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Bae – USABC, Juzkow – Leyden Energy III.A.8 Advanced, Lithium Ion, 12V Start-Stop Battery Cell development. Over the course of this program Leyden transitioned from 0.8Ah prototypes to 2.2Ah prototypes. The new cell design incorporates thicker (300μm) and wider (20mm) aluminum tabs resulting in low 1.5mΩ impedance and the ability to support up to continuous 50C discharges and 100C pulses. Process development included qualification of a new automated stacker, new top and side sealer as well as improved ultrasonic welder horn design. During the month of October, we assembled the first 20Ah cell prototypes (see Figure III - 33). Electrodes were coated at Leyden and shipped to Dow Kokam where they were punched, dried, stacked and packaged. Ready-to-fill cells were shipped to Leyden for filling and formation. Figure III - 33: 2.2Ah and 20Ah cell prototype We confirmed capability of the cells to support cold- cranking requirements and initiated limited cycle life testing. After aging and binning, a number of cells were shipped to Flextronics to assemble the first 12V 40Ah packs. Pack and electronics. Balancing circuitry (see Figure III - 34) for the prototype packs was developed independently by both Leyden and Flextronics. The circuitry decreases the charging current to a cell if its voltage exceeds a set threshold. The parasitic currents of the circuitry were confirmed to be in double digits of microamps. Figure III - 34: Leyden pack balancing circuitry Pack concept drawings were completed and prototypes were assembled during the month of November. The pack consists of 2p cell modules with thermal barrier/expansion pads between the cells constrained by aluminum plates with a molded retention frame positioned around the cell. Modules are connected to each other with two sets of aluminum bus bars; cell tabs protrude through the bottom bus bars and are clamped with a top bus bar. The module and pack drawing are shown in Figure III - 35 and Figure III - 36 below. FY 2013 Annual Progress Report 59 Energy Storage R&D Figure III - 35: Cell module assembly drawingPDF Image | Advanced Battery Development
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