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III.A.7 12 Volt Start/Stop Battery Development (Saft) Harshad Tataria, USABC Program Manager Subcontractor: Saft Michael Duffield, Program Manager 13575 Waterworks Street Jacksonville, FL 32221-2215 Phone: (904) 861-1521; Fax: (904) 772-1463 E-mail: michael.duffield@saftbatteries.com Subcontractors: Wildcat Discovery Technologies Virginia Commonwealth University Start Date: April 2013 Projected End Date: March 2014 Objectives To develop an advanced, high-performance battery for 12V Start-Stop (12VSS) vehicle applications based on Saft’s advanced NMC-LTO lithium-ion battery technology. Technical Barriers The cost of automotive battery is the single most critical challenging requirement and a generally acknowledged critical path to widespread deployment of the Li-ion battery in the automotive industry. About 20% of the cost of a robust cell design in volume- production today is in the cell hardware. Cell hardware is anything other than electrodes including the foils, separator, and electrolyte. Another 50% cost burden is added as cells are integrated into a turnkey battery pack. Thus, the hardware in a Li-ion battery pack is responsible for a combined 80% of the cost add-on before indirect costs (G&A, O/H, and Profit), and is the single most significant part of the total unit cost. A dramatically different approach to the way Li-ion cells are fabricated and assembled into a battery is needed for a significant reduction in the hardware cost. Technical Targets Develop a novel cell assembly process which reduces the overall battery cost. Reduce elevated temperature impedance growth in order to meet cycle life requirements. Identify polymer materials that can hermetically seal the stack from external moisture and prevent electrolyte egress. Optimization of LTO and electrolytes for - 30°C performance, while maintaining calendar life and cycle life up to 75°C Accomplishments Saft has successfully supplied NMC based Li- ion cells for high power, high temperature automotive application. Saft is producing the NMC line of products in two formats, cylindrical and prismatic. Saft LTO technology has excellent power capability with a 15s pulse-discharge impedance of around 1.6 m in small cells. Introduction Saft’s NMC-LTO technology will meet or exceed the USABC requirements for this application. Saft can meet all of the performance requirements for power, cycle life, cold cranking power, etc. using the LTO technology already demonstrated. Integration of Saft’s high temperature stable NMC technology will allow for additional improvements to cell calendar life. Accordingly, this development program will scale up the Saft LTO technology from small cells to a 10-20Ah PHEV-2 VDA size prismatic cell as a demonstration of the ability to meet cost and size requirements. Approach A key innovation in the effort, primarily focused on cost reduction, is combining the cell and module packaging in a single injection-molded thermoplastic polymer (IMTP) monoblock. Further proposed cost reductions include optimization of the electrolyte and NMC cathode to meet the cold-cranking requirements. LTO is a chemistry particularly well suited to this optimization, as the lack of solid-electrolyte interphase (SEI) allows for the use of very low cost, low temperature electrolytes. In order to reduce the electrode material costs, the LTO manufacturing process is being addressed by large volume manufacturers of TiO2 for the paint industry. This could result in extremely low cost LTO, giving a significant cost advantage over graphite-based Li-ion. FY 2013 Annual Progress Report 53 Energy Storage R&DPDF Image | Advanced Battery Development
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