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III.A USABC Battery Development Projects III.A.1 EV Battery Development (Envia Systems) Harshad Tataria, USABC Program Manager Subcontractor: Envia Systems Herman A. Lopez, Program Manager, 7979 Gateway Boulevard Newark, CA 94560 Phone: (510) 962-3687; Fax: (510) 372-0318 E-mail: hlopez@enviasystems.com Start Date: December 2010 Projected End Date: July 2013 Objectives Develop and evaluate high capacity manganese rich (HCMRTM) cathode materials and screen various electrolyte formulations that meet the material target specifications. Design, build and test large capacity pouch cells integrating Envia’s HCMRTM cathode and optimized electrolyte formulations that meet the USABC minimum goals for long term commercialization. Technical Barriers One challenge is to develop a cathode material with very specific electrochemical performance and incorporate it into a cell expected to meet numerous USABC cell targets. Many of the cell target specifications as with the material specifications will require optimization and balance in order to meet the various targets. In the cell, a balance between energy and power will exist and in the material, a compromise between specific capacity and cycle and calendar life will exist. This project consists of developing the best materials and integrating them in an optimal cell design to meet the USABC targets. Another challenge is that the HCMRTM cathode is a relatively new material. Unlike other more established cathode chemistries where there is an abundance of data and performance trends, HCMRTM cathode data in many occasions (specially for large cell data) is being reported for the first time. Envia’s HCMRTM/graphite cells potentially operate at higher voltages than commercially available cells. In order to meet the USABC targets, this will require an electrolyte that operates at high voltages, low and high temperatures and supports long cycle and calendar life. Some specific barriers that have been addressed throughout this project are: High irreversible capacity loss (IRCL) Oxygen loss during cycling (Li2MnO3 MnO2 + 2 Li+ + 1/2O2), which leads to gassing in the pouch cell High DC-Resistance Fade in average voltage upon cycling High Manganese dissolution leading to poor cycle life and calendar life Technical Targets Develop a high specific capacity cathode (>200mAh/g at C/3) able to meet the energy, power, cycle life, calendar life and cost targets. Develop and utilize a high voltage, stable electrolyte formulation that can operate in the temperature range of -40°C to 55°C and be able to support high energy and power, a cycle life of 1,000 cycles and a calendar life of 10 years. Design, develop, build and test >20Ah cells, which meet the USABC minimum goals for long term commercialization of EVs. Accomplishments FY 2013 Annual Progress Report 29 Energy Storage R&D Envia down-selected an HCMRTM cathode after extensive material development with respect to composition, dopants and surface coatings. The material development consisted of optimizing the chemical and physical properties of the cathode to improve the specific discharge capacity, rate capability, cycle life, transition metal (TM) dissolution, and DC-resistance of the material. The down selected cathode materials were scaled up to kilogram levels and integrated in large capacity cells to support a total of nine project cell builds. A new baseline electrolyte was selected based on improved low temperature performance while maintaining similar room temperature cycling stability, power and energy characteristics compared to Envia’s high voltage baseline electrolyte.PDF Image | Advanced Battery Development
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