LIE 600

BFE100

Johan Dahlström
 Battery
• A battery is a device consisting of one or
more electrochemical cells with external connections[for
powering electrical devices such as flashlights, mobile
phones, and electric cars.
• When a battery is supplying electric power, its positive
terminal is the cathode and its negative terminal is
the anode
CO2 emissions from vehicles

www.iea.org 2019_global outlook for electrical vehicle

• Which additional
components do we need?

Harper2019
Size and energy
Size Energy density
Active materials 0,1 to 10 nm
Electrode microstructure 10 to 1000 nm
Cell components 1 to 1000 micrometer
Cell 1 to 100 mm 0,25 kWh/kg
Module 0,1 to 1 m 0,20 kWh/kg
Pack 1 to 10 m 0,16 kWh/kg
LIB generations

EU2018
Cell type
Cell
• Cathode
– Aluminium current collector
– LiTM oxide on current collector
• Anode
– Coppper current collector
– Graphite on current collector
• Separator
– Prevent direct contact between
electrodes
• Electrolyte
– Li ions transport
 Reactions
• Half cell reactions
+ −
– 𝐶𝐶𝐶𝐶𝑂𝑂2 + 𝐿𝐿𝐿𝐿 + 𝑒𝑒 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝑂𝑂2
E=1V
– Li++C6+e- LiC6
E=-3V
• During discharge
– CoO2+LiC6 LiCoO2+C6
E=4V
Li ions is released from the
graphite and get attached to the
CoO2
Periodic table
Lithium-ion cells
• Group of secondary batteries
– Specific energy, specific power, durability, cost, charge ability & safety
• Depends mainly on electrode material
• Lithium ion move from negative electrode to the positive
during discharge
• Anode:𝐿𝐿𝐿𝐿𝐿𝐿6 𝐿𝐿𝐿𝐿 + + 𝑒𝑒 − + 6𝐶𝐶
• Cathode: 2𝐿𝐿𝐿𝐿0,5 𝐶𝐶𝐶𝐶𝐶𝐶2 + 𝐿𝐿𝐿𝐿 + + 𝑒𝑒 − 2𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿2
Electrode
• Anode
– Active LiTMO2 on an Aluminum strip (current collector
• TM is transition metal
• Cathode
– Active carbon/graphite layer on a Cupper strip (current collector)
 Reactions
• Half cell reactions
+ −
– 𝐶𝐶𝐶𝐶𝑂𝑂2 + 𝐿𝐿𝐿𝐿 + 𝑒𝑒 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝑂𝑂2 E=1V
– Li++C6+e- LiC6 E=-3V
• During discharge
– CoO2+LiC6 LiCoO2+C6 E=4V
Li ions is released from the graphite and get attached to the CoO2
LIB Cathode (A best, E worse)
Cathode LCO LFP LMO NCA NMC
Chemical formula LiCoO2 LiFePO4 LiMn2O4 Li(Ni,Co,Al)02 LiNi1/3Mn1/3Co1/3
O2
Structure Layered Olivine Spinel Layered Layered
Year introduce 1991 1996 1996 1999 2008
Safety D A B C C
Energy density B C C A A
Power density C B B B C
Calender lifetime C B B B B
Cycle lifetime C B C B C
Performance B B C B B
Cost E B B C C

Harper2019
Crystal structure
• Cubic,
– One atom in each corner
– FCC
• Face centered
– Additional ½ atom on all faces
• Body centered
– Additional atom in the center
• Hexagonal
– One side is longer
• Orthorhombic
– Two sides are longer
Crystal structure
• Layered
– 2 dimensions with little bond to the next layer
• Li ions between the layers
• Less stability
• Spinel
– Belong to cubic crystal structure group
• Olivine
– Orthorhombic crystal structure
• Stable
Layered structure, active cathode
• LCO, NCA, MNC
– Li ion easy migration, which has positive and negative effect
• MNC
– Today is the ratio Ni:Co 1:1
– For years tried to increase Ni and reduce Co but come into problem
• With higher Ni:Co ratio, the structure becomes more instable (more easily
dendritic growth)→increased resistance in the cell→fire→the fire will
generate heat and oxygen→more fire this is called thermal runaway
Spinels (LMO), active cathode
• LiMn2O4
• Ideal shape for intercalations of Li ions
• Begin breakdown in cycling
– Due to instability of the electrochemically active Mn3+ above 55 C
• Dope with (Al, Co, Cr, Fe, Mg, Ni, Mg etc)
Olivine, LFP, active cathode
• LiFePO4
• Non toxic
• Little capacity decline during lifecycle
• Orthorhombic crystal structure
– Small volume changes
• Poor conductivity
Actice cathode

Duan2020
LIB Cathode (A best, E worse)
Cathode LCO LFP LMO NCA NMC
Chemical formula LiCoO2 LiFePO4 LiMn2O4 Li(Ni,Co,Al)02 LiNi1/3Mn1/3Co1/3
O2
Structure Layered Olivine Spinel Layered Layered
Year introduce 1991 1996 1996 1999 2008
Safety D A B C C
Energy density B C C A A
Power density C B B B C
Calender lifetime C B B B B
Cycle lifetime C B C B C
Performance B B C B B
Cost E B B C C

Harper2019
Discussion
• Which cathode would you select for
– Bike
– City bus
– City car
– Light truck
– Heavy truck

_
Anode
• Graphite
– Li ions inserts itself between the graphite (2 dimensional sheets) and
the sheets rearrange themself
– Poor intercalation capacity
• Less common
– Carbon + Lithium alloyed metall
– Li4Ti5O12
• Spinel shape
Electrolyte
• Polymer base
– Li polymer salts or polymer
– Electrochemical stable
– Few can obtain good ion conduction
• Liquid electrolyte
– Most common
Electrolyte, today
• The electrolyte infills the space between the separator and
electrodes.
• The electrolyte formulation in LiBs is dependent on the
electrode materials and operating conditions
• The typical electrolyte for LiBs is
– made of a flammable carbonate-based organic solvent such as ethylene carbonate (EC),
dimethyl carbonate (DMC), diethyl carbonate (DEC) and ethyl methyl carbonate (EMC),
and/or propylene carbonate (PC)
– with additives including lithium hexafluorophosphate (LiFP6), lithium hexafluoroarsenate
monohydrate (LiAsF6), lithium perchlorate (LiClO4), and lithium tetrafluoroborate (LiBF4)
to improve cycling.
Separator
• Separate cathode and anode
• Allow transport of Li ions
• Porous membrane
• Microporous films or laminates
– Polyethylene (PE, 135 C melting point), Polypropylene (PP, 165 C)
• Research
– Porous ceramic composites, Si / polyvinylidene
– PE fiber
 Casing

• Function
• Typical materials

Ely2019
Safety protection-Cell
• Chemicals of materials
• Case and vent design
• Current interrupt device
System hardware
• Electronics hardware
– Over voltage protection
– Over temperature
– Cell balancing circuitry
• Electrical hardware
– Fusing for over current
– Contractors
• Mechanical hardware
– Structural protection
– Gas containment or evacuations system
System software
• Measure of battery system
– Cell/Pack voltage
– Temperature
– Current
– Sensor validity
• Default or failure detection and appropriate control actions
– Battery status and safety control software
BMS
• EV has a battery management system (BMS) that executes operations such as
– state of charge(SOC) monitoring,
– battery health estimation,
– remaining life prediction,
– temperature management,
– battery equalization, and fault diagnosis
Traction cell types, LIB
g/kg

Elwert2016
Cell to module
• Battery cell
• Terminals
• Casing
Module to pack
• Bus bars
• Electronics
• Wiring looms
• Modules
• Fixture
• Cooling (usually)
– Cooling pipes
– Cooling sheets
Packing density
• Tesla, cylindrical cell
• BMW i3, prismatic
• Nissan leaf, pouch
• Blade from BYD
Design
• Thermal stability
• Vibration isolation
• Impact resistance,
• Minimize
– Thermal and mechanical interactions between different units of
battery pack.
Design-Interfaces
Interface Definition Formed by
Mechanical Mechanical design features incl. Cell spacers, damping pads, gasket,
safety reasons valves
Structural Members that provided required Case, cover, end-plates, rods, cross
protection and isolation members
Thermal Regulates battery cell temperature Coolant, fans, pumps, heat
exchanger
Electrical Transmits power from and to the Bus bars, cable, contactors, fuse,
battery pack relays
Support Vehicle body parts providing Axles, chassis, seats, vehicle floor
additional support
Control Monitor and regulate the state of Battery management system, sensors
battery pack
Personal car

Bischopp2019
Electrical abuse
• Electrical abuse (over-charging/discharging):
• Over-charging or discharging to voltages beyond the manufacturers
specified charge window can cause
– lithium plating, or dendrite formation, on the anode.
– Over time, this may pierce the separator causing a
– short circuit between electrodes and lead to thermal runaway.
Thermal abuse
• Thermal abuse (over-temperature) I
• Internal temperature in the 90–120 C range
– will cause the SEI layer within a LiB to decompose exothermically.
• At temperatures above 200 C,
– the hydrocarbon electrolyte can decompose and release heat.
Mechanical abuse
• Mechanical abuse (penetration, pinch, and bend)
• Mechanical abuse, usually caused by external mishap to the LiB such as
car crash or during installation, can result in
• electrical shorting between the electrodes, via the electrolyte,
producing localised heating.
Vibration isolation
• Vertical low frequency vibrations are transmitted continuously
to an EV structure as it driven on a highway
• Shocks that cause vertical vibrations, from un even surface
• → dynamical loads develop on the electrical subsystem such as
terminal connectors and bus bars in a battery pack, which can
result in loss of electrical continuity and fatigue failure of the
casing
Crash protection
• T shape
– Safe area
• Between rear passenger seats extending along the tunnel between the 2 rows
of seats
• Prevent frontal and side direct impact thanks to the vehicle structure as crash
barrier
• Floor
– Maximize space for passengers and luggage
– Increase stability thanks to lowering the center of gravity
– Reduce ground clearance
Battery cell protection
• Casing made of plastic or metal
• Module housing
• Vehicle structure
– Transverse cross members, doors, floors
• 1 to 6 mm thick metal (floor design)
• Coated to prevent from rust
EV in Shanghai
• https://www.youtube.com/watch?v=sAQlLu5ttOk