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III.A.4 Advanced High-Performance Batteries for PEV Applications Arsenault – USABC, Judes – JCI ratio (P:E) to the practical boundary where acceptable performance and life characteristics are maintained. This is being achieved by the aforementioned campaigns to increase specific capacity of the active material, increase energy density of the coated electrodes, and increase the loading level itself. Increased Upper V Limit and Increased SOC Window. Increasing the upper voltage limit beyond its current value of 4.1 V offers increased energy density and reduced $/kWh, but may adversely impact life and abuse tolerance. To surmount these issues, stabilized active materials and electrode and interface stabilization will be evaluated. Stabilization of the negative electrode/electrolyte interface would in turn allow expansion of the SOC window beyond 70% thus offering an opportunity to reduce the Battery Size Factor (BSF) and hence cost. Test efforts seek the lowest operating voltage limit where the inevitable trade-offs in life remain acceptable in magnitude. Expansion efforts would focus on moving from 25 to 95% SOC to a stretch goal of 15 to 95% SOC. Mechanical Design and Advanced Manufacturing. Significant effort is directed at advancing the cell design and manufacturing processes, striving to minimize the void volume in the cell and achieve a step-change reduction in component and assembly costs. Some of the concepts being investigated are: thin wall cans with special features, mandrel elimination, current collector design optimization, reduced foil margin (wider electrode coated width), electrolyte fill hole closure using torsional ultrasonic welding, and low pressure vent development. WBS 5.0 Abuse Tolerance. Abuse tolerance improvement is a critical enabler to all other work aimed at increasing energy content of the cell, and is being pursued on multiple parallel fronts: High temperature separator. JCI is working closely with separator developer Entek to optimize their ceramic filled separator technology and solve several manufacturing related issues. JCI’s Thermal Protective Barrier (TPB) technology. JCI applied TPB on the anode in the last program and are now optimizing TPB coating, including thickness, coverage, and uniformity. Overcharge protection additives. These are being tested both in the electrolyte and in the electrode itself. Results For discussion purposes, the key design versions from the previous program are defined in Table III - 6. Table III - 6: Version parameters and base & mid-program performance Cell Type Size 1C_Rate Capacity (Ah) Energy Density (Wh/L) Discharge Power (10s, 50%SOC) (W) Discharge R (10s, 50%SOC) (mOhm) P/E Ratio USABC 4th Build (Last Program) 141x124x22.6 23.7 245 1510 1.99 17 Baseline New Program 148x91x26.5 27.0 275 1540 1.92 16 Mid-Program 148x91x26.5 33.3 345 1880 1.60 16 Final 148x91x26.5 36 375 TBD TBD TBD The new electrolyte additive developed in the last program and anode active material implemented in the baseline cell have remarkably low cell resistance growth during storage at elevated temperatures. This can be seen in Figure III - 10, which shows cell resistance increasing only 13% and 34% after one year calendar life at 45°C and 60°C respectively. The prismatic cell representing mid-program results has an increased energy density of 26%. It shows good discharge and regeneration power capability, with similar power/energy ratio as baseline. With increased upper voltage at 4.2V, the resistance growth in calendar life at 60 ̊C is higher than baseline at 4.1V after 100 days. However, their capacity fade remains the same as the baseline at 4.1V, as seen in Figure III - 11. Energy Storage R&D 40 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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