What a Bag of Chips Revealed About Optima's Battery Technology at Pikes Peak

      Optima

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      Car racing has always been recognized as the quintessential platform for developing new automotive technologies, with elements such as aerodynamics and paddle shifters transitioning from advanced racing vehicles to everyday cars. However, with much already explored, it’s challenging to envision what further insights can be gained.

      To uncover more, Optima Batteries invited me to partake in the 2025 Pikes Peak International Hill Climb. At this event, a group of BBI Autosport Porsche race cars would be equipped with the company’s OrangeTop QH6 lithium battery, and I aimed to understand how significant this iconic 12.42-mile ascent on America’s Mountain could be for modern battery innovation.

      Curiously, I learned about the formidable challenges posed by Pikes Peak to essential components like car batteries through a simple bag of potato chips.

      Elizabeth Blackstock

      First, let's address why racing matters to a company like Optima Batteries. Tom Downie, the vice president of communications at Clarios (which owns Optima Batteries), elucidated this.

      Motorsport allows us to test our products beyond what an average consumer would, and the insights gained from this research and development are incorporated into our standard products.

      This strategy not only targets performance-driven aftermarket consumers seeking upgrades for their stock components but also involves observing how original equipment manufacturers are developing specific features through racing and offering Optima products if their technology is lacking.

      Elizabeth Blackstock, Optima

      From a sales perspective, this is logical. However, to grasp what can actually be learned at an event like the PPIHC—or, as Daryl Brockman, director of global sales, marketing, and product planning at Optima mentioned, at venues like King of the Hammers and the Baja 1000—you must consider the unique environment of this race.

      Certainly, durability is crucial for race cars, but Brockman noted that the PPIHC presents an intriguingly serious challenge, which I experienced firsthand with my aforementioned snack.

      I purchased a bag of chips in Colorado Springs, situated at an altitude just over 6,000 feet. The bag remained unopened in my front seat as I crossed the race’s starting line at 9,390 feet, gradually ascending to the summit of Pikes Peak, which reaches 14,115 feet.

      A sealed item like that bag of chips will undergo a dramatic transformation: it distends and expands. This happens because the air pressure inside the bag remains constant, as it was when sealed closer to sea level, while the external air pressure diminishes. The internal air pushes outward, resulting in significant surface tension, a phenomenon referred to by scientists as Boyle’s Law.

      Optima

      Similarly, batteries are fully sealed units, and the elevation changes during the race will affect the battery in the same way they impact the chip bag: as you climb higher, the external air pressure drops, while the internal air pressure of the battery stays unchanged.

      Shifts in pressure can compromise the structural integrity of a sealed lithium battery pack, potentially leading to leaks or explosions. Additionally, reduced cooling efficiency can cause the battery to overheat. These effects are certainly undesirable, but they become even more critical when those batteries are paired with specially designed cars aiming to complete the ascent in less than 10 minutes.

      “Our batteries feature a breather valve that permits the internal pressure to equalize with the atmospheric pressure outside,” Brockman explained. “It’s one of the details that sets our batteries apart from some competitors who may overlook it.”

      Elizabeth Blackstock

      And this is a detail that cannot be replicated in a laboratory setting—not completely.

      Brockman noted that the OrangeTop QH6 underwent a year and a half of lab testing, during which the Optima team resolved initial issues. The subsequent phase involved creating pre-production prototypes that Optima distributed to race teams and enthusiasts who would rigorously test these batteries.

      “A lab test is conducted in a controlled environment, meaning the assumptions may not align with real-world conditions,” Brockman clarified.

      “You may have estimates regarding the power required to start the vehicle, which can differ significantly between various models; the time it takes to crank; and the variations in starting when the engine is cold versus hot. Uncovering these discrepancies beyond initial assumptions is crucial for developing a consistently high-performing product.”

      Elizabeth Blackstock, Optima

      The breather valve is relatively straightforward; under sea-level atmospheric conditions, this valve remains sealed. However, as one ascends a mountain and pressure builds inside the battery, it compresses the valve, which then allows the pressure to escape. Once the air pressure inside and outside the battery equalizes, the valve closes. If my chip bag had a similar feature, it wouldn’t appear to be straining at the seams at the summit of Pikes Peak.

      The valve may be inconspicuous, but the OrangeTop QH6 is also equipped with numerous sensors that track battery