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III.A.5 Development of a High-Performance PHEV Battery Pack (LG Chem) Paul Groshek, USABC Project Manager Contractor: LG Chem Power, Inc. Mohamed Alamgir, Program Manager E-mail: alamgir@lgcpi.com 1857 Technology Drive Troy, MI 48083 Phone: (248) 291-2375; Fax: (248) 597-0900 Subcontractor: LG Chem, Seoul, South Korea Start Date: January 1, 2008 Projected End Date: March 31, 2010 Objectives This is a 24 month program focused on developing a Li-ion pack technology that meets the energy, power and life requirements of the 40-Mile PHEV program of the USABC. A key part of the work is aimed at developing a cell that will significantly reduce cost to meet the USABC pack cost target by utilizing high specific energy cathode materials. An important objective of the program is also to develop an automotive-grade, self-contained battery pack using a refrigerant-based cooling system. The goal is to increase the efficiency of the thermal management system to increase life, lower cell count and more importantly, lower pack cost. The system is expected to be much more efficient and robust than its liquid- cooled counterpart commonly used in PHEV packs. Technical Barriers The project is addressing the following technical barriers. (1) Validation of the high capacity of new generation of Mn-rich cathode materials. (2) Demonstration of cycle-life of > 5,000 cycles (3) Demonstration of calendar-life of 15 years (4) Make considerable progress towards achieving the USABC pack cost target of $3,400. Extensive studies of the material and electrode properties such as morphology, surface area and porosities were carried out to identify electrode formulations optimal from performance as well as from life points of view. Process variables such as formation conditions which affect the amounts of gas generated as well as life have been examined and optimized. Since this high capacity cathode material necessitates the use of high-voltage electrolyte additives to prolong life at high voltage have been studied. Cyclability of the cathode has been found to be strongly dependent on the charge voltage as well as the SOC window of operation. Key among the root causes for cell degradation is the dissolution of Mn from the cathode particles and subsequent passivation of the anode. Stabilization of the cathode particle surface leads to significantly improved life characteristics. Material we have developed in-house demonstrates state-of-the-art cathode capacity as well as life. Current estimates show that this material when fully developed will lead to a cell cost target of below $200/kWh. The thermal system and pack volumetric efficiency have been significantly improved by optimizing compressor and evaporator designs, as well as by improving the contact between the thermal fins and the cold plate. Modules and packs have been designed, built and delivered to the National Labs for testing. FY 2013 Annual Progress Report 45 Energy Storage R&D Technical Targets Establish the high specific energy of new generation of Mn-rich cathode materials. Demonstrate both cycle- and calendar-life under USABC test conditions. Develop a cooling system that is electrically and mechanically robust and efficient. Develop a pack design that is modular, easy to manufacture and close to the USABC cost target. AccomplishmentsPDF Image | Advanced Battery Development
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