A single injection to revive batteries! Fudan team achieves another breakthrough

At a dust-free workstation in a Fudan University laboratory, a group of retired power batteries with a remaining capacity of just 68% is undergoing a "rebirth." Researchers are using a specially designed syringe to inject 0.5 mL/Ah of a transparent restorative solution through the electrolyte injection port. Twenty minutes later, the lithium battery‘s lifespan is extended by one to two orders of magnitude. The entire process resembles a precise "minimally invasive surgery" for batteries, providing a critical technological foundation for industry transformation.

Technological Breakthrough: Nano-Level Life Reconstruction

The research, titled "External Li Supply Reshapes Li-Deficiency and Lifetime Limit of Batteries," was published in Nature on February 13. This globally pioneering repair technology achieves three major breakthroughs:

• Molecular-Level Repair Mechanism – The restorative solution regulates lithium-ion solvation structures, forming a 5-nanometer protective layer on the cathode surface, effectively suppressing electrolyte decomposition side reactions.
• Lattice Reconstruction Capability – Molecular dynamics simulations confirm that the repair components precisely fill lattice defects in ternary materials, restoring lithium-ion transport channels to 92% of their original state.
• Industrial Validation – Test data shows that repaired batteries achieve a 2.3x extension in cycle life, with a single repair costing only 1.2% of the battery’s residual value—an 85% reduction in energy consumption compared to traditional dismantling and maintenance methods.

After more than four years of research, this technology has completely overturned the industry‘s conventional practice of dismantling battery packs to replace cells. Instead of undergoing a costly and invasive process, high-value power battery packs can now be regenerated through a mere 2mm injection port. The technology is applicable to lithium supplementation, energy storage, and integrated solar-storage systems.

Industry Transformation: From Manufacturing to "Intelligent Healing"

Once synthesized, the research team validated that this molecule meets stringent lithium-ion carrier performance requirements. It is low-cost, easy to synthesize, and highly compatible with various battery active materials, electrolytes, and other components. The technology has been successfully applied to lithium polymer pouch batteries, cylindrical batteries, prismatic batteries, and fiber-based lithium-ion batteries.

The application of this technology is reshaping the industry ecosystem:

• Front-End Design – Electrolyte injection ports are becoming a standard component in new energy vehicles, similar to the Type-C interface in consumer electronics.
• Midstream Services – The "Battery Hospital" in Shanghai Lingang is now operational, integrating CT scanning, electrochemical testing, and a cloud-based health management system to create a digitalized "diagnosis-repair-warranty" loop.
• Back-End Value – NIO’s BaaS 3.0 service now includes battery health rights, increasing the asset utilization cycle of battery banks by 40%.

According to 2023 industry data estimates, this technology can reduce carbon emissions by 120 kg per battery over its lifecycle. When scaled to China’s annual installed capacity of power batteries, it equates to preventing heavy metal pollution in 18 West Lake-sized bodies of water each year.

Environmental Benefits: The Key to Overcoming Resource Crises

With global lithium reserves expected to last only 20 more years, the environmental value of this technology is increasingly evident:

• Resource Conservation – Repairing one ton of batteries saves the equivalent of mining 200 tons of lithium ore.
• Energy Efficiency – The repair process consumes only 5% of the energy required to produce a new battery, saving 40,000 liters of industrial water per ton.
• Business Innovation – Ping An Insurance has introduced battery health insurance, while the demand for battery repair technicians has surged, with an estimated shortage of 100,000 professionals.

Pilot data from Tesla’s V4 Supercharger stations indicates that integrating this repair technology into maintenance services reduces single-station operational costs by 15%. This transformation has also given rise to a new profession—battery diagnostic engineers—who now earn three times the hourly wage of traditional repair technicians.

A Technological Blueprint for a Sustainable Future

Much like a medical injection, this carrier molecule can be introduced into aged, degraded batteries to precisely replenish lost lithium ions, restoring battery capacity without any degradation. Inspired by medical syringes, this innovation is setting new industry standards for renewable energy:

• Precision Monitoring – Cloud-based systems can track capacity degradation down to 0.1% accuracy.
• Standardization Efforts – The International Electrotechnical Commission (IEC) has initiated the development of Technical Guidelines for Power Battery Repair.
• Material Advancements – The organic-inorganic hybrid materials used in the restorative solution have already led to three derivative patents.

With Germany‘s TÜV Rheinland certification body incorporating this technology into its 2025 battery safety evaluation system, this innovation represents more than just a Chinese breakthrough—it signifies a global industry consensus on sustainability.

In the second chapter of the renewable energy revolution, perhaps the most remarkable innovation isn’t about making batteries more powerful—it’s about ensuring every battery ages gracefully.