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Nine – NETL, O’Driscoll – Dow Kokam III.B.2 Large Format Lithium-Ion Cells with Higher Energy Density materials or conventional graphite as the anode. 2 Ah format sample cells will be used as a common platform during the evaluation of the materials. 40 Ah production size cells will be produced and delivered to demonstrate that the materials can be scaled up to a production scale manufacturing environment. Approach The following approach will be taken to achieve the goals: Design and fabricate baseline cells in 2 Ah format. The cell design is a direct reduction of the 40 Ah production cell produced by DK. Develop a cell performance model to represent the behavior of the cell. This model will be used to predict the performance of cells when the novel materials described above are used. Evaluate those novel materials in half-cell format to understand their performance. The data will be used to design full cells with these materials as the electrodes. Design and construct a small-volume slot die coating system that can produce electrodes with very little material and have the same quality as production scale electrodes. Design and fabricate samples cells, of the 2 Ah format, using HVC and HCC materials as the cathode and HCA or conventional graphite as the anode. Design and fabricate a full size, 40 Ah cell that can be produced in DK’s cell manufacturing facility. Collaborate with WDT to develop the cathode materials and with Oak Ridge National Laboratory (ORNL) to characterize these materials. Results Baseline cell. Cells were designed, built, and tested. Test results show that these 2 Ah cells behave very similar to the 40 Ah, large format, cells Dow Kokam manufactures. Eighteen cells have been delivered to Argonne National Laboratory for testing. High Capacity Anode Material. Two silicon- based anodes were selected. The maximum specific capacities of these materials were both above 2,500 mAh/g. However, if utilized above 1,250 mAh/g the materials showed fast decay. It was found that matching the electrode designs between the HCA and the cathode is extremely important to the performance of the cell. Sample cells made with HVC and HCA were fabricated and tested at Dow Kokam. To date, cells with 570 mAh/L energy densities has been demonstrated, Figure III - 43. Optimization of cell design is in progress. Figure III - 43: Cycle performance of an HVC/Si-based anode cell High Voltage Cathode Material. In addition to the CM1 material developed by WDT, Dow Kokam has also been testing NMC-class materials operating at higher voltages under a research program funded by the Department of Defense. Applying the knowledge gathered, Dow Kokam has demonstrated 500 Wh/L energy density using HVC with graphite in a 2 Ah cell format. The energy density of these cells using HVC and HCA is expected to be >600 Wh/L. When charged to 4.4 V, the energy density of an HVC/graphite cell at various discharge rates is shown in Figure III - 44. FY 2013 Annual Progress Report 67 Energy Storage R&D Figure III - 44: Energy density of an HVC/graphite sample cell The stability of this material as a function of the charge voltage was investigated by differential scanning calorimetry (DSC) at ORNL. It was concluded that the behavior of this NMC material, when charged to 4.4 V is similar to when it is charged to 4.2 V below ~600°C, as shown in Figure III - 45.PDF Image | Advanced Battery Development
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