have revealed high concentrations of metals in deposited dust, particularly metals that were a part of the battery. These include, for example, the carcinogenic metals nickel and cobalt, and manganese. The proportions of the metals in the residues from the fire tests reflect their use in the batteries [29]. Finally, evaluation of the safety of cabinets for storing lithium batteries, which constitute hazardous substances, is the subject of research: a detailed test procedure is to be developed for the qualification of safety cabinets’ behaviour in the event of fires breaking out inside them [30]. Together, these further developments enable the risks to be reduced for workers down the battery value chain, i.e. in production, logistics/transport, maintenance, recycling, disposal and deployment of the emergency services.

    New types of battery may pose chemical risks, for example owing to them containing highly reactive metals (such as lithium or sodium) or liquid electrolytes, which can be dangerous when present in large quantities or should the batteries be handled improperly or be defective. The hazards include an elevated risk of fire and explosion and the release of toxic liquids or gases that can be harmful to health, particularly to the respiratory tract.

    Nanotechnology may also be a factor in battery technology. The use of nanostructured materials (CNTs) can make batteries more efficient and powerful [31-33]. During the manufacture, recycling and disposal of batteries and in the event of accidents, a risk therefore exists of nanomaterials entering the atmosphere and presenting a danger to health if inhaled or absorbed into the body.

    Changes in the technology of battery manufacture may require new machinery and processes that potentially give rise to new hazards. These include higher temperatures or reactions at high pressures, and special tools, machinery or equipment. The introduction of new automated systems and manufacturing processes for battery production requires more intensive monitoring and coordinated safety precautions, at least during the implementation phase, to avert mechanical hazards. For example, short-circuits leading to fires or explosions,as well as crush, puncture and cut injuries, if battery cells are pierced, deformed or crushed.

    In addition, manufacture and handling of new batteries may require changes in work processes. Larger or heavier batteries place a greater physical workload on workers during transport or assembly and can therefore contribute to musculoskeletal disorders.

    New types of battery with a more complex or modified material composition may have an impact on the waste disposal and recycling industry through workers’ contact with end-of-life or damaged batteries. Particular attention is required for what is known as black mass. This refers to a fine, dark powder that is generated especially during the recycling of lithium-ion batteries and contains recoverable metals. Black mass poses risks such as an increased cancer risk, corrosive effects, high dust exposure, fires or explosions, and should therefore be handled in closed systems [33]. Fire safety measures throughout the entire life cycle may have to be adapted, as new batteries may be more prone to overheating and fire hazards. Conversely, new, improved materials and innovative battery concepts also present opportunities for minimising risks during manufacturing, use and recycling.

    In addition to lithium, fluorspar (fluorite, CaF2) is also essential for lithium batteries and is an equally critical resource. To reduce the dependency on imports of this mineral and establish battery production based on a domestic value chain, efforts are being made to resume mining of these substances in Germany [34; 35]. Besides having an enormous environmental impact, mining of raw materials poses considerable risks to workers and challenges for occupational safety and health, particularly since knowledge, safety and preventive measures must be established (or re-established) in new mines.

    The Battery Passport is an important part of the EU Battery Regulation, which has been in force since 2024. The Battery Passport is a digital document containing detailed information on a battery and documenting its entire life cycle – from production, through use and ultimately to recycling – in order to create greater transparency in the value chain, promote the circular economy and facilitate comparison between batteries [36]. It will also make the handling of batteries safer, as it makes data relevant to safety available immediately, especially in the event of accidents or during disposal. As of January 1st 2026, manufacturers and distributors of industrial batteries and traction batteries will be required to make the digital Battery Passport available, and it will become mandatory throughout the EU in February 2027 [37].

  • What observations have been made for occupational safety and health, and what is the outlook?
    • The risks associated with lithium-ion batteries – including high-voltage storage batteries for electric mobility applications – are well known in principle, and preventive measures have already been established. Nevertheless, a major need for information and training still exists. This is partly due to the increasing spread of the technology in various areas of work, including integration into power grids through vehicle-to-grid (V2G) technologies, the use of electric vehicles as emergency sources of power [38] and micromobility.
    • Batteries are an indispensable part of the efforts to attain a low-carbon economy and create of a more sustainable future. At the same time, Europe is heavily dependent on critical raw materials such as lithium and cobalt, which are required for this purpose. Increased efforts to extract lithium in Germany – whether as part of geothermal projects or by conventional mining – are creating new jobs, with challenges of their own for occupational safety and health.
    • The growth in new types of batteries is accompanied by requirements concerning occupational safety and health, above all in the recycling and waste disposal industry. However, production, use and storage also harbour potential new risks, although they may also reduce existing risks (examples being the reduced fire and explosion hazard of solid-state batteries, and LFP batteries’ superior protection against short-circuits and overcharging), and reduce the dependency on critical materials.
    • Cooperation between the German Social Accident Insurance institutions, industry, the research community and government bodies can help to raise awareness of the hazards from the very outset of development of new processes and materials and promote safety aspects being taken into account at an early stage.
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Contact

Dipl.-Psych. Angelika Hauke

Work Systems of the Future

Tel: +49 30 13001-3633


Dipl.-Übers. Ina Neitzner

Work Systems of the Future

Tel: +49 30 13001-3630
Fax: +49 30 13001-38001