Sadly as far as I'm concerned it seems that the Hyundai EV battery situation is an out of control dumpster fire at this point. I love the EV but the company is atrocious, with abhorrent communication skills. Hearing that the recalled replacement batteries are also catching fire is just crazy.
https://www.carindigo.com/news/hyun...ter-getting-back-from-official-company-recall
I suspect Hyundai will eventually figure this out but at this point my advice to anyone lurking and thinking of buying a new or used Hyundai EV is don't. The Ionic 5 might be OK as the batteries are supposed to be sourced from SK and CATL but I suspect they will cock something else up.
Its troubling to hear that the GM/LG packs are affected up to current production. As much as folks will claim they are completely different the production process and LG sites for the pouch cells may be more similar than we think.
Cells in GM, Hyundai EV battery fires linked to several LG plants
"Documents filed by General Motors and Hyundai Motor Co. with the U.S. auto safety regulator show how the two automakers separately identified the same cause of battery fires in their newest electric vehicles, tracing them to similar manufacturing defects in battery cells made at at least two plants operated by a unit of LG Chem."
https://www.autonews.com/regulation...dai-ev-battery-fires-linked-several-lg-plants
"The original (GM/bolt) recall was blamed on a manufacturing defect at a South Korean factory run by LG Chemical Solution, GM’s battery supplier. But the company said an investigation showed that the defects are possible in batteries made at other(LG) sites."
https://apnews.com/article/technolo...t-and-nature-bbe51b0c8e644c4448d634fc3c0f3461
It looks like the LG pouch cells are not just having problems with bent anodes as Hyundai recently indicated the cause of concern but it also appears there is an issue with damaged separators.
Greg Less, technical director of the University of Michigan’s Battery Lab.
“What we’re looking at is a perfect storm,” Less said. The Bolt’s battery packs are made up of pouch-type cells, which are essentially layers of cathodes, anodes, and separators that are flooded with liquid electrolyte and encased in a flexible polymer pouch. The torn anode tab, he said, would create a projection in what should be an otherwise flat battery. The projection brings the anode closer to the cathode. “And that would probably be OK if the separator was where it was supposed to be,” he said. But in problematic Bolt batteries, the separator wasn’t where it was supposed to be. Separators are placed between the anode and cathode to prevent the two electrodes from touching. A torn tab wouldn’t necessarily be an issue on its own because the separator would prevent any projection from bridging the anode-cathode gap. In cells with a folded separator, though, the gap would be missing from at least part of the battery. If the anode bridges the gap, Less said, “you have a short, and it’s all downhill from there.”
https://arstechnica.com/cars/2021/0...ot-may-have-sparked-chevy-bolt-battery-fires/
Now there seems to be several anecdotal reports of Kona/LG battery pack built as late as March of 2021(i.e. similar manufacturing dates to current recall replacement packs) bricking presumably due to a BMS indicated battery short that requires replacement.
"Don't celebrate too early yet.
I am seeing new batteries having the same issue as before. Looks like LG did not get to the root of the problem.
A friend's car, MY2021, Battery Mar 2021, ODO 2106 km only. Now parked at dealer waiting for battery replacement."
"this is a new 2021/22 kona with new battery from lg chem, manufactured in march 2021, i.e. improved version.
i would assume all replacement batteries are the same as the one in this new car"
https://www.hyundaikonaforum.com/threads/2019-2020-ev-battery-recall.4377/page-20
I remain unconvinced Hyundai or LG have a handle on the battery problem yet. I strongly suspect some of the recent recall replacement packs potentially are still defective. Hyundai's only response up to now has been has been mostly silence to it consumers, begrudgingly stating maybe a folded anode and we got it fixed in March of 2020 and "trust us we got this" to regulators with no real evidence to the contrary, well at least none for the lowly proletariat. I don't know Hyundai, it smells and looks like a dumpster fire, I got a feeling its a dumpster fire.