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Jorgensen – USABC, Stoneberg – Maxwell III.A.6 Energy Storage System for High Power HEV Applications large cell is being leveraged to produce the lowest cost and smallest/lightest system possible while meeting LEESS power and energy requirements. Cell performance has been improved by: Identifying and selecting the highest performing anode and cathode carbons leveraging over a decade of previous carbon screening work. Identifying and selecting a stable electrolyte in conjunction with the University of Rhode Island. Identifying and characterizing separator materials with good performance but significant cost reduction. Use of a completely dry electrode fabrication process (solvent-free, reduced processing) to decrease cell manufacturing cost and increase cell lifetime. Quantifying performance/weight/size reduction of new cell architecture via cell-level electrochemical and physical testing. Figure III - 21: 3.8 Wh third generation HPPC BOL pulse power capability LEESS Module Development. The LEESS Module (Figure III - 22) has been designed and tested and high- level prototypes have been completed. Full modules and sub-modules have been shipped to Idaho National Laboratory (performance), National Renewable Energy Laboratory (thermal) and Sandia National Laboratories (safety) for evaluation. Cells life at Idaho National Laboratory, for abuse tolerance at Sandia National Laboratories, and for thermal performance at the National Renewable Energy Laboratory. Results Electrode Development. The electrode material and processing method for third generation cells was finalized at the end of 2012. Focus in 2013 was on the scale-up of electrode for larger quantity cell production. Ongoing optimization of the Maxwell electrode dry process for improved electrode physical and performance characteristics have yielded opportunities for overall improved cell performance. Electrolyte Development. The current Maxwell control electrolyte was selected for the third generation cell and has proven to be stable in a temperature window of -20 to 55oC. Ongoing electrolyte screening has identified a stable candidate that meets the -30°C operational requirement that will undergo further evaluation beyond the program. Cell Development. 3.8 Wh third generation cells have been designed, produced and shipped to Idaho National Laboratory for testing per the USABC Battery Test Manual. Internal HPPC BOL data indicates that the cell chemistry meets LEESS EOL performance targets (Figure III - 21). and systems will be tested for performance and Figure III - 22:- Maxwell LEESS module Cost Modeling. System cost is a critical program element and all decisions from cell component selection to system design have been driven by the cost model in order to deliver the lowest cost, highest value system possible. Projected end of program cost is $920 – matching the program target of $920. Conclusions and Future Directions In 2013, the third generation cell chemistry and configuration was finalized and scalable production processes validated. Maxwell testing has confirmed that cell safety, stability and performance meet program requirements with the exception of low temperature operation related to electrolyte selection. Over 1,000 FY 2013 Annual Progress Report 51 Energy Storage R&DPDF Image | Advanced Battery Development
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