The Handbook of Lithium-Ion

Battery Pack Design

This page intentionally left blank
 The Handbook of Lithium-Ion
Battery Pack Design
Chemistry, Components, Types and Terminology

John Warner
XALT Energy, Midland, MI, USA

AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK • OXFORD

PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO
Elsevier
Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK
225 Wyman Street, Waltham, MA 02451, USA

Copyright © 2015 Elsevier Inc. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing
from the publisher. Details on how to seek permission, further information about the Publisher’s permissions
policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright
Licensing Agency, can be found at our website: www.elsevier.com/permissions.

This book and the individual contributions contained in it are protected under copyright by the Publisher (other
than as may be noted herein).

Notices
Knowledge and best practice in this field are constantly changing. As new research and experience broaden our
understanding, changes in research methods, professional practices, or medical treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any
information, methods, compounds, or experiments described herein. In using such information or methods they
should be mindful of their own safety and the safety of others, including parties for whom they have a professional
responsibility.

To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability
for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or
from any use or operation of any methods, products, instructions, or ideas contained in the material herein.

ISBN: 978-0-12-801456-1

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library

Library of Congress Cataloging-in-Publication Data

A catalog record for this book is available from the Library of Congress

For Information on all Elsevier publications

visit our website at http://store.elsevier.com/
Contents
Figure Captions .................................................................................................. ix
Preface ............................................................................................................ xiii
Acknowledgments ...............................................................................................xv
Acronyms List ..................................................................................................xvii
Chapter 1: Introduction ........................................................................................1
Factors Influencing Consumer Adoption of Electric Vehicles ...................................... 2
Evolving Vehicle Technology Needs ............................................................................ 3
Purpose of the Book ..................................................................................................... 4
Chapter Outline............................................................................................................. 6
Chapter 2: History of Vehicle Electrification ...........................................................9
The History of the Modern Storage Battery ............................................................... 10
An Electrical Industry Emerges .................................................................................. 14
Early Electric Vehicle Development ........................................................................... 14
Modern Vehicle Electrification ................................................................................... 16
Chapter 3: Basic Terminology .............................................................................23
Vehicle and Industry Terms ........................................................................................ 23
Stationary and Grid Terminology ............................................................................... 27
Battery Terms.............................................................................................................. 28
Chapter 4: Battery Pack Design Criteria and Selection ..........................................35
Ohm’s Law and Basic Battery Calculations ............................................................... 38
Converting Customer Requirements into Pack Designs ............................................. 45
Power to Energy Ratios .............................................................................................. 47
Large Stationary and Grid Systems ............................................................................ 48
Quick Formula Summary ........................................................................................... 48
Chapter 5: Design for Reliability/Design for Service ..............................................51
Design for Reliability/Design for Service .................................................................. 52
Quality and Reliability................................................................................................ 53
Failure Modes Effects Analysis .................................................................................. 54
Design for Service ...................................................................................................... 56
Chapter Summary ....................................................................................................... 57

v
vi Contents

Chapter 6: Computer-Aided Design and Analysis ..................................................59

Organizations and Analysis Products ......................................................................... 59
Analysis Tools............................................................................................................. 61
Battery Sizing Tools.................................................................................................... 62
Chapter 7: Lithium-Ion and Other Cell Chemistries ...............................................65
Lead Acid .................................................................................................................... 66
Nickel Metal-Based Chemistries ................................................................................ 72
Sodium-Based Chemistries......................................................................................... 74
Lithium-Ion Cells ....................................................................................................... 75
Cathode Chemistries ................................................................................................... 78
Anode Materials.......................................................................................................... 80
Separators ................................................................................................................... 81
Electrolytes ................................................................................................................. 82
Safety Features............................................................................................................ 83
Lithium-Ion Cell Types and Sizes .............................................................................. 84
Lithium-Ion Cell Manufacturers ................................................................................. 86
Chapter 8: Battery Management System Controls .................................................91
BMS Typologies ......................................................................................................... 92
BMS Hardware ........................................................................................................... 93
Balancing .................................................................................................................... 95
Active versus Passive Balancing................................................................................. 98
Additional BMS Functionality ................................................................................... 99
Software and Controls .............................................................................................. 100
Chapter 9: System Control Electronics ...............................................................103
Contactors/Relays ..................................................................................................... 104
High-Voltage Interlock Loop .................................................................................... 106
Fuses ......................................................................................................................... 106
Battery Disconnect Unit ........................................................................................... 108
Connectors ................................................................................................................ 109
Charging ................................................................................................................... 110
Chapter 10: Thermal Management ....................................................................115
Why Cooling? ........................................................................................................... 119
Why Heating? ........................................................................................................... 122
Active Thermal Management Systems ..................................................................... 123
Passive Thermal Management Systems .................................................................... 127
Temperature—Protection and Insulation .................................................................. 128
Thermocouples and Measurement ............................................................................ 129
Chapter 11: Mechanical Packaging and Material Selection ...................................131
Module Designs ........................................................................................................ 132
Use of Metals in Battery Design............................................................................... 133
Use of Plastics and Composites in Battery Design................................................... 135
Sealed Enclosures ..................................................................................................... 135
 Contents vii

Chapter 12: Battery Abuse Tolerance ................................................................139

Failure Modes of Lithium-Ion Batteries ................................................................... 141
Characterization and Performance Testing ............................................................... 142
Safety and Abuse Testing .......................................................................................... 146
Certification Testing.................................................................................................. 148
Chapter 13: Industrial Standards and Organizations ...........................................153
Voluntary Standards .................................................................................................. 155
Research and Development and Trade Groups ......................................................... 163
Mandatory Standards Organizations......................................................................... 165
Chinese Standards and Industry Organizations ........................................................ 166
European Standards and Industry Organizations ...................................................... 166
Chapter 14: Second Life and Recycling of Lithium-Ion Batteries ............................169
Repairing and Remanufacturing ............................................................................... 170
Refurbishing, Repurposing, and Second Life ........................................................... 170
Second Life Partnerships .......................................................................................... 173
Recycling .................................................................................................................. 174
Chapter 15: Lithium-Ion Battery Applications ....................................................177
Personal Transportation Applications ....................................................................... 177
Automotive Applications .......................................................................................... 183
Bus and Public Transportation .................................................................................. 194
HD Truck Applications ............................................................................................. 196
Industrial Applications .............................................................................................. 196
Robotics and Autonomous Applications................................................................... 198
Marine and Maritime Applications ........................................................................... 199
Grid and Stationary Applications ............................................................................. 200
Aerospace Applications ............................................................................................ 206
Chapter 16: The Future of Lithium-Ion Batteries and Electrification ......................211
Major Trends............................................................................................................. 211
Technological Trends ................................................................................................ 212
Future Trends in Battery Technology ....................................................................... 214
Conclusion ................................................................................................................ 216
References ......................................................................................................217
Appendix A: USABC 12-V Stop/Start Battery Pack Goals ...................................223
Appendix B: USABC 48-V Battery Pack Goals ...................................................225
Appendix C: USABC HEV Battery Pack Goals ...................................................227
Appendix D: USABC PHEV Battery Pack Goals .................................................229
Appendix E: USABC EV Battery Pack Goals ......................................................231
Index ..............................................................................................................233