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Arsenault – USABC, Judes – JCI III.A.4 Advanced High-Performance Batteries for PEV Applications Figure III - 14: PHEV cycle life: 95%-25% vs 95%-15%SOC Mechanical Design and Advanced Manufacturing. Numerous concepts were studied that have the potential to dramatically drive down component cost and assembly complexity, increasing cell energy density and performance. Torsional ultrasonic welding was selected as the lead alternative fill hole closure method after extensive evaluation of competing methods. The novel sealing process was successfully developed in a production-like environment (Figure III - 15). The approach shows great potential to reduce cell void volume and replace baseline rivet insertion. The design of a thin wall can with inwardly embossed features was completed. It has the potential to reduce the complexity of tolerance management and clamping forces needed in future module designs. Figure III - 15: Cell sealed by torsional ultrasonic welding Mandrel-less cells produced in the mid-term build are on test with promising results and are planned for incorporation into the final build. Current collector width was optimized using results of component level high current pulse tests. This, along with foil margin reduction and electrode layout redesign, increased cell capacity by 4.5%. A low pressure vent is being developed to investigate whether earlier activation and associated release of thermal energy and fuel might avoid or mitigate thermal runaway. Abuse testing with prototypes is planned. Abuse Tolerance: Joint trials were conducted with Entek to address manufacturing and performance issues of the ceramic filled separator. These separators provided remarkable improvement in cell resistance, power capability, and life. At 25°C, cell power improved by 30%, and 20% at -25°C. In calendar life at 60°C, no resistance increase was measured after 262 days at 4.1V. FY 2013 Annual Progress Report 43 Energy Storage R&DPDF Image | Advanced Battery Development
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