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III.A.6 Energy Storage System for High Power HEV Applications (Maxwell) Scott Jorgensen, USABC Program Manager Subcontractor: Maxwell Technologies, Inc. Allen Stoneberg, Program Manager 3912 Calle Fortunada San Diego, CA, 92123 Phone: (858) 503-3582 E-mail: astoneberg@maxwell.com Collaborators: University of Rhode Island Start Date: January 2011 Projected End Date: March 2014 Objectives Design, build, and test hybrid ultracapacitor cells and packs capable of meeting USABC goals for LEESS HEV applications. Extend device upper voltage range above 4.0 V with good life and low temperature performance. Develop and demonstrate a new design architecture for cell and system which is cost effective, small and light. Technical Barriers Low temperature performance (operation at - 30oC). Energy density (increased stable operating voltage window). Cell and system cost decreases. Technical Targets Develop a hybrid capacitor cell and associated module to meet LEESS HEV power and energy goals. Develop and utilize a stable electrolyte system that has a voltage window of 4.0 V or higher and can operate in the temperature range of -30 to 55 oC. Identify optimal electrode materials for higher energy, lower impedance, and stability at increased potential over lifetime, and lower cost relative to existing commercial capacitive technologies. Identify a separator that represents a significant cost reduction while maintaining or exceeding existing performance and safety metrics. Accomplishments Completed the development and fabrication of third generation 3.8 Wh hybrid ultracapacitor cells. Representative cells have been sent to Idaho National Laboratory for testing. Produced over 1,000 third generation cells in support of module build utilizing Maxwell’s low cost dry electrode fabrication process. Finalized the design of the Maxwell LEESS Module incorporating key features to optimize cost, weight and volume. Completed production of LEESS modules and packs in support of internal and testing at national labs per the FreedomCAR Battery Test Manual. Demonstrated over 390,000 HEV cycles with first generation cells. These cells are still exceeding performance requirements. 15% reduction of EOP Projected Cost matching SOW requirement. Introduction Maxwell Technologies is developing a new energy storage system based on a novel hybrid ultracapacitor to meet LEESS HEV requirements while maintaining long life, excellent safety, and low cost. While conventional ultracapacitors generally lack the energy density required for automotive traction applications, Maxwell’s hybrid technology almost triples the energy density of state of the art conventional ultracapacitors. New approaches to packaging and manufacturing are focused on significantly reducing the system cost. Key improvements to be demonstrated over existing capacitive technologies are increased energy density and low temperature performance at a size, weight, and cost that is practical for consumer vehicle use. Approach Leveraging its capabilities in low cost ultracapacitor manufacturing, Maxwell has developed a new large format hybrid ultracapacitor cell capable of cycling to at least 4.0 V. The compact and economical design of this Energy Storage R&D 50 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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