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III.A.4 Advanced High-Performance Batteries for Plug-In Hybrid Electric Vehicle Applications (JCI) Renata Arsenault, USABC Project Manager Subcontractor: Johnson Controls Inc. Avie Judes, JCI Program Manager 5757 N. Green Bay Road Glendale, WI 53209 Phone: (414) 524-6173 E-mail: avie.judes@jci.com Start Date: April 1, 2012 End Date: March 31, 2014 Objectives Build on the prismatic cell platform developed in the previous program and achieve a step- change in energy density from 275 Wh/L to a 375 Wh/L. stretch goal. Achieve cost target of $250/kWh for the prismatic cell. Target EUCAR 4 abuse tolerance rating or better. Deliver two generations of prismatic cells. Technical Barriers Higher specific capacity cathode materials of interest have reduced thermal stability (reduced life). Novel electrode material processing techniques may have a negative impact on performance and life. Lowering the power to energy ratio must not result in an unacceptable reduction in low temperature power. Higher upper voltages adversely affect life and require countermeasures to stabilize the chemistry. Abuse tolerance improvements require material and process innovation to overcome impact on life and cost. Technical Targets Available Energy (Charge Depleting mode): 5.8 kWh for 20-mile system at End of Life (EOL). Energy Density: 375 Wh/L (stretch goal). Packaged Energy Cost: $250/kWh for cell. EUCAR 4 abuse tolerance rating or better. Accomplishments Evaluated multiple cathode materials from six suppliers. Two materials remain as candidates after exhaustive down selection trials. Mid-program cells demonstrated a 25% capacity increase. Projected final cell design translates to 40% cost reduction at the system level. Dry compounding trials achieved desired reduction of solvent and binder. High resistance growth and cost have eliminated this process technique going forward. Paste mix processing was evaluated using an in-line compound mixer as a potential enabler of solvent reduction goals. Promising results were obtained, attaining the high electrode densities needed for the cell energy density targets. Testing through December 2013 will assess potential for anode and cathode high solids processing. Evaluated 4.2V and 4.3V upper voltage limits in parallel with electrolyte development (base solvents and additives) for enhanced stability. Demonstrated results at 4.2V have allowed Vmax increase from 4.1V. Mechanical improvement activity resulted in mandrel elimination as well as current collector and coating area optimization, plus alternate fill hole closure method down- selection. Results inform final build choices. Abuse tolerance improvements focused on Thermal Protective Barrier (TPB), ceramic coating on anode, ceramic separators, electrolytes and cathodes with functional overcharge additives, all leading to improved over-charge protection and enhanced understanding. Introduction In 2011, JCI completed a three-year program which developed a first generation NMC-graphite, rigid prismatic cell technology headed for commercialization Energy Storage R&D 38 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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