some high energy density some high energy density lithium battery ...
gi ne er in g
“WHAT DREAMS MAY COME”; ONLY IF IT WORKS RIGHT!!!
TI N
En
SOME HIGH ENERGY DENSITY LITHIUM BATTERY SAFETY CONCERNS CONCERNS. – Eddie Forouzan, Ph.D.
– President, ARTIN Engineering and Consulting Group, Inc.
AR
– 4/9/2013 1 © Copyright 2013 PSES-SD Chapter
gi ne er in g
INTRODUCTION TO ARTIN ENGINEERING
– Specializes in the design, development, testing and certification of cells, battery packs and devices equipped with electrochemical energy storage p ((lithium,, NiMH,, NiCd,, Alkaline,, lead acid etc..)) capabilities. – ISO17025 compliant – CTIA approved test lab – accredited by A2LA
En
– We are:
– Our A2LA accreditation includes IEEE 1725, IEEE1625, IEC 61000-4-2, IEC 61000-4-5, ISO 7637-2 and National Motor Freight Classification 180; ASTM D5276.
TI N
– Additional capabilities;
– Forensic analysis (x-ray, SECM, elemental analysis etc..) – Energy efficiency measurement: California Battery Mandate, IEC62301 – Consulting © Copyright 2013 PSES-SD Chapter
AR
2
gi ne er in g
OUTLINE
– This presentation pertains to high energy density secondary lithium batteries (rechargeable). – Will focus on batteries made with common cathode materials: Lithium cobalt oxide
•
Lithium manganese oxide
•
Lithium nickel manganese oxide
En
•
– Some new trends in lithium battery chemistries and design will be discussed. “High High Voltage” 4.35V 4 35V cells
– Q&A
© Copyright 2013 PSES-SD Chapter
AR
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TI N
•
gi ne er in g
© Copyright 2013 PSES-SD Chapter
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En
CELL
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CELL CONSTRUCTION
Predominantly cylindrical or prismatic (lithium ion ion, polymer) Concept p is the same:
© Copyright 2013 PSES-SD Chapter
AR
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TI N
En
¾Current collectors ¾Anode ¾Cathode p ¾Separator ¾ Electrolyte
gi ne er in g
SOME SUGGESTED CELL SAFETY CHARACTERIZATION:
© Copyright 2013 PSES-SD Chapter
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¾Isolation Properties ¾Separator p Shrinkage g @ Room Temperature p ¾Separator Shrinkage @ Elevated Temperature ¾Electrode Capacity Balance and Geometry ¾Electrode Tabs (connection to cell terminals) ¾Application of Insulation ¾Cell Vent Mechanism ¾Internal Short Avoidance ¾Positioning g of Insulating g Plate ¾Cell Thermal Test ¾Evaluation of Excess Lithium Plating and Short-Circuit Test on Cycled Cells ¾External Shorting of Cell Terminals
gi ne er in g
SOME MANUFACTURING PROBLEMS
En
–Contamination
TI N
–Lack of process control
–Lack L k off generall kknow-how h and d experience i © Copyright 2013 PSES-SD Chapter
AR
7
gi ne er in g
© Copyright 2013 PSES-SD Chapter
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En
BATTERY PACK
gi ne er in g
SOME SUGGESTED BP PERFORMANCE CHARACTERIZATION: CHARACTERIZATION
© Copyright 2013 PSES-SD Chapter
AR
9
TI N
En
¾Life cycle ¾Capacity (%SOC) ¾Thermal (Room Temp., Hot, Cold, Thermal shock) ¾Impedance ¾Altitude ¾Mechanical (drop, shock, crush, vibration and impact) ¾Nail Penetration ¾Force test ¾ESD (IEC 61000-4-2) ¾Surge (IEC 61000-4-5, 4-11, 4-4) ¾Short circuit ¾Power
These are performance related but may have long-term safety effects.
gi ne er in g
SOME SUGGESTED BP SAFETY CHARACTERIZATION: ¾Chemistry (Is it suitable for the application??) ¾Protection Device: ¾Current
(Over and Under-current)
¾Voltage
(Over and Under-voltage)
Output Current (External Short-Circuit Considerations)
¾Thermal
En
¾Limit
Protection Design ¾Mechanical Considerations ¾ Drop
Test
© Copyright 2013 PSES-SD Chapter
AR
10
TI N
¾ESD ¾Pack Manufacturer / Supplier Traceability (Minimize recall liability)
gi ne er in g
SOME BATTERY PACK PROTECTION NEEDS (NEED LOTS MORE; ONLY A FEW ARE DISCUSSED)
En
– Under and Over-voltage protection
© Copyright 2013 PSES-SD Chapter
AR
11
TI N
– Pack Over-current protection at various temperatures (-20, 25 & 60 oC)
gi ne er in g
© Copyright 2013 PSES-SD Chapter
AR
12
TI N
En
HOST LEVEL VERIFICATION
gi ne er in g
SOME SUGGESTED HOST LEVEL VERIFICATION TESTING: TESTING ¾Charge/Discharge Algorithm ¾I and V characteristics ¾Thermal (Room Temp., Hot, Cold) ¾
Is the cell being heated? Or portion of the cell heated?
¾ESD
En
¾Mechanical (drop, shock, crush, vibration and impact) ¾ How does the host behave after ESD and Surge testing? (IEC 61000-4-2)
(IEC 61000-4-5, 4-11, 4-4) ¾Sh t circuit ¾Short i it ¾Pack ID
TI N
¾Surge
¾Is
the system smart enough to detect a knockoff battery?
¾What Wh t
© Copyright 2013 PSES-SD Chapter
AR
13
action ti does d the th system t take? t k ?
These are performance related but may have long-term safety effects.
gi ne er in g
TI N
En
CHARGE ALGORITHM VERIFICATION
Play within the manufacturer recommended operational window…… Do not allow overcharge, overdischarge, over-temperature etc… © Copyright 2013 PSES-SD Chapter
AR
14
gi ne er in g
© Copyright 2013 PSES-SD Chapter
AR
15
TI N
En
DEVELOPMENTS ALLOWING SAFER LITHIUM CELLS
gi ne er in g
MOSTLY PROPRIETARY BUT……: ¾Low Power … e g LiFePO4 e.g.
En
¾High Power ¾Active material protected
© Copyright 2013 PSES-SD Chapter
AR
16
TI N
¾in order to decrease the probability of thermal runaway and Electrolyte decomposition
These are performance related but may have long-term safety effects.
gi ne er in g © Copyright 2013 PSES-SD Chapter
AR
17
TI N
En
Q&A
“WHAT DREAMS MAY COME”; ONLY IF IT WORKS RIGHT!!!
TI N
En
SOME HIGH ENERGY DENSITY LITHIUM BATTERY SAFETY CONCERNS CONCERNS. – Eddie Forouzan, Ph.D.
– President, ARTIN Engineering and Consulting Group, Inc.
AR
– 4/9/2013 1 © Copyright 2013 PSES-SD Chapter
gi ne er in g
INTRODUCTION TO ARTIN ENGINEERING
– Specializes in the design, development, testing and certification of cells, battery packs and devices equipped with electrochemical energy storage p ((lithium,, NiMH,, NiCd,, Alkaline,, lead acid etc..)) capabilities. – ISO17025 compliant – CTIA approved test lab – accredited by A2LA
En
– We are:
– Our A2LA accreditation includes IEEE 1725, IEEE1625, IEC 61000-4-2, IEC 61000-4-5, ISO 7637-2 and National Motor Freight Classification 180; ASTM D5276.
TI N
– Additional capabilities;
– Forensic analysis (x-ray, SECM, elemental analysis etc..) – Energy efficiency measurement: California Battery Mandate, IEC62301 – Consulting © Copyright 2013 PSES-SD Chapter
AR
2
gi ne er in g
OUTLINE
– This presentation pertains to high energy density secondary lithium batteries (rechargeable). – Will focus on batteries made with common cathode materials: Lithium cobalt oxide
•
Lithium manganese oxide
•
Lithium nickel manganese oxide
En
•
– Some new trends in lithium battery chemistries and design will be discussed. “High High Voltage” 4.35V 4 35V cells
– Q&A
© Copyright 2013 PSES-SD Chapter
AR
3
TI N
•
gi ne er in g
© Copyright 2013 PSES-SD Chapter
AR
4
TI N
En
CELL
gi ne er in g
CELL CONSTRUCTION
Predominantly cylindrical or prismatic (lithium ion ion, polymer) Concept p is the same:
© Copyright 2013 PSES-SD Chapter
AR
5
TI N
En
¾Current collectors ¾Anode ¾Cathode p ¾Separator ¾ Electrolyte
gi ne er in g
SOME SUGGESTED CELL SAFETY CHARACTERIZATION:
© Copyright 2013 PSES-SD Chapter
AR
6
TI N
En
¾Isolation Properties ¾Separator p Shrinkage g @ Room Temperature p ¾Separator Shrinkage @ Elevated Temperature ¾Electrode Capacity Balance and Geometry ¾Electrode Tabs (connection to cell terminals) ¾Application of Insulation ¾Cell Vent Mechanism ¾Internal Short Avoidance ¾Positioning g of Insulating g Plate ¾Cell Thermal Test ¾Evaluation of Excess Lithium Plating and Short-Circuit Test on Cycled Cells ¾External Shorting of Cell Terminals
gi ne er in g
SOME MANUFACTURING PROBLEMS
En
–Contamination
TI N
–Lack of process control
–Lack L k off generall kknow-how h and d experience i © Copyright 2013 PSES-SD Chapter
AR
7
gi ne er in g
© Copyright 2013 PSES-SD Chapter
AR
8
TI N
En
BATTERY PACK
gi ne er in g
SOME SUGGESTED BP PERFORMANCE CHARACTERIZATION: CHARACTERIZATION
© Copyright 2013 PSES-SD Chapter
AR
9
TI N
En
¾Life cycle ¾Capacity (%SOC) ¾Thermal (Room Temp., Hot, Cold, Thermal shock) ¾Impedance ¾Altitude ¾Mechanical (drop, shock, crush, vibration and impact) ¾Nail Penetration ¾Force test ¾ESD (IEC 61000-4-2) ¾Surge (IEC 61000-4-5, 4-11, 4-4) ¾Short circuit ¾Power
These are performance related but may have long-term safety effects.
gi ne er in g
SOME SUGGESTED BP SAFETY CHARACTERIZATION: ¾Chemistry (Is it suitable for the application??) ¾Protection Device: ¾Current
(Over and Under-current)
¾Voltage
(Over and Under-voltage)
Output Current (External Short-Circuit Considerations)
¾Thermal
En
¾Limit
Protection Design ¾Mechanical Considerations ¾ Drop
Test
© Copyright 2013 PSES-SD Chapter
AR
10
TI N
¾ESD ¾Pack Manufacturer / Supplier Traceability (Minimize recall liability)
gi ne er in g
SOME BATTERY PACK PROTECTION NEEDS (NEED LOTS MORE; ONLY A FEW ARE DISCUSSED)
En
– Under and Over-voltage protection
© Copyright 2013 PSES-SD Chapter
AR
11
TI N
– Pack Over-current protection at various temperatures (-20, 25 & 60 oC)
gi ne er in g
© Copyright 2013 PSES-SD Chapter
AR
12
TI N
En
HOST LEVEL VERIFICATION
gi ne er in g
SOME SUGGESTED HOST LEVEL VERIFICATION TESTING: TESTING ¾Charge/Discharge Algorithm ¾I and V characteristics ¾Thermal (Room Temp., Hot, Cold) ¾
Is the cell being heated? Or portion of the cell heated?
¾ESD
En
¾Mechanical (drop, shock, crush, vibration and impact) ¾ How does the host behave after ESD and Surge testing? (IEC 61000-4-2)
(IEC 61000-4-5, 4-11, 4-4) ¾Sh t circuit ¾Short i it ¾Pack ID
TI N
¾Surge
¾Is
the system smart enough to detect a knockoff battery?
¾What Wh t
© Copyright 2013 PSES-SD Chapter
AR
13
action ti does d the th system t take? t k ?
These are performance related but may have long-term safety effects.
gi ne er in g
TI N
En
CHARGE ALGORITHM VERIFICATION
Play within the manufacturer recommended operational window…… Do not allow overcharge, overdischarge, over-temperature etc… © Copyright 2013 PSES-SD Chapter
AR
14
gi ne er in g
© Copyright 2013 PSES-SD Chapter
AR
15
TI N
En
DEVELOPMENTS ALLOWING SAFER LITHIUM CELLS
gi ne er in g
MOSTLY PROPRIETARY BUT……: ¾Low Power … e g LiFePO4 e.g.
En
¾High Power ¾Active material protected
© Copyright 2013 PSES-SD Chapter
AR
16
TI N
¾in order to decrease the probability of thermal runaway and Electrolyte decomposition
These are performance related but may have long-term safety effects.
gi ne er in g © Copyright 2013 PSES-SD Chapter
AR
17
TI N
En
Q&A
