What a Bag of Chips Taught Me About Optima's Battery Tech at Pikes Peak

Yahoo

30-06-2025

Car racing has long been hailed as the ultimate test bed for burgeoning automotive technologies, with everything from aerodynamics to paddle shifters making their way from high-tech racing machines to consumer cars. But with so much of that already done, it's hard to imagine what, exactly, is left to learn.
To find out, Optima Batteries invited me to the 2025 Pikes Peak International Hill Climb. There, a fleet of BBI Autosport Porsche race cars would be outfitted with the company's OrangeTop QH6 lithium battery, and I was determined to discover exactly how relevant the iconic 12.42-mile run up America's Mountain can be in modern battery development.
Interestingly enough, it didn't take some complex concept or high-tech machine to teach me why Pikes Peak presents an enormous challenge to a vital component like a car battery. In fact, all it took was a silly bag of potato chips.
But first things first: Why is racing relevant to a company like Optima Batteries? Tom Downie, vice president of communications at Clarios (which owns Optima Batteries), explained just that.
Motorsport 'gives us a chance to push some of our products more than the average consumer might, and all of that [research and development] goes into our regular products.'
This approach may include not only appealing to performance-oriented aftermarket customers who want to upgrade their stock equipment, but also monitoring how OEMs are developing certain elements of their machines through racing and pitching Optima products to them if their technology falls short.
From a sales angle, that makes sense. But to understand what, exactly, can be learned at an event like the PPIHC—or, as Daryl Brockman, director of global sales, marketing, and product planning at Optima added—the King of the Hammers and the Baja 1000—you must look at this race's extremely unique environment.
Sure, you want your race cars to be durable, but Brockman explained that the PPIHC raises a frankly fascinating challenge, one that I experienced myself with the aforementioned salty snack.
I bought a bag of chips down in Colorado Springs, which sits at an altitude of just over 6,000 feet. It sat, unopened, in the front seat with me as I crossed the race's starting line at 9,390 feet, and made the slow ascent up Pikes Peak to the summit, which stands at 14,115 feet of elevation.
A sealed container like that bag of chips will undergo a wild change: It swells and expands. That's because the air pressure inside the bag remains the same as it was when it was sealed closer to sea level, while the air pressure outside the bag decreases. The internal air wants to push outside of the bag, which causes some extreme surface tension. Scientists call this Boyle's Law.
Just like the chip bag, batteries are also fully sealed containers, and the altitude change during the race is going to impact the battery the same way it impacts your chip bag: Namely, as you ascend higher up a mountain, the external air pressure is going to drop, but the internal air pressure in your battery will remain the same.
Pressure changes can impact the structural integrity of a sealed lithium battery pack, which can cause your battery to leak or even explode, while decreases in cooling efficiency mean your battery can overheat. It should go without saying that all of these impacts are bad, but they become particularly concerning when those batteries are mated to purpose-built cars that are trying to race up a huge mountain in 10 minutes or less.
'Our batteries actually have a breather valve that allows the pressure inside the battery to equalize compared to the atmospheric air pressure,' Brockman told me. 'It's one of the small details that our batteries have that some of our other competitors may not have considered.'
And it's a detail that can't be replicated through lab conditions—not really.
Brockman pointed out that the OrangeTop QH6 spent a year and a half in the lab, during which time the Optima development crew worked out any initial kinks. The next step is actually crafting pre-production prototypes that Optima has distributed to race teams and other enthusiasts who will really put those batteries to the test.
'A lab test is a controlled environment, so the assumptions don't always match reality,' Brockman explained.
'You'll have assumptions on how much power it takes to start the vehicle, which can vary wildly from one vehicle to another; the amount of cranking time; the differences in how a vehicle starts when the engine's cold versus when it's hot. Sometimes you'll find things outside of your initial assumptions, and those are the things we learned along the way to make sure that we have a product that will always perform.'
A breather valve is a fairly simple feature; under sea-level atmospheric conditions, this valve remains a sealed component of the battery. But as you climb further up a mountain and the pressure inside the battery builds, it compresses the valve and allows that air pressure to escape. When the air pressure inside and outside of the battery is equalized, the valve shuts. If my chip bag had a similar feature, it wouldn't look like it was bursting at the seams up at the summit of Pikes Peak.
The valve may be small, but the OrangeTop QH6 is also outfitted with a load of sensors that monitor battery health, all of which can be transmitted to an app on your phone via Bluetooth. Without the breather valve, Optima could see exactly how sudden changes in elevation and atmospheric pressure compromised battery integrity and lifespan. Add in the breather valve, and the data showed a dramatically different story, though the Optima crew was reluctant to hand off any proprietary details.
So, while the 2025 running of the PPIHC was the first time Optima had officially debuted its OrangeTop QH6 battery in a race car as a final product, it wasn't the first time a car had carried some version of that battery up a mountain; its adventure-focused product testers had been enthusiastically scaling summits for about a year before the company knew it had a battery that could withstand the pressures of competition. The difference is that now, Optima has completed the testing of its prototypes and feels confident enough to offer it to consumers.
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