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III.B.4 High Energy Novel Cathode/Alloy Automotive Cell (3M) John Tabacchi, DOE Program Manager Award Recipient - 3M Company Jagat D. Singh, Program Manager 3M Center, Building 209-2C-26 St Paul, MN 55144 Phone: (651) 575-1230; Fax: (651) 736-7478 E-mail: jdsingh@mmm.com Start Date: October 2011 Projected End Date: January 2015 Objectives Develop a >2 Ah cylindrical wound or stacked pouch cell with high energy density at low cost for automotive application. Integrate advanced chemistries including an advanced high-voltage cathode, high capacity alloy anode and advanced electrolyte materials as well as enabling technologies related to electrode preparation and cell build such as binder, conductive agent, and processing aids. Technical Barriers This project addresses the following technical barriers associated with the combination of high energy cathode and advanced alloy anode material: Low Cycle Life. Low Rate Capability. High irreversible capacity leading to low overall cell energy density. Large volume expansion of alloy anode. Technical Targets Establish a baseline cell with similar energy density to USABC EV targets with commercial LiMn1/3Ni1/3Co1/3O2 (NMC 111) cathode and graphite anode. Provide an advanced cell with at least 40% (1.4 x baseWh/L) increase in energy density compared to the baseline cell. Demonstrate as good or superior thermal stability, long-term cycling, and rate capability, of the advanced cell compared to baseline test cell. Demonstrate by calculation at least 25% lower cost per unit energy at the cell level for comparative integrated advanced materials cell to a baseline materials cell. Accomplishments Downselected high energy core shell cathode and Si alloy anode materials for 18650 performance optimization. Demonstrated material scale up to multi kg levels. Optimized pilot process parameters to improve process robustness. Demonstrated advanced materials stability large scale dispersion preparation, electrode coating and 18650 assembly with advanced materials. Demonstrated >40% energy increase, with intermediate design (C/S||Si) in 18650 cells over baseline (NMC || Graphite). Improved cycle life using electrolyte formulations including novel high voltage (>4.5V) additives. Sampled 18650 format cells to ANL for testing; 18 cells with baseline materials and 6 cells with intermediate materials. Introduction In order to design a lithium-ion cell with a stepfunction increase in energy, it is necessary to start from scratch with new well designed and matched active materials. First, the cathode needs to have a Cathode Energy Factor (CEF) beyond the traditional LCO and NMC materials. This invariably requires charging to higher cell voltage. Second, the cathode irreversible capacity has to “match” the irreversible capacity of the composite alloy anode. In fact, for cell balance and control of the lower cut of cell voltage, it is convenient if the irreversible capacity of the composite cathode is slightly larger than that of the anode. For the Active alloy it is critical to have the proper morphology (amorphous active phase), the proper particle size (microns), and the proper activity leading to a volume expansion of 110 to 120% upon lithiation. Next, the composite electrode has to be formulated with graphite for highest density and best inter particle contact, while still providing the required volumetric energy when fully lithiated. Finally, the electrolyte and separator must be stable against the two active composite FY 2013 Annual Progress Report 75 Energy Storage R&DPDF Image | Advanced Battery Development
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