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III.D.3 Internal Short Circuits in Lithium-Ion Cells for PHEVs (TIAX) Christopher Johnson, NETL Project Manager Subcontractor: TIAX LLC Suresh Sriramulu Richard Stringfellow TIAX LLC 35 Hartwell Avenue Lexington, MA 02421 Phone: (781) 879-1240; Fax: (781) 879-1209 E-mail: sriramulu.suresh@TIAXLLC.com Start Date: May 2010 Projected End Date: May 2013 Objectives Develop an improved understanding of the conditions under which a thermal runaway will occur in a Li-ion cell. Use modeling to determine the threshold conditions for thermal runaway following an internal short circuit. Identify design factors for cells that can reduce propensity for thermal runaway. Identify and analyze opportunities for prevention of internal short circuits, or intervention/mitigation before they can cause thermal runaway. Technical Barriers On rare occasions, Li-ion cells experience thermal runaway during normal charge/discharge cycles because of internal short-circuits; we term such incidents “field- failures.” Even though such incidents are rare, the potential consequences can be very serious. Safety technologies currently employed in Li-ion cells, such as positive thermal coefficient current limiting devices (PTC), current interrupt devices (CID), shut-down separators, etc., have not prevented thermal runaway due to internal shorts in commercial Li-ion cells. Development of new safety technologies is hindered by the rarity of field-failures in Li-ion cells, and the current incomplete understanding of field-failures. In this program, we fabricate Li-ion cells with various means to stimulate or develop appropriate internal shorts in order to study the effect of cell design variables, and cell-level materials choices. This improved understanding will help identify and evaluate technologies that enhance the safety of PHEV Li-ion batteries. Technical Targets Develop guidelines that will enable the development of technologies for a safe battery. Establish a facility for fabricating Li-ion cells to (1) study the effect of cell materials and cell design parameters on thermal runaway, (2) compare to TIAX’s Li-ion cell finite element analysis (FEA) model predictions, and (3) validate FEA model. Establish an experimental facility that permits testing the efficacy of technologies developed to mitigate safety incidents that occur in the field. Select and test approaches to enhance Li-ion battery safety using validated model and experimental data. Accomplishments Set-up fully functional cell prototyping facility with capability to fabricate high-quality multi- Ah cells. Adapted method for stimulating thermal runaway to cells fabricated on our prototyping line. Conducted experiments to induce thermal runaway of custom-built Li-ion cells under a range of external heat transfer conditions. V alidated FEA model for simulating thermal runaway of Li-ion cells by fitting experimental thermal runaway data. Demonstrated ability to stop the progression to thermal runaway by adjusting the rate of heat transfer out of the cell. Introduction Concerns regarding the safety of Li-ion batteries could severely limit their use in PHEVs, and undermine the prospects for realizing the appealing benefits of PHEVs. Recent highly-publicized safety incidents and the ensuing widespread recalls of Li-ion batteries used in laptops and cell phones have elevated such concerns. In these safety incidents, called field-failures, Li-ion batteries operating under otherwise normal conditions undergo what appear to be spontaneous thermal runaway events, with violent flaming and extremely high temperatures. These field-failures cause significant damage to cells, packs and devices, and sometimes to Energy Storage R&D 110 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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