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This is Part 2 of the Presentations from the
       EV Li-ion Battery Forum 2009
              Forum Day 1 & 2
         September 2009 Shanghai




                            Battery




                                                    Join in the discussion
                                                         look for the
                                                             group on




  For more information, please call +65 6243 0050
    or email yvonne@ev-li-ionbatteryforum.com


    www.ev-li-ionbatteryforum.com
Lithium Ion Battery and Electric Cars
                      Shanghai Sept 2009

                 Dr. Sankar Das Gupta
                      CEO , Electrovaya




• Climate Change                 900 million vehicles
                                 worldwide rely on
• Urban pollution                fossil fuels
• Rising oil prices              50 - 70 million new
• Energy security                vehicles on the road
                                 each year
• Healthcare costs
                                 85 Million Barrels
• Government initiatives         of oil Burnt every
                                 day
“It’s the batteries, Stupid”
                                                           The Honorable R. James Woolsey
                                                           The Honorable George P. Shultz
                                                           Co-Chairmen




                                                       Notes:   (1) James Woolsey – former CIA Director
                                                                (2) George Shultz – former US Secretary of State




  Electric Vehicle Components                                                 Unnecessary Internal Combustion Components


Battery System
                                                                                                 Gas Tank



                                                                                                  Engine

Electric Motor                                                                                    Transmis
                                                                                                  sion

                                                                                               Muffler
                                                                                                Fuel reformer
Onboard Charge &
Motor Controller                                                                                Oil Lines
                                                                                                Oil Pan
                                                                                                Water Cooling system
                                                                                                Catalytic Converter
                                Electric drive train
                                                                                                Fuel Injection System
                                                                                                Various Auxiliary System
Nanotechnology




A 30 kWh system (e.g. small BEV) requires

                              240 x   Electrovaya
                                      35Ah cells
                             7120 x   18650 cells
                                      (commercial phosphate)

                             3390 x   26650 cells
                                      (commercial phosphate)
Energy Density (Wh/kg)
• Most of world Lithium Ion Battery production
  uses organic liquid NMP (N- Methyl Pyrollidone)
• NMP recently suspected of reproductive Toxicity
  (birth defects) California 2001, EU 2003
• Electrovaya – Unique Production Technology
  does not use NMP
 “Zero Emission Manufacturing for Zero
 Emission Vehicles”.
Control
              Distributed     Intelligence
              Intelligence




            Battery System




Battery Engineering Team

Thermal Engineering Team

Power Electronics Team

Mechanical Engineering Team

Electrical Engineering Team
1.   Mississauga, Ontario Canada

                                                  2.   New York State, U.S.A.
                                                  3.   Licensee, Miljobil Joint Venture
                                                       - Norway




Strategic Implications of Unique Manufacturing:
•    Zero emission manufacturing process - Thus can manufacture anywhere – urban areas
     (Toronto), countries (Norway) with minimal environmental footprint
•    Capital cost for Manufacturing Plant is lowest for the industry - Thus can expand more
     cost effectively




                       Mississauga, Ontario Canada
Production Flow




                          Pre-commercialization Activities
                          Cell Mfg.     Module Build                                              integration
                                                          System design        system build                        verification

                                                                                                                                      Commercial



                            Systems Engineering (Engineers, Scientists, Technicians)
Type of Labour Required




                            Battery R&D Team (Scientists, Engineers, Technicians)

                                Thermal Engineering Team (Engineers, Technicians)

                                            Power Electronics Team (Computer Scientists, Engineers, Technicians)

                                            Mechanical Engineering Team (Scientists, Engineers, Technicians)

                                            Electrical Engineering Team (Engineers, Electricians, Technicians)

                            Mechatronics Team




                                                                                                                                         iterative
                                                                                                                                         work




                                            Battery Electric Vehicles
                                                                                              Production : USA, Canada,
                                                                                                       Norway
                                        Plug-in Hybrid Electric Vehicles




                                                     Passenger              Delivery Vans                  Off-Road               maya-300
                              OEMs                                            & Buses
                                                       Cars                                                                       Urban cars
PHEV Conversions   Delivery Vans




•
•
•
Corporate
    Homepage
    Feature




•
•

•
•
•

•
奇瑞新能源   目
CNEAT




                          二00九年九月




                          C - Pure electricity Technology




奇瑞新能源
CNEAT
        目
                提

   一、奇瑞公司           介
   二、奇瑞新能源       展

   三、主要     池   品技   参数

   四、下一步的需求




                          C - Pure electricity Technology
奇瑞新能源   目
CNEAT
    奇瑞      品已出口到全球70多个国家和地区




                          C - Pure electricity Technology




奇瑞新能源
CNEAT
        目
                提

   一、奇瑞公司       介

   二、奇瑞新能源           展
   三、主要     池   品技   参数

   四、下一步的需求




                          C - Pure electricity Technology
奇瑞新能源   目
CNEAT




                              C - Pure electricity Technology




奇瑞新能源   目
CNEAT



2000.12,完成奇瑞    汽  目的可行性分析与立 ,成立       汽   目
2001.10,申 承担了“十五”一期863 划“奇瑞混合 力   ” 目
2002.12,第一 3 ISG混合 力功能    研制完成,于2003.2通 863 划 收。
2004.09,第二 5 ISG混合 力功能    研制完成,并承担了“十五”二期863
        划“QR混合 力  研   。




                              C - Pure electricity Technology
奇瑞新能源    目
CNEAT



2002.01,A11        公司内立   ,并申   承担了“十五”一期863       划“QR
           ” 目
2002.12,第一 2 A11     功能    研制完成。
2003.02,第二 5 A11     功能    研制完成,并通      863   划    收。




                                   C - Pure electricity Technology




奇瑞新能源    目
CNEAT




                                   C - Pure electricity Technology
奇瑞新能源      目
CNEAT
 2004.11,以奇瑞 主 ,国 合作研 , 行A21_ISG中度混合与A21_BSG
度混合等两款混合 力       工程化与 化研 :
        行了3   化   开 , 了奇瑞两种混合 力      的  化
      建立了新能源开 平台,如 件、硬件平台等
      培养了奇瑞新能源开 的核心人
      列入863 划有4个                 ISG中度混合 力
      技 与 利 奇瑞所有




BSG   度混合      力


                                       C - Pure electricity Technology




奇瑞新能源      目
CNEAT




      2007年10月,奇瑞在       湖投放10台A21 BSG出租    行示范        。每台
      行超   20万公里,共累       示范    超 200万公里
      据    与反      ,在   湖市出租   行,BSG 油在10%左右




                                       C - Pure electricity Technology
奇瑞新能源   目
CNEAT




奇瑞公司提供58 A21_ISG与A21_BSG两种混合 力 ,在2008年北京
奥 会期 ,成功 行了示范      ,体 了“ 色奥 ”的宗旨。




                            C - Pure electricity Technology




奇瑞新能源   目
CNEAT




  2009年1月,奇瑞A21 BSG混合 力   在 湖批量上市,首期上市
  150 。截至 在,      已 行近8万公里,累   行 1200万公里。
  2009年底,奇瑞A21 ISG混合 力   将批量上市




                            C - Pure electricity Technology
奇瑞新能源     目
CNEAT

                                             Q21
                     S18                                              A5



                                                     Q21

                                                               S18b
                      QQ3


     全混                                        B22
混
合
    中混:ISG    A5
                                                      A3

力    混:BSG
                             A5

              2008    2009        2010   C - Pure 2011
                                                   electricity Technology
                                                               2012




奇瑞新能源
CNEAT
          目
                       提

    一、奇瑞公司            介

    二、奇瑞新能源                展

    三、主要             池       品技     参数
    四、下一步的需求




                                         C - Pure electricity Technology
奇瑞新能源   目
CNEAT


                 1000
                            6                                                      IC Engine
                            4
                                                                                           EV
                            2
                                 Li - ion                                                PHEV
                      100
            (Wh/kg)



                            6
                                                         Ni - MH
                            4
                                Lead - Acid
                            2                                                HEV

                       10
                            6                                                                  Capacitors
                            4

                            2

                        1
                            0                        1                   2                      3                4
                         10                     10                  10                     10               10
                                                                   (W/kg)




                                                                                     C - Pure electricity Technology




奇瑞新能源   目
CNEAT




                                            NiH


                       AGM

                                                           QQ EV                M1             A5 PHEV
                                                                               PHEV
                                              ISG
                      BSG



                                                                                     C - Pure electricity Technology
奇瑞新能源    目
CNEAT




                                     C - Pure electricity Technology




奇瑞新能源    目
CNEAT




    a)
    b)         336 V
    c)         40Ah
    d)                 0.2C   98%
    e)                 80%
    f)                  1C
    g)         13.4 kWh
    h)              3C
    i)                  1C
    j) 30                     21KW
    k) 100%DOD             2000
    l)             220 kg

                                     C - Pure electricity Technology
奇瑞新能源   目
CNEAT




                          C - Pure electricity Technology




奇瑞新能源
CNEAT
        目
                提

   一、奇瑞公司       介

   二、奇瑞新能源       展

   三、主要     池   品技   参数

   四、下一步的需求




                          C - Pure electricity Technology
奇瑞新能源   目
CNEAT

              我    的目




              ……




                        C - Pure electricity Technology




奇瑞新能源   目
CNEAT


            安全与主要性能相兼




                        C - Pure electricity Technology
奇瑞新能源   目
CNEAT


                  池本体

        一步提高比能量(EV及PHEV)
        一步提高比功率(PHEV)
        一步提高高温循 和低温性能
        一步提高均匀一致性和安全性
        一步降低成本(重要)




                        C - Pure electricity Technology




奇瑞新能源   目
CNEAT


              系    池包

    化    、   等
   循 寿命考核,如常 循 和工况循
   安全性能考核,如使用初期和使用中后期
    境 用性考核,如温度和机械等




                        C - Pure electricity Technology
奇瑞新能源   目
CNEAT


            控制(管理系   )

    化SOC和SOH算法,特别是SOH算法
   开展 磁兼容性能考核
    池包系 包括管理系 在内的 力蓄 池系                   性能
   的 合考核,如寿命、 境适 性等




                     C - Pure electricity Technology




奇瑞新能源   目
CNEAT




                     !



                     C - Pure electricity Technology
8Ah LMO Hi-Power cell, 89Wh/Kg, 1700W/Kg




 Cycling peformance of LMO cell module (100%DOD)
Rate performances of 40Ah LFP cell at 25°C
Power density

Energy density                   Working temp.range



       Safety                    Cost

                    Life
FreedomCAR Energy Storage Goals




            J.M. Tarascon, M. Armand, Nature, 414, 2001, 359
Cathode                 Voltage       Specific   Price    Application   Safety
                        vs Graphite   Capacity
          LiCoO2        3.7V          140Ah/kg   $35/kg   Consumer      Low
          LiNoCoMn      3.6V          155Ah/kg   $24/kg   Consumer      mid
                                                          Powertool
          LiNiCoAl      3.55V         170Ah/kg   $26/kg   Consumer      Low/mid
                                                          Industial
          LiMn2O4       3.8V          110Ah/kg   $12/kg   Powertool     High
                                                          Vehicel
          LiFePO4       3.2V          150Ah/kg   $30/kg   Powertool     High
                                                          Vehicel


                        Voltage       Specific   Price
                        vs Graphite   Capacity
Anode     Graphite      0V            330Ah/kg   $10/kg
          Hard Carbon   0.3V          250Ah/kg   $40/kg
          Li4Ti5O12     1.3V          160Ah/kg   $25/kg




                             Graphite Anode
Hard Carbon Anode                  Li4Ti5O12 Anode




                                                    Si


                                        Si

                                                  Cu foil

 nano-Si/C        After discharging

                   Electrochem. agglomeration




 H. Li, X. J. Huang et al,
 Electrochemical and Solid-State Letters, 2 (11) 547-549 (1999)
Si Composite Anode materials
1

                 2
                 3
                 4
                 5
                 6
                 7
                 8

LFP/Graphite

               *Patent licensing fee is not included
Tianjin Lishen Battery Joint-stock Co.,Ltd

                   Zhang Na


2-3 Sep, 2009 EV Li-ion Battery Forum, Shanghai, China




                   Outline
Background-Key Materials Challenges


   Safety              The number one concern for passenger vehicles


   Availability        Meet a wide temperature range of -30     to 60

   Durability          Cycle and calendar life must allow for 10~15
                       years of battery operation

   Cost                Batteries for EV with large batteries require low cost




               Cathode Chemistry in Lishen

 KPI of Cathode Materials
            Voltage        Capacity /
                                           Cycle Life       Cost          Safety
            Range/V        (mAh/g)

LiMn2O4      3.0-4.2       100    120        Good           Low           Better

LiFePO4      2.0-3.6       130    150      Excellent        Low         Excellent

 NCM         2.5-4.2             150         Better         High          Good

 NCA         2.5-4.2             150         Better         High          Good

 •At least four different cathode chemistries are being considered in power battery

 •NCA and NCM are the choices for high energy density

 •LFP shows the lowest energy density due to low voltage and low material density
Safety of Cathode Material



                                             DSC of LiNi1/3Co1/3Mn1/3O2 LiMn2O4
                                             LiFePO4 and Electrolyte at 4.3V




   •Most cathode materials exhibit a strong exothermal reaction with the electrolyte in
   the charged state which can lead to a thermal runaway of the battery

   •LFP is completely stable and allows the development of an intrinsically safe cell




           Study on LiFePO4 in Lishen—Basic Performance

                                             Energy Type                    Power Type
Items                           A      B       C      D       E       F      G          H
Surface area (m2/g)             9      11      16     10      14     18     15      14
Tapped density   (g/cm3)       0.8     1.0    0.9     1.1    1.0     1.0    1.0     0.6
Particle size (μm)    (D10)    2.2     1.5    0.6     1.1    0.8    0.75    0.2     0.2
                      (D50)    5.4     3.4    2.3     4.2    4.5     5.1    0.8     0.6
                      (D90)    9.1     5.9    11.2   10.3    12.2   16.6    4.8     5.0
Moisture (ppm)                 420    800     300    500     1100    100    410     700
Discharge capacity (mAh/       148    150     145    148     145     143    143     152
g)
Processability                 Hard   Hard    Hard   Hard    OK      OK    Hard Harder
Study on LiFePO4 in Lishen—SEM




 A                     B




 C                     D




Study on LiFePO4 in Lishen—SEM




 E                     F




 G                     H
Study on LiFePO4 in Lishen—Discharge Performance




                                   Discharge Performance:
                                   A E B C D F




       Study on LiFePO4 in Lishen—Cycle Life




Cycle Life( According to cycle life trend line): B C   A    E   D
Study on LiFePO4 in Lishen—Discharge Performance




                                      Discharge Performance:
                                      G     E




     Study on LiFePO4 in Lishen—Safety performance

   No            Hot Oven                      Nail Penetration No
 Explosion       150 /10min                    Nail: 3- 8mm, Explosion
  No Fire                                      Speed:10-40mm/s No Fire

  No                                                             No
Explosion    Over             Safety & Abuse          Over     Explosion
 No Fire     Discharge            Testing             Charge    No Fire
                                                      1C/10V

       No                                                        No
     Explosion       Crush                     Short Circuit   Explosion
      No Fire                                                   No Fire


                   All the Materials are Safe!
Anode Chemistry in Lishen

 Properties of anode materials

  Item          MCMB                     HC                 SC                   LTO


Structure



  SEM




                             KPI of anode materials


             Particle size    Capacity   Tap Density/
                                                           Advantage          Disadvantage
              D50/(μm)        /(mAh/g)      (g/cc)
  Graphite                                                  Low cost;           Low temp.;
                8.104           300           1.3
  (MCMB)                                                   High capacity       Rapid charge

                                                                              Energy; Initial
    Hard                                                   High Power;
                9.146           430           0.9           Longevity
                                                                               Efficiency; low
   Carbon                                                                       tap density
                                                                                Low energy
    Soft
                11.216          360           0.8       Low cost; Longevity   density; low tap
   Carbon                                                                         density
                                                           High Power;
                                                                                Low energy
  Li4Ti5O4       9.7            150           1.2           Longevity
                                                                                  density
                                                        Low Temp.; Safety
Charge curves of anode materials

                                           No SEI forming, which can
                                         improve the low temp. electron
                                        conductivity. the voltage Vs. Li is
        Anode electrode Potential (V)




                                        1.5V, which can effectively avoid       Hard carbon has the excellent
                                           the creating of the lithium        specific capacity, and the charge
                                                    dendrites.                and discharge curve shows good
                                                                               gradient, which is propitious to
                                                                              estimate the SOC of the battery .
                                                                                                         1.5V Vs Li
                                                                              LTO
                                                       Hard Carbon
                                                                                        The properties of soft carbon
                                               Soft Carbon                              is between hard carbon and
                                                                                              artificial graphite.
                                        Graphite
0.1V Vs Li

                                                           Charge Capacity (mAh)




                        Electrochemical performances—rated discharge

                                                                               Because of the intrinsic properties,
                                                                               hard carbon is benefit to be
                                                                               discharged at large current. The
                                                                               hard carbon displays the higher
                                                                               voltage than soft carbon and
                                                                               MCMB at high rate discharge.
Electrochemical performances—rated charge

                                      LTO shows excellent high rate
                                      charging property, which is
                                      better than HC and SC, and the
                                      high rate charging capacity of
                                      the MCMB is the least.




Time of charging to 90%SOC (10C)

    Anode         Time/min
     MCMB             12.8
      HC              7.3
      SC              5.4
      LTO             5.6




            Electrochemical performances—cycle life
Low temperature performance




                          Conclusions
Batteries are the primary barrier in making electric-drive vehicles
possible. Li-ion batteries can best meet the electric-drive challenge;

LiFePO4 is an intrinsically safe system with good cycle life. At present
LiFePO4 platform is one of the best choice for EV/HEV application in
Lishen;

MCMB and hard carbon are used in Lishen present EV/ HEV cell
products; Li4Ti5O12 has higher rate charge ability (at low Temp. vs. AG) ,
so it seems that Li4Ti5O12 is the best choice for next generation HEV
application;

Raw material is one of the key premise for good battery, but the
electrode process is a big challenge for battery maker due to the property
of LiFePO4. Lishen has sound base and enough manufacture experience
to penetrate the EV market.
Thank You!
Solar   Wind
°


    °


        2   3 4   5
                          °

        1




1           2     3   4       5
μ
(1st cycle rate: C/20, other cycles: C/5)
http://www.hnei.hawaii.edu/




  Carbon-based economy (pollutions) will be gone
  eventually




  Clean electricity-based economy will take over
       Electrified transportation will prevail
  How can we insure a safe and optimal operation of a
   power source or energy storage (PS/ES) system?
      Field testing?
      Laboratory testing?
      Modeling & simulation?
      All of the above?
  What tools do we need to reach that objective?
      Model/simulation? Diagnosis? Prognosis?
      Are they easy to handle?
      Can they be used in real time ?
      Can they be used to forecast the available capacity ?




                             How to understand field data?
                                  Analyze the duty/generation cycle
                                       Link usage (duty cycle) to size &
                                        performance of the PS/ES system
    Data collection                    Allow accurate sizing of the battery pack
                                        for geographically-dependent duty cycle
             Pattern
             Recognition


Duty cycle
 analysis
Data collection                              Event D, high wind speed,
                                                     low gusts distribution


                   Pattern
                   Recognition


 Duty cycle          Event cycle
  analysis            analysis


    Event forecasting




  How to understand battery
  degradation ?
     Battery electrochemical behavior is:
             Rate dependent
                                                     Small scale tests
             Temperature dependent                  Specific protocols
             Age dependent
       Need to test the cells under              Performance         Rate, T, …
        appropriate protocols                      under load          effects
             Derived from representative usage
              schedule (rate, temperature)
             Matrix of different parameters
                  Rate
                  Pulses
                  Temperature
                  …
  Degradation is often complex
       Need a reference point (SOC tracing)
       Need in situ characterization
            Incremental capacity analysis
            Close-to-equil. OCV analysis            Small scale tests
                                                     Specific protocols




                                                     Life & degradation
                                                     mechanisms




  Single cell model
       Derived from performance tests

                                                     Small scale tests
                                                     Specific protocols

                               Cell performance                  Rate, T
                                                  Performance
                                     model                       effects
                                                   under load

       ECM approach: accurate & not computation intensive
  Single cell to pack modeling
       Accommodate cell-to-cell variations
       Adapt to topology
                                                  Small scale tests
                                                  Specific protocols

                           Cell performance                    Rate, T
                                 model        Performance
                                               under load      effects

                             Pack model          Cell to cell variations




  Diagnostic and prognostic tools
     Developed from knowledge in
      single cell testing and analysis
     Nominal vs. anomalies
     ID & Quantification
                                                 Small scale tests
                                                 Specific protocols

                          Cell performance                    Rate, T
                                              Performance
                                model                         effects
                                               under load

                             Pack model         Cell to cell variations

                          Diagnostic model
                                                 Life & degradation
                          Prognostic model       mechanisms
  Diagnostic and prognostic tools




                               V,SOC
Real time data
                 I,T,SOC,SOH            Analysis
                                          and
                               V,SOC   prognostic
                                        module
Representative
                                        usage schedule
                                                                       Small scale tests
     Data collection
                                                                       Specific protocols

               Pattern                 Cell performance                              Rate, T
                                                                  Performance
               Recognition                   model                                   effects
                                                                   under load

                                           Pack model                Cell to cell variations
Duty cycle         Event cycle
 analysis           analysis
                                       Diagnostic model
                                                                   Life & degradation
   Event forecasting                   Prognostic model            mechanisms




  More details ―
        Roadmap
             M. Dubarry, V. Svoboda, R. Hwu and B.Y. Liaw, “A roadmap to understand
              battery performance in electric and hybrid vehicle operation,” J. Power Sources
              174 (2007) 366.
             M. Dubarry, N. Vuillaume, B.Y. Liaw, and T. Quinn, “Vehicle evaluation, battery
              modeling, and fleet-testing experiences in Hawaii: A roadmap to understanding
              evaluation data and simulation” J. Asian Electric Vehicles 5 (2007) 1033.
        Event pattern recognition
             B.Y. Liaw, M. Dubarry, “From driving cycle analysis to understanding battery
              performance in real-life electric hybrid vehicle operation” (invited) to the Special
              Issue on Hybrid Electric Vehicles, J. Power Sources 174 (2007) 76.
        Battery Analysis
             M. Dubarry, V. Svoboda, R. Hwu and B.Y. Liaw, “Capacity and power fading
              mechanism identification from a commercial cell evaluation,” J. Power Sources
              165 (2007) 566.
             M. Dubarry, V. Svoboda, R. Hwu and B.Y. Liaw, “Capacity loss in rechargeable
              lithium cells during cycle life testing: The importance of determining state-of-
              charge” J. Power Sources 174 (2007) 1121.
        Modeling
             M. Dubarry and B.Y. Liaw, “Development of a universal modeling tool for
              rechargeable lithium batteries,” J. Power Sources 174 (2007) 856.
Troy A. Hayes, Ph.D., P.E.
             General Manager
             Exponent China
             +1 (650) 688-7127 (US)
             +86 (571) 2802 1727 (China)
             thayes@exponent.com




         September 3, 2009
    TRK7335.000 61CN 0109 FLA1
TRK7335.000 61CN 0809 EV09




                             Who We Are

       • Professional services firm
       • Engineering & scientific consulting
       • 650+ consulting and technical staff
       • Best known for analyzing accidents
         & failures
       • Design and manufacturing
         consulting based on FA experience




TRK7335.000 61CN 0809 EV09
Outline
       • Technologies used for identifying defective
            cells
               –      X-Ray
               –      CT Scanning
               –      Hi-Pot testing
               –      OCV
               –      Sorting
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               – Recalls – when and why?
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X-Ray
       • X-Ray is useful as a 100% inspection
            procedure to verify proper anode/cathode
            alignment
               – Note: this is not 100% accurate
       • X-Ray is also useful when used on a sampling
            basis (using both is most desirable)




TRK7335.000 61CN 0809 EV09




                             X-Ray




                                             Ni tab kink




TRK7335.000 61CN 0809 EV09
X-Ray




TRK7335.000 61CN 0809 EV09




                             CT Scanning
       • CT Scanning can be used on a sampling basis
            to evaluate:
               –     Metallic contamination
               –     Holes in active material
               –     High-density spots in active material
               –     Wrinkles in electrodes/current collectors
               –     Delamination of electrodes
               –     Detailed alignment
               –     Deformation of windings associated with tabs,
                     bends etc.
       • Disadvantages:
               – Slow for a complete scan (7 hours for an 18650)
               – Expensive ($250K USD for a good machine)
TRK7335.000 61CN 0809 EV09
CT Scanning




TRK7335.000 61CN 0809 EV09   100 x 100 x t=50 μm Fe   50 x 50 x t=20 μm Ni




                             CT Scanning
                                                       • Cu dissolution
                                                         due to
                                                         repeated over-
                                                         discharge
                                                       • Cathode
                                                         delamination




TRK7335.000 61CN 0809 EV09
Hi-Pot Testing
       • How were the Hi-Pot values chosen?
               – Need a properly-designed DOE
                 • Metallic particle size/type
                 • Voltage level and application time
               – Will vary with capacity/size
       • Hi-Pot failures
               – Data analysis
               – Failure analysis
               – Closed-loop corrective action

TRK7335.000 61CN 0809 EV09




                        OCV Testing
       • How are the limits chosen?
               – IEEE 1725 5.5.7
       • Data analysis
       • Failure analysis
       • Closed-loop corrective action




TRK7335.000 61CN 0809 EV09
Sorting
       • Why sort?
       • Do you really know what causes the variation
            between cells of various classes?
               – Loading versus other properties
               – Self discharge rate
       • Is it possible for two independent causes to
            create a cell of a particular class?
               – If so, cells of one class may age differently
                              Cap 2,000 – 2,150    2,151 – 2,300
                   Voltage         mAh             mAh
                   V 3.82V         Grade B         Grade A

                             3.82 > V 3.77 Grade D   Grade C
TRK7335.000 61CN 0809 EV09




                             Laser Weld Visual Inspection




       • Entirely dependent on operator skill
       • Is the visual inspection reliable?

TRK7335.000 61CN 0809 EV09
Impedance Measurement Between
                             Tab and Cell (Soft Pouch)
       • When the inner polymer layer on the Al
            pouch is compromised, a current
            leakage path can occur
               – Corrosion
               – Gas generation
               – Cell swelling
               – Electrolyte leakage

       • Compromised pouches can be identified
            during production by measuring the
            impedance between the negative tab
            and the Al pouch after cell formation
            and aging
TRK7335.000 61CN 0809 EV09




               Part 2: Maintaining Your Brand’s Trust




TRK7335.000 61CN 0809 EV09
Maintaining Your Brand’s Trust
       • Recalls are for the consumer’s
         protection
       • Recalls must be properly managed
       • Recall as soon as possible – don’t wait
       • Recall everywhere, not just where you
         are required (e.g., by the CPSC)
       • Consumers will have more confidence
         in your brand if they know you are
         acting in their best interest
       • Communicate to the customer
TRK7335.000 61CN 0809 EV09




                             Limiting a Recall – TRACEABILITY
       • Tracing all material lots and equipment is
            extremely important!
               –      Cap assemblies
               –      Electrode batches
               –      Current collectors
               –      Slitting blade number
               –      Winding machine
               –      The more detail, the better
       • Remember, most date codes disappear during
            a thermal runaway event
               – Can you differentiate dates and machines by
                 something internal to the cell?
TRK7335.000 61CN 0809 EV09
Data Analysis
       • Need to consider
               – End of life
               – Time in service at time of incident
               – Geography and power type/stability where
                 incidents occur
               – Differences in population versus failure rate
                 (e.g., type of charger, etc.)
               – Changes on manufacturing line
               – Material changes
               – Design changes
               – Failure rates (Hi-Pot, OCV, etc.)
               – Other factors
TRK7335.000 61CN 0809 EV09




                                     Data Analysis
               Expected Number of Failures
                    per Million Cells




TRK7335.000 61CN 0809 EV09
Timeline for Possible Contributing
                             Factors
      2007                        2008                                                   2009
          11        12        1     2      3     4   5   6    7   8   9   10   11   12   1   2   3   4   5   6   7




                                                                  Factor A

                                         Factor B

                                                     Anode material B


                         Cu Foil B


                                               Can vendor B


                             Winder #2 in use

                             Winder #16 in use
TRK7335.000 61CN 0809 EV09




                             Summary
       • Technologies used for identifying defective
            cells
               –      X-Ray
               –      CT Scanning
               –      Hi-Pot testing
               –      OCV
               –      Sorting
               –      Imaging laser tab welds
               –      Tab-to-cell impedance (soft pouch)
       • Maintaining your brand’s trust
               – Recall if necessary
               – Manage the recall and communicate to the customer
TRK7335.000 61CN 0809 EV09

                 Make your product as traceable as possible
Questions?




TRK7335.000 61CN 0809 EV09




                                 Cell and Battery Pack Analysis, Including:

                      Auditing, Failure Analysis, Design Review, Testing, CTIA
                               Certification and Regulatory Consulting

                                              24 Offices Worldwide

                             Boston, Los Angeles, Phoenix, San Francisco and China



                   +1-888-656-EXPO (US)                      +86 571 2802 1788 (China)
                 www.exponent.com/batteries                   www.exponentchina.com
                    info@exponent.com                      exponentchina@exponent.com
    TRK7335.000 61CN 0109 FLA1
TRK7335.000 61CN 0809 EV09

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Evlib part 2

  • 1. This is Part 2 of the Presentations from the EV Li-ion Battery Forum 2009 Forum Day 1 & 2 September 2009 Shanghai Battery Join in the discussion look for the group on For more information, please call +65 6243 0050 or email yvonne@ev-li-ionbatteryforum.com www.ev-li-ionbatteryforum.com
  • 2.
  • 3. Lithium Ion Battery and Electric Cars Shanghai Sept 2009 Dr. Sankar Das Gupta CEO , Electrovaya • Climate Change 900 million vehicles worldwide rely on • Urban pollution fossil fuels • Rising oil prices 50 - 70 million new • Energy security vehicles on the road each year • Healthcare costs 85 Million Barrels • Government initiatives of oil Burnt every day
  • 4. “It’s the batteries, Stupid” The Honorable R. James Woolsey The Honorable George P. Shultz Co-Chairmen Notes: (1) James Woolsey – former CIA Director (2) George Shultz – former US Secretary of State Electric Vehicle Components Unnecessary Internal Combustion Components Battery System Gas Tank Engine Electric Motor Transmis sion Muffler Fuel reformer Onboard Charge & Motor Controller Oil Lines Oil Pan Water Cooling system Catalytic Converter Electric drive train Fuel Injection System Various Auxiliary System
  • 5.
  • 6. Nanotechnology A 30 kWh system (e.g. small BEV) requires 240 x Electrovaya 35Ah cells 7120 x 18650 cells (commercial phosphate) 3390 x 26650 cells (commercial phosphate)
  • 8. • Most of world Lithium Ion Battery production uses organic liquid NMP (N- Methyl Pyrollidone) • NMP recently suspected of reproductive Toxicity (birth defects) California 2001, EU 2003 • Electrovaya – Unique Production Technology does not use NMP “Zero Emission Manufacturing for Zero Emission Vehicles”.
  • 9.
  • 10. Control Distributed Intelligence Intelligence Battery System Battery Engineering Team Thermal Engineering Team Power Electronics Team Mechanical Engineering Team Electrical Engineering Team
  • 11. 1. Mississauga, Ontario Canada 2. New York State, U.S.A. 3. Licensee, Miljobil Joint Venture - Norway Strategic Implications of Unique Manufacturing: • Zero emission manufacturing process - Thus can manufacture anywhere – urban areas (Toronto), countries (Norway) with minimal environmental footprint • Capital cost for Manufacturing Plant is lowest for the industry - Thus can expand more cost effectively Mississauga, Ontario Canada
  • 12. Production Flow Pre-commercialization Activities Cell Mfg. Module Build integration System design system build verification Commercial Systems Engineering (Engineers, Scientists, Technicians) Type of Labour Required Battery R&D Team (Scientists, Engineers, Technicians) Thermal Engineering Team (Engineers, Technicians) Power Electronics Team (Computer Scientists, Engineers, Technicians) Mechanical Engineering Team (Scientists, Engineers, Technicians) Electrical Engineering Team (Engineers, Electricians, Technicians) Mechatronics Team iterative work Battery Electric Vehicles Production : USA, Canada, Norway Plug-in Hybrid Electric Vehicles Passenger Delivery Vans Off-Road maya-300 OEMs & Buses Cars Urban cars
  • 13. PHEV Conversions Delivery Vans • • •
  • 14. Corporate Homepage Feature • • • • • •
  • 15.
  • 16. 奇瑞新能源 目 CNEAT 二00九年九月 C - Pure electricity Technology 奇瑞新能源 CNEAT 目 提 一、奇瑞公司 介 二、奇瑞新能源 展 三、主要 池 品技 参数 四、下一步的需求 C - Pure electricity Technology
  • 17. 奇瑞新能源 目 CNEAT 奇瑞 品已出口到全球70多个国家和地区 C - Pure electricity Technology 奇瑞新能源 CNEAT 目 提 一、奇瑞公司 介 二、奇瑞新能源 展 三、主要 池 品技 参数 四、下一步的需求 C - Pure electricity Technology
  • 18. 奇瑞新能源 目 CNEAT C - Pure electricity Technology 奇瑞新能源 目 CNEAT 2000.12,完成奇瑞 汽 目的可行性分析与立 ,成立 汽 目 2001.10,申 承担了“十五”一期863 划“奇瑞混合 力 ” 目 2002.12,第一 3 ISG混合 力功能 研制完成,于2003.2通 863 划 收。 2004.09,第二 5 ISG混合 力功能 研制完成,并承担了“十五”二期863 划“QR混合 力 研 。 C - Pure electricity Technology
  • 19. 奇瑞新能源 目 CNEAT 2002.01,A11 公司内立 ,并申 承担了“十五”一期863 划“QR ” 目 2002.12,第一 2 A11 功能 研制完成。 2003.02,第二 5 A11 功能 研制完成,并通 863 划 收。 C - Pure electricity Technology 奇瑞新能源 目 CNEAT C - Pure electricity Technology
  • 20. 奇瑞新能源 目 CNEAT 2004.11,以奇瑞 主 ,国 合作研 , 行A21_ISG中度混合与A21_BSG 度混合等两款混合 力 工程化与 化研 : 行了3 化 开 , 了奇瑞两种混合 力 的 化 建立了新能源开 平台,如 件、硬件平台等 培养了奇瑞新能源开 的核心人 列入863 划有4个 ISG中度混合 力 技 与 利 奇瑞所有 BSG 度混合 力 C - Pure electricity Technology 奇瑞新能源 目 CNEAT 2007年10月,奇瑞在 湖投放10台A21 BSG出租 行示范 。每台 行超 20万公里,共累 示范 超 200万公里 据 与反 ,在 湖市出租 行,BSG 油在10%左右 C - Pure electricity Technology
  • 21. 奇瑞新能源 目 CNEAT 奇瑞公司提供58 A21_ISG与A21_BSG两种混合 力 ,在2008年北京 奥 会期 ,成功 行了示范 ,体 了“ 色奥 ”的宗旨。 C - Pure electricity Technology 奇瑞新能源 目 CNEAT 2009年1月,奇瑞A21 BSG混合 力 在 湖批量上市,首期上市 150 。截至 在, 已 行近8万公里,累 行 1200万公里。 2009年底,奇瑞A21 ISG混合 力 将批量上市 C - Pure electricity Technology
  • 22. 奇瑞新能源 目 CNEAT Q21 S18 A5 Q21 S18b QQ3 全混 B22 混 合 中混:ISG A5 A3 力 混:BSG A5 2008 2009 2010 C - Pure 2011 electricity Technology 2012 奇瑞新能源 CNEAT 目 提 一、奇瑞公司 介 二、奇瑞新能源 展 三、主要 池 品技 参数 四、下一步的需求 C - Pure electricity Technology
  • 23. 奇瑞新能源 目 CNEAT 1000 6 IC Engine 4 EV 2 Li - ion PHEV 100 (Wh/kg) 6 Ni - MH 4 Lead - Acid 2 HEV 10 6 Capacitors 4 2 1 0 1 2 3 4 10 10 10 10 10 (W/kg) C - Pure electricity Technology 奇瑞新能源 目 CNEAT NiH AGM QQ EV M1 A5 PHEV PHEV ISG BSG C - Pure electricity Technology
  • 24. 奇瑞新能源 目 CNEAT C - Pure electricity Technology 奇瑞新能源 目 CNEAT a) b) 336 V c) 40Ah d) 0.2C 98% e) 80% f) 1C g) 13.4 kWh h) 3C i) 1C j) 30 21KW k) 100%DOD 2000 l) 220 kg C - Pure electricity Technology
  • 25. 奇瑞新能源 目 CNEAT C - Pure electricity Technology 奇瑞新能源 CNEAT 目 提 一、奇瑞公司 介 二、奇瑞新能源 展 三、主要 池 品技 参数 四、下一步的需求 C - Pure electricity Technology
  • 26. 奇瑞新能源 目 CNEAT 我 的目 …… C - Pure electricity Technology 奇瑞新能源 目 CNEAT 安全与主要性能相兼 C - Pure electricity Technology
  • 27. 奇瑞新能源 目 CNEAT 池本体 一步提高比能量(EV及PHEV) 一步提高比功率(PHEV) 一步提高高温循 和低温性能 一步提高均匀一致性和安全性 一步降低成本(重要) C - Pure electricity Technology 奇瑞新能源 目 CNEAT 系 池包 化 、 等 循 寿命考核,如常 循 和工况循 安全性能考核,如使用初期和使用中后期 境 用性考核,如温度和机械等 C - Pure electricity Technology
  • 28. 奇瑞新能源 目 CNEAT 控制(管理系 ) 化SOC和SOH算法,特别是SOH算法 开展 磁兼容性能考核 池包系 包括管理系 在内的 力蓄 池系 性能 的 合考核,如寿命、 境适 性等 C - Pure electricity Technology 奇瑞新能源 目 CNEAT ! C - Pure electricity Technology
  • 29.
  • 30.
  • 31. 8Ah LMO Hi-Power cell, 89Wh/Kg, 1700W/Kg Cycling peformance of LMO cell module (100%DOD)
  • 32. Rate performances of 40Ah LFP cell at 25°C
  • 33. Power density Energy density Working temp.range Safety Cost Life
  • 34. FreedomCAR Energy Storage Goals J.M. Tarascon, M. Armand, Nature, 414, 2001, 359
  • 35. Cathode Voltage Specific Price Application Safety vs Graphite Capacity LiCoO2 3.7V 140Ah/kg $35/kg Consumer Low LiNoCoMn 3.6V 155Ah/kg $24/kg Consumer mid Powertool LiNiCoAl 3.55V 170Ah/kg $26/kg Consumer Low/mid Industial LiMn2O4 3.8V 110Ah/kg $12/kg Powertool High Vehicel LiFePO4 3.2V 150Ah/kg $30/kg Powertool High Vehicel Voltage Specific Price vs Graphite Capacity Anode Graphite 0V 330Ah/kg $10/kg Hard Carbon 0.3V 250Ah/kg $40/kg Li4Ti5O12 1.3V 160Ah/kg $25/kg Graphite Anode
  • 36. Hard Carbon Anode Li4Ti5O12 Anode Si Si Cu foil nano-Si/C After discharging Electrochem. agglomeration H. Li, X. J. Huang et al, Electrochemical and Solid-State Letters, 2 (11) 547-549 (1999)
  • 37. Si Composite Anode materials
  • 38. 1 2 3 4 5 6 7 8 LFP/Graphite *Patent licensing fee is not included
  • 39.
  • 40. Tianjin Lishen Battery Joint-stock Co.,Ltd Zhang Na 2-3 Sep, 2009 EV Li-ion Battery Forum, Shanghai, China Outline
  • 41. Background-Key Materials Challenges Safety The number one concern for passenger vehicles Availability Meet a wide temperature range of -30 to 60 Durability Cycle and calendar life must allow for 10~15 years of battery operation Cost Batteries for EV with large batteries require low cost Cathode Chemistry in Lishen KPI of Cathode Materials Voltage Capacity / Cycle Life Cost Safety Range/V (mAh/g) LiMn2O4 3.0-4.2 100 120 Good Low Better LiFePO4 2.0-3.6 130 150 Excellent Low Excellent NCM 2.5-4.2 150 Better High Good NCA 2.5-4.2 150 Better High Good •At least four different cathode chemistries are being considered in power battery •NCA and NCM are the choices for high energy density •LFP shows the lowest energy density due to low voltage and low material density
  • 42. Safety of Cathode Material DSC of LiNi1/3Co1/3Mn1/3O2 LiMn2O4 LiFePO4 and Electrolyte at 4.3V •Most cathode materials exhibit a strong exothermal reaction with the electrolyte in the charged state which can lead to a thermal runaway of the battery •LFP is completely stable and allows the development of an intrinsically safe cell Study on LiFePO4 in Lishen—Basic Performance Energy Type Power Type Items A B C D E F G H Surface area (m2/g) 9 11 16 10 14 18 15 14 Tapped density (g/cm3) 0.8 1.0 0.9 1.1 1.0 1.0 1.0 0.6 Particle size (μm) (D10) 2.2 1.5 0.6 1.1 0.8 0.75 0.2 0.2 (D50) 5.4 3.4 2.3 4.2 4.5 5.1 0.8 0.6 (D90) 9.1 5.9 11.2 10.3 12.2 16.6 4.8 5.0 Moisture (ppm) 420 800 300 500 1100 100 410 700 Discharge capacity (mAh/ 148 150 145 148 145 143 143 152 g) Processability Hard Hard Hard Hard OK OK Hard Harder
  • 43. Study on LiFePO4 in Lishen—SEM A B C D Study on LiFePO4 in Lishen—SEM E F G H
  • 44. Study on LiFePO4 in Lishen—Discharge Performance Discharge Performance: A E B C D F Study on LiFePO4 in Lishen—Cycle Life Cycle Life( According to cycle life trend line): B C A E D
  • 45. Study on LiFePO4 in Lishen—Discharge Performance Discharge Performance: G E Study on LiFePO4 in Lishen—Safety performance No Hot Oven Nail Penetration No Explosion 150 /10min Nail: 3- 8mm, Explosion No Fire Speed:10-40mm/s No Fire No No Explosion Over Safety & Abuse Over Explosion No Fire Discharge Testing Charge No Fire 1C/10V No No Explosion Crush Short Circuit Explosion No Fire No Fire All the Materials are Safe!
  • 46. Anode Chemistry in Lishen Properties of anode materials Item MCMB HC SC LTO Structure SEM KPI of anode materials Particle size Capacity Tap Density/ Advantage Disadvantage D50/(μm) /(mAh/g) (g/cc) Graphite Low cost; Low temp.; 8.104 300 1.3 (MCMB) High capacity Rapid charge Energy; Initial Hard High Power; 9.146 430 0.9 Longevity Efficiency; low Carbon tap density Low energy Soft 11.216 360 0.8 Low cost; Longevity density; low tap Carbon density High Power; Low energy Li4Ti5O4 9.7 150 1.2 Longevity density Low Temp.; Safety
  • 47. Charge curves of anode materials No SEI forming, which can improve the low temp. electron conductivity. the voltage Vs. Li is Anode electrode Potential (V) 1.5V, which can effectively avoid Hard carbon has the excellent the creating of the lithium specific capacity, and the charge dendrites. and discharge curve shows good gradient, which is propitious to estimate the SOC of the battery . 1.5V Vs Li LTO Hard Carbon The properties of soft carbon Soft Carbon is between hard carbon and artificial graphite. Graphite 0.1V Vs Li Charge Capacity (mAh) Electrochemical performances—rated discharge Because of the intrinsic properties, hard carbon is benefit to be discharged at large current. The hard carbon displays the higher voltage than soft carbon and MCMB at high rate discharge.
  • 48. Electrochemical performances—rated charge LTO shows excellent high rate charging property, which is better than HC and SC, and the high rate charging capacity of the MCMB is the least. Time of charging to 90%SOC (10C) Anode Time/min MCMB 12.8 HC 7.3 SC 5.4 LTO 5.6 Electrochemical performances—cycle life
  • 49. Low temperature performance Conclusions Batteries are the primary barrier in making electric-drive vehicles possible. Li-ion batteries can best meet the electric-drive challenge; LiFePO4 is an intrinsically safe system with good cycle life. At present LiFePO4 platform is one of the best choice for EV/HEV application in Lishen; MCMB and hard carbon are used in Lishen present EV/ HEV cell products; Li4Ti5O12 has higher rate charge ability (at low Temp. vs. AG) , so it seems that Li4Ti5O12 is the best choice for next generation HEV application; Raw material is one of the key premise for good battery, but the electrode process is a big challenge for battery maker due to the property of LiFePO4. Lishen has sound base and enough manufacture experience to penetrate the EV market.
  • 51.
  • 52.
  • 53. Solar Wind
  • 54.
  • 55. ° ° 2 3 4 5 ° 1 1 2 3 4 5
  • 56. μ
  • 57. (1st cycle rate: C/20, other cycles: C/5)
  • 58.
  • 59.
  • 60.
  • 61.
  • 62.
  • 63.
  • 64. http://www.hnei.hawaii.edu/   Carbon-based economy (pollutions) will be gone eventually   Clean electricity-based economy will take over   Electrified transportation will prevail
  • 65.   How can we insure a safe and optimal operation of a power source or energy storage (PS/ES) system?   Field testing?   Laboratory testing?   Modeling & simulation?   All of the above?   What tools do we need to reach that objective?   Model/simulation? Diagnosis? Prognosis?   Are they easy to handle?   Can they be used in real time ?   Can they be used to forecast the available capacity ?   How to understand field data?   Analyze the duty/generation cycle   Link usage (duty cycle) to size & performance of the PS/ES system Data collection   Allow accurate sizing of the battery pack for geographically-dependent duty cycle Pattern Recognition Duty cycle analysis
  • 66. Data collection Event D, high wind speed, low gusts distribution Pattern Recognition Duty cycle Event cycle analysis analysis Event forecasting   How to understand battery degradation ?   Battery electrochemical behavior is:   Rate dependent Small scale tests   Temperature dependent Specific protocols   Age dependent   Need to test the cells under Performance Rate, T, … appropriate protocols under load effects   Derived from representative usage schedule (rate, temperature)   Matrix of different parameters   Rate   Pulses   Temperature   …
  • 67.   Degradation is often complex   Need a reference point (SOC tracing)   Need in situ characterization   Incremental capacity analysis   Close-to-equil. OCV analysis Small scale tests Specific protocols Life & degradation mechanisms   Single cell model   Derived from performance tests Small scale tests Specific protocols Cell performance Rate, T Performance model effects under load   ECM approach: accurate & not computation intensive
  • 68.   Single cell to pack modeling   Accommodate cell-to-cell variations   Adapt to topology Small scale tests Specific protocols Cell performance Rate, T model Performance under load effects Pack model Cell to cell variations   Diagnostic and prognostic tools   Developed from knowledge in single cell testing and analysis   Nominal vs. anomalies   ID & Quantification Small scale tests Specific protocols Cell performance Rate, T Performance model effects under load Pack model Cell to cell variations Diagnostic model Life & degradation Prognostic model mechanisms
  • 69.   Diagnostic and prognostic tools V,SOC Real time data I,T,SOC,SOH Analysis and V,SOC prognostic module
  • 70. Representative usage schedule Small scale tests Data collection Specific protocols Pattern Cell performance Rate, T Performance Recognition model effects under load Pack model Cell to cell variations Duty cycle Event cycle analysis analysis Diagnostic model Life & degradation Event forecasting Prognostic model mechanisms   More details ―   Roadmap   M. Dubarry, V. Svoboda, R. Hwu and B.Y. Liaw, “A roadmap to understand battery performance in electric and hybrid vehicle operation,” J. Power Sources 174 (2007) 366.   M. Dubarry, N. Vuillaume, B.Y. Liaw, and T. Quinn, “Vehicle evaluation, battery modeling, and fleet-testing experiences in Hawaii: A roadmap to understanding evaluation data and simulation” J. Asian Electric Vehicles 5 (2007) 1033.   Event pattern recognition   B.Y. Liaw, M. Dubarry, “From driving cycle analysis to understanding battery performance in real-life electric hybrid vehicle operation” (invited) to the Special Issue on Hybrid Electric Vehicles, J. Power Sources 174 (2007) 76.   Battery Analysis   M. Dubarry, V. Svoboda, R. Hwu and B.Y. Liaw, “Capacity and power fading mechanism identification from a commercial cell evaluation,” J. Power Sources 165 (2007) 566.   M. Dubarry, V. Svoboda, R. Hwu and B.Y. Liaw, “Capacity loss in rechargeable lithium cells during cycle life testing: The importance of determining state-of- charge” J. Power Sources 174 (2007) 1121.   Modeling   M. Dubarry and B.Y. Liaw, “Development of a universal modeling tool for rechargeable lithium batteries,” J. Power Sources 174 (2007) 856.
  • 71.
  • 72. Troy A. Hayes, Ph.D., P.E. General Manager Exponent China +1 (650) 688-7127 (US) +86 (571) 2802 1727 (China) thayes@exponent.com September 3, 2009 TRK7335.000 61CN 0109 FLA1 TRK7335.000 61CN 0809 EV09 Who We Are • Professional services firm • Engineering & scientific consulting • 650+ consulting and technical staff • Best known for analyzing accidents & failures • Design and manufacturing consulting based on FA experience TRK7335.000 61CN 0809 EV09
  • 73. Outline • Technologies used for identifying defective cells – X-Ray – CT Scanning – Hi-Pot testing – OCV – Sorting – Imaging laser tab welds – Tab-to-cell impedance (soft pouch) • Maintaining your brand’s trust – Recalls – when and why? – Managing a recall TRK7335.000 61CN 0809 EV09 TRK7335.000 61CN 0809 EV09
  • 74. X-Ray • X-Ray is useful as a 100% inspection procedure to verify proper anode/cathode alignment – Note: this is not 100% accurate • X-Ray is also useful when used on a sampling basis (using both is most desirable) TRK7335.000 61CN 0809 EV09 X-Ray Ni tab kink TRK7335.000 61CN 0809 EV09
  • 75. X-Ray TRK7335.000 61CN 0809 EV09 CT Scanning • CT Scanning can be used on a sampling basis to evaluate: – Metallic contamination – Holes in active material – High-density spots in active material – Wrinkles in electrodes/current collectors – Delamination of electrodes – Detailed alignment – Deformation of windings associated with tabs, bends etc. • Disadvantages: – Slow for a complete scan (7 hours for an 18650) – Expensive ($250K USD for a good machine) TRK7335.000 61CN 0809 EV09
  • 76. CT Scanning TRK7335.000 61CN 0809 EV09 100 x 100 x t=50 μm Fe 50 x 50 x t=20 μm Ni CT Scanning • Cu dissolution due to repeated over- discharge • Cathode delamination TRK7335.000 61CN 0809 EV09
  • 77. Hi-Pot Testing • How were the Hi-Pot values chosen? – Need a properly-designed DOE • Metallic particle size/type • Voltage level and application time – Will vary with capacity/size • Hi-Pot failures – Data analysis – Failure analysis – Closed-loop corrective action TRK7335.000 61CN 0809 EV09 OCV Testing • How are the limits chosen? – IEEE 1725 5.5.7 • Data analysis • Failure analysis • Closed-loop corrective action TRK7335.000 61CN 0809 EV09
  • 78. Sorting • Why sort? • Do you really know what causes the variation between cells of various classes? – Loading versus other properties – Self discharge rate • Is it possible for two independent causes to create a cell of a particular class? – If so, cells of one class may age differently Cap 2,000 – 2,150 2,151 – 2,300 Voltage mAh mAh V 3.82V Grade B Grade A 3.82 > V 3.77 Grade D Grade C TRK7335.000 61CN 0809 EV09 Laser Weld Visual Inspection • Entirely dependent on operator skill • Is the visual inspection reliable? TRK7335.000 61CN 0809 EV09
  • 79. Impedance Measurement Between Tab and Cell (Soft Pouch) • When the inner polymer layer on the Al pouch is compromised, a current leakage path can occur – Corrosion – Gas generation – Cell swelling – Electrolyte leakage • Compromised pouches can be identified during production by measuring the impedance between the negative tab and the Al pouch after cell formation and aging TRK7335.000 61CN 0809 EV09 Part 2: Maintaining Your Brand’s Trust TRK7335.000 61CN 0809 EV09
  • 80. Maintaining Your Brand’s Trust • Recalls are for the consumer’s protection • Recalls must be properly managed • Recall as soon as possible – don’t wait • Recall everywhere, not just where you are required (e.g., by the CPSC) • Consumers will have more confidence in your brand if they know you are acting in their best interest • Communicate to the customer TRK7335.000 61CN 0809 EV09 Limiting a Recall – TRACEABILITY • Tracing all material lots and equipment is extremely important! – Cap assemblies – Electrode batches – Current collectors – Slitting blade number – Winding machine – The more detail, the better • Remember, most date codes disappear during a thermal runaway event – Can you differentiate dates and machines by something internal to the cell? TRK7335.000 61CN 0809 EV09
  • 81. Data Analysis • Need to consider – End of life – Time in service at time of incident – Geography and power type/stability where incidents occur – Differences in population versus failure rate (e.g., type of charger, etc.) – Changes on manufacturing line – Material changes – Design changes – Failure rates (Hi-Pot, OCV, etc.) – Other factors TRK7335.000 61CN 0809 EV09 Data Analysis Expected Number of Failures per Million Cells TRK7335.000 61CN 0809 EV09
  • 82. Timeline for Possible Contributing Factors 2007 2008 2009 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 Factor A Factor B Anode material B Cu Foil B Can vendor B Winder #2 in use Winder #16 in use TRK7335.000 61CN 0809 EV09 Summary • Technologies used for identifying defective cells – X-Ray – CT Scanning – Hi-Pot testing – OCV – Sorting – Imaging laser tab welds – Tab-to-cell impedance (soft pouch) • Maintaining your brand’s trust – Recall if necessary – Manage the recall and communicate to the customer TRK7335.000 61CN 0809 EV09 Make your product as traceable as possible
  • 83. Questions? TRK7335.000 61CN 0809 EV09 Cell and Battery Pack Analysis, Including: Auditing, Failure Analysis, Design Review, Testing, CTIA Certification and Regulatory Consulting 24 Offices Worldwide Boston, Los Angeles, Phoenix, San Francisco and China +1-888-656-EXPO (US) +86 571 2802 1788 (China) www.exponent.com/batteries www.exponentchina.com info@exponent.com exponentchina@exponent.com TRK7335.000 61CN 0109 FLA1 TRK7335.000 61CN 0809 EV09