7502-Introduction to Lithium Ion Batteries

Scene Number: 75021000 - Course Information

All numbers and specifications listed in this program are used for illustration purposes only. Current
information can be found in the Service Manuals located on QuickServe Online.

Scene Number: 75021010 - Safety Everytime

The following course may contain demonstrations of service procedures that require special safety
considerations.
Always refer to QuickServe Online for the latest information and safety instructions, as requirements
dictated during the procedure may change. It is important to always follow the most recent
recommended safety procedures on QuickServe Online and check for updates each time you perform
any procedure.
Always follow your company's recommended job safety assessment (JSA) procedures prior to
performing any task or procedure.
During this course, warning symbols like the one seen below will be displayed where special attention
and/or safety precautions within a service procedure should be considered.
For reference, a PDF document is available for this information.

Scene Number: 75021020 - Objectives

Upon completion of this course the technician will have a basic understanding of:
the history of lithium ion batteries,
the parts of a lithium ion battery,
the makeup of a lithium ion battery system,
the differences between lithium ion batteries and lead acid batteries,
the functionality of lithium ion batteries and
the charging of lithium ion batteries.

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Scene Number: 75021030 - What is a Lithium Ion Battery

Lithium is the lightest of all metals and has the 4th greatest electro-chemical potential while providing
the largest specific energy per weight. Ions are atoms that have lost or gained electrons and have
become electrically charged. In comparison, lithium metal has a charge of ‘0’.
There are two types of batteries that use these properties of lithium. Lithium, sometimes called lithium
metal batteries and lithium ion batteries. In the most basic definition, lithium batteries, based on 2019
technology, are primary cells which are not rechargeable and lithium ion batteries secondary cells
which are rechargeable.
Lithium batteries use lithium metal as a negative electrode which does not allow them to easily or
safely be recharged. Current lithium batteries do offer more improvement of capacity and energy
density compared to lithium ion batteries. These properties make them good for uses such as in
implanted pacemakers, smoke detectors or any place where the batteries can not be changed that
often.
Lithium ion batteries use intercalation or insertion materials in their negative electrode that allow them
to be recharged over and over again for many years. Their ability to be recharged make them prefect
for portable devices such tools, cell phones and laptops as well as electric vehicles.

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Scene Number: 75021040 - What is a Lithium Ion Battery Made Of?

Like most batteries designed for a discharge state, lithium ion batteries have a negative electrode
called an anode, a positive electrode called a cathode, an ionic conductor called electrolyte and a
separator that electrically isolates the two electrodes. It is the material that these parts are made of
that give each type of battery their differing properties.
The negative electrode, the anode, for a lithium ion battery is typically made of an intercalated carbon
based material like graphite that is layered on copper scaffolding or foil called a current collector. To
be intercalated means it allows ions to be inserted or positioned between the layers of its existing
structure. In the case of a lithium ion battery, lithium ions are inserted into the carbon during charging
and released during discharge.
The positive electrode, the cathode, for a lithium ion battery is typically made of lithiated metal oxides.
The typical metal oxides that are combined with lithium are colbalt, nickel, manganese, iron and
aluminum. The lithiated metal oxide is layered on an aluminum scaffolding or foil called a current
collector. During discharging, lithium ions migrate from the anode to the cathode and during charging
the lithium ions move from the cathode back to the anode.
The electrolyte for a lithium ion battery can be a liquid, gel or dry polymer that facilitates the
movement of lithium ions between the anode and cathode. It is typically made of a solution of lithium
salts with organic solvents similar to ethylene carbonate mixed with diverse carbonates (DEC, DMC,
PC) that provides higher conductivity and expands the temperature range. The exact mixture varies
based on the type and manufacturer.
The separator for a lithium ion battery is essentially membranes made up of a gelatinous material,
usually a polyethylene, to prevent short-circuiting of the electrodes but promotes the movement of
ions between cathode and anode. The separator itself has no electrical conductivity. It can act as a
fuse in lithium ion batteries by melting in some cases when the battery gets too hot, closing off pores
and stopping the flow of ions.

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Scene Number: 75021050 - How a Lithium Ion Battery Works

Like all batteries, lithium ion batteries convert chemical energy stored in the electrodes to electrical
energy through a process called electro-chemical reaction. This reaction causes electrons to be
released. The flow of the electrons from the anode to the cathode through an external load circuit is
what produces electricity. This reaction was discovered by Alessandro Volta in the 1780s.
When a lithium ion battery is first assembled, all the lithium ions with their electrons reside in the
lithium metal oxide of the cathode and the graphite lattice of the anode is empty. The battery is in a
discharged state.
When a power source is attached to the battery, the electrons from the lithium ions in the lithium
metal oxide cathode are attracted to the current collector of the cathode. Without their electrons, the
lithium ions are now positively charged and attracted to the negatively charged anode.
The electrons flow through the circuit to the anode as they can not flow through the electrolyte and
separator. The electrons are stored in the lattice or layers of the graphite to be reunited with their
lithium ions.
The lithium ions that are without their electrons in the cathode are positively charged. These positively
charged ions can travel through the electrolyte and separator towards the negatively charged anode.
In the anode, they are reunited with their electrons and the graphite layers traps them there. This
leaves the lithium ions in an unstable state as the want to go back to their home in the lithium metal
oxide.
Once all of the lithium ions and their electrons are in the graphite lattice of the anode; they are
trapped there and the battery is fully charged, ready for use.
Once a load is attached to the battery, the electrons can now travel through the circuit, since they can
not travel through the electrolyte and separator. Then again without their electrons, the lithium ions
travel back through the electrolyte and separator where they are reunited with their electrons in the
lithium metal oxide of the cathode. This is the discharge cycle of the battery.

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Scene Number: 75021060 - Evolution of the Lithium Ion Battery

Even though lithium ion batteries are a relatively new and still developing technology, their roots go
back more than a hundred years. While the roots of all batteries go back more than two thousand
years. The concept of a battery utilizing lithium started to emerge in 1912 with the pioneering work of
American physical chemist Gilbert N. Lewis and his work with chemical bonding.
However, it was not till the 1970s that the evolution of rechargeable lithium batteries began to really
take off. Prior to the 1970s, lithium batteries were only non-rechargeable primary cells. Then British
chemist M. Stanley Whittingham working for Exxon, began working with metallic lithium as the anode
and titanium sulfide as the cathodes for creating a rechargeable lithium battery. However, the choice
of using those metals for the electrodes made their batteries impractical due to the safety and
expense of creating the batteries.
Lithium is a highly reactive element when exposed to water forming lithium hydroxide and hydrogen
gas which can ignite and degrades in contact with both humid and dry air. For these reasons,
researchers have driven the technology to the use of more stable lithium compounds, instead of
metallic lithium. Titanium sulfide is also reactive with air making it dangerous and very expensive.
Between 1974 and 1976, working and studying at TU Munich, Jurgen O. Besenhard discovered
reversible intercalation material with graphite and cathodic oxides in which could be used for lithium
ion batteries. Now instead of using metallic lithium, lithium ions could be inserted into intercalated
graphite minimizing the problems associated with metallic lithium as an anode. This was the birth of
the lithium ion battery. Unfortunately, the electrolyte compounds of the day reacted and decomposed
when used with graphite.
In 1977, Samar Basu followed Besenhard's proposal and demonstrated the electro-chemical
intercalation of lithium in graphite while at the University of Pennsylvania. This led to the lithium
intercalated graphite anode developed at Bell Labs.

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Scene Number: 75021070 - Continued Evolution of the Lithium Ion Battery

Now that we had the basis of the anode for the lithium ion battery, work began on creating a suitable
cathode. Titanium did not work, so in 1979 and on into 1980, John Goodenough and Koichi
Mizushima used lithium cobalt dioxide as a cathode in conjunction with lithium metal as the anode to
demonstrate a rechargeable lithium battery. However, with the lithium cobalt dioxide acting as a
donor of lithium ions, the anode no longer had to be made of metallic lithium.
With a stable, easy to work with cathode, Goodenough and Mizushima 's battery became one of the
first commercially viable rechargeable lithium batteries. Goodenough continued his work into the
1980s developing other lithium metal oxides such as manganese spinel, lithium copper oxide and
lithium nickel oxide. We now have the basis for both the anode and cathode of the modern lithium ion
battery, but they were yet to be combined.
In 1980 while demonstrating the reversible electro-chemical intercalation of lithium in graphite, Rachid
Yazami used a solid electrolyte that did not react with the graphite, giving us the basis of the
electrolyte needed for lithium ion batteries. Yazami's cathode is still widely used.
Finally in 1985, it all came together when Akira Yoshino combined a carbonaceous anode, with the
lithium cobalt oxide cathode, and an improved electrolyte creating a commercially viable lithium ion
battery that can be industrially produced.
Development of these new technologies and materials continued into the early 1990s. In 1991 Sony
released the first truly commercial lithium ion batteries. Innovations in ion battery technology continue
to this day.

Scene Number: 75021080 - Uses of Lithium Ion Batteries

Since 1991, the use of lithium and lithium ion batteries have grown exponentially. They show up in
devices most people use every day. By viewing this course on a computer, you are using a lithium ion
battery. There is a small lithium battery on the mother board of your computer.
The cell phone on your desk or in your pocket is also powered by a lithium ion battery.
Those cordless tools that you use in the shop are all moving over from big bulky nickel metal hydride
batteries to lithium ion batteries.
Almost any portable device, that you plug in to be recharged these days has a lithium ion battery in
them.
And now, in more recent years, electric vehicles are using lithium ion batteries. Since you are viewing
this course, you will more than likely be working with those lithium ion batteries in electric vehicles
very soon if you are not already doing so.

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Scene Number: 75021090 - What is a Lithium Ion Battery System?

A lithium ion battery system is a collection of cells and the system to monitor and regulate the
batteries.
Lithium ion batteries are scalable. The scalability is achieved by linking the cells together in series,
parallel or a combination of series and parallel depending on the application.
The smallest and most basic unit of a lithium ion battery is the cell. The cell contains the anode,
cathode, electrolyte and separator encased in a hermetically sealed container. These cells are
typically on the order of 3.5 volts.
The lithium ion cells can be linked together in series, parallel of a combination of series and parallel.
Linking cells together in series adds to the overall voltage while linking the cells together in parallel
attains higher capacity by increasing the total ampere-hours, ampacity. It also allows increased
current flow. It is important to use the same battery cell type with equal voltage and capacity and
never to mix different makes and sizes. These linked cells are refered to as a battery module or sub
module.
Like the lithium ion battery cells, the modules can be linked together to provide the necessary power
needed for applications such as electric vehicles. The individual modules can be linked together in
series, parallel or a combination of series and parallel is referred to as a battery pack.
The battery pack is the largest unit of measure for a lithium ion battery in a lithium ion battery system.
There can be many or a few modules in a pack; it depends on your need.

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Scene Number: 75021100 - Lithium Ion Battery System

Lithium ion battery packs need to be monitored and regulated so that they are not damaged and
maximize the calendar and cycle life, which is the job of the battery management system.
Key components of the battery management system include: The Thermal Management System and
the Battery Management Controller, which help to monitor the temperatures and voltages of the
battery packs, modules and cells.
The Battery Management Controller constantly monitors the battery pack voltage; state of charging
and discharging and battery pack temperature.
The Battery Thermal Management SystemTemperatures of the battery pack, modules and individual
cells are controlled by the flow of coolant through a system of tubes managed by .
Together th primary job of the Battery Thermal Management System and the Battery Management
controller is to oversee the overall health of the battery pack, modules and individual cells. This is
accomplished by maintaining safe operating temperatures for the battery packs, modules and cells;
consistent charging and discharging rates; and consistent coolant flow throughout the system.
This system helps to provide important information about how the battery packs and vehicle are
performing overall. The Battery Management Controller, which helps maintain a safe charge and
discharge rates. This is important when the vehicle is being charged. It also can send information to
technicians or the driver to alert them to potential problems with charging; remaining distance
capacity; or temperature issues.

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Scene Number: 75021110 - Lithium Ion Batteries vs Lead Acid Batteries

As engine technicians, it is safe to say that you have at least some experience in dealing with lead
acid batteries. Other than the fact that they are both batteries that use chemical reactions to produce
electricity, they are quite different systems and have differing roles. The chemistry, efficiency,
duration, power and weight differ between the two.
The two battery system have different chemistry of the anode, cathode and electrolyte. The anode
and cathode of a lead acid battery are typically made from lead and lead dioxide and are bridged by
an electrolyte of a solution that is roughly one-third sulfuric acid. While the lithium ion battery typically
has a graphite anode, a lithium metal oxide cathode and a lithium salt electrolyte.
When comparing the efficiency of the two battery systems, lithium ion batteries are 95 percent
efficient or more, meaning that 95 percent or more of the energy stored in a lithium-ion battery is
actually able to be used. While Lead acid batteries are only at 80 to 85 percent efficiency. Lithium ion
batteries are more expensive to make but have a lower cost per kilowatt hour. The charge retention of
the lead acid batteries is best among rechargeable batteries but generally lithium ion batteries last for
several times the number of cycles, leading to a longer effective lifespan.
Lithium ion batteries are more durable than lead acid batteries although lead acid batteries do
perform better at low temperatures. Lithium ion batteries really pull away from lead acid in durability
when it comes to the number of charging cycles they can handle. The discharge/charge cycle of a
lead acid battery permanently robs the battery of a small amount of capacity which reduces battery
life and does not happen with lithium ion batteries.
The power of the two batteries are different and serve different purposes. Lithium ion batteries have a
higher energy density between the two. Lead acid batteries can deliver a bigger jolt of power all at
once for applications like starting an internal combustion engine but lithium ion batteries can
discharge more energy over a longer period of time for powering devices for a long period of time.
The most notable difference in the power of the two batteries is that the power remains constant with
a lithium ion battery while the power of a lead acid battery decreases as it discharges.
Finally, the two batteries forr the same energy have different weights. Lead acid batteries are big and
heavy with a poor weight to energy ratio. By contrast lithium ion batteries are much lighter and have a
higher weight to energy ratio. Lithium ion batteries have about a 4 time higher specific energy as it
relates to watt hours per kilogram.

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Scene Number: 75021120 - Battery Charging

As with batteries, there are different chargers for different jobs. It is important that you use the correct
charger, Direct Current Voltage for the batteries that you want to charge. Using the incorrect charger
or voltage can lead to shortened battery life or even destruction of the battery.
We can break down battery chargers into two categories; simple and intelligent.
Simple chargers, that simply supply constant power to a battery, must be manually disconnected at
the end of the charge cycle. They have no way of sensing the condition of the battery, the flow of
power or turning itself off to prevent over charging which can lead to reduced capacity, reduced
lifetime, overheating or even going into thermal runaway and exploding. Simple chargers should not
be used with lithium ion batteries without constant monitoring.
Intelligent chargers have sensing circuits and a microprocessor controller to safely adjust the
charging current and voltage, determine the state of charge, and cut off at the end of charge. When
charging lithium ion batteries, always use an intelligent charger designed for the batteries you are
charging.

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Scene Number: 75021130 - Lithium Ion Battery Chargers

Lithium ion batteries have higher voltage per cell (4.2 volts), tighter voltage tolerances and cannot
float charge at full charge like lead acid batteries. Lithium ion batteries are very strict on the correct
setting due to the fact that they cannot accept an overcharge without damaging the battery. An
intelligent charger must always be used to charge lithium ion batteries. A lithium ion battery should
not get overly hot, greater than 60 degrees Celsius, (140 degrees Fahrenheit), while charging.
Themal runaway can occur at 140 degrees Celsius (284 degrees Fahrenheit). If this happens,
discontinue usage of the battery.
Intelligent chargers for lithium ion batteries can vary in the time it takes to fully charge the batteries.
The speed at which you can charge your lithium ion batteries depends on the design of your batteries
and the rating of the charger. The most basic safest charger is the slow overnight charger. The faster
the charge, the tighter the communication between the charger and battery must be. Using fast or
ultra fast chargers on batteries not designed to handle the speed and high current can lead to
reduced capacity, reduced lifetime, over heating or even exploding.
Typical charging of lithium ion batteries happens in three stages. Stage one is the constant current
phase where the charger applies a constant current at a steadily increasing voltage. Stage two is the
constant voltage phase where the current is slowly reduced to ~1/20th of the original current to top off
all of the battery cells. During this phase the current gradually decreases to zero. Stage thre is the
balance phase where all cells of a mulit-cell battery are brought to the same level of charge voltage
followed by a top off charge.
Fast and ultra fast charging occurs in the first stage of charging when more current shortens the
amount of time that it takes for the battery to get to 70 percent state-of-charge which can happen in
less than an hour. When utilizing an ultra fast charger, your batteries must capable of high current
rate charging. Ultra fast charging of mismatched or aging battery cells can lead to undue stress on
the weaker cells and damage to all the battery cells. Ultra fast charging requires that charging takes
place under moderate temperatures conditions. Charging at temperatures less than 0°C can lead to
irreparable degradation of the cell.

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Scene Number: 75021140 - Guidelines for Charging Lithium Ion Batteries

There are several factors that you need to keep in mind when charging lithium ion batteries. These
include:
Number one, know the chemical make-up of your batteries. As mentioned earlier in this training,
lithium ion batteries can have different chemical make ups.
Number two, choose the correct charger for the chemical make-up of your batteries. Most chargers
only serve one chemistry.
Number three, know the age and monitor the performance of your batteries. Utilizing fast and ultra-
fast charge on aged and low-performing batteries can further damage the batteries or cause a fire.
Take old and low performing batteries out of service.
Number four, only use fast or ultra fast charging when absolutely necessary. Charging your batteries
at a moderate rate will reduce the stress on the batteries and increase their life span.
Number five, charge batteries at moderate temperatures especially when using fast or ultra fast
chargers. The chemistry of lithium ion batteries require a tighter window of temperature for charging
than for usage.
And finally, read and understand all the manufacturers instructions for the batteries you are using. Do
not assume that all lithium ion batteries are the same because they are not, which brings us back to
number one. Know your batteries.

Scene Number: 75021150 - Conclusion

You are about to leave the virtual classroom and take the assessment.
Select next to continue to the assessment. Select back to return to the virtual classroom or click on
the program guide icon to view the program guide.

Scene Number: 75021160 - Assessment

What charge does Lithium have?

Scene Number: 75021170 - Assessment

Label the different parts of the Lithium Ion Battery

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Scene Number: 75021180 - Assessment

What is allowed to pass through the separator of a Lithium Ion Battery?

Scene Number: 75021190 - Assessment

What is the name of the process that allows electrons to be released in a Lithium Ion battery?

Scene Number: 75021200 - Assessment

When and who created the first rechargeable Lithium Ion battery?

Scene Number: 75021210 - Assessment

Linking battery cells together in series will increase:

Scene Number: 75021220 - Assessment

Linking battery cells together in parallel will increase:

Scene Number: 75021230 - Assessment

What helps regulate the battery system temperature?

Scene Number: 75021240 - Assessment

Place the statements that apply under Lithium Ion Batteries or Lead Acid Batteries.

Scene Number: 75021250 - Assessment

Label each charging stage with the correct charging phase name.

Scene Number: 75021260 - Assessment

What is the positive electrode of a Lithium Ion battery called?

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Scene Number: 75021270 - Assessment

What is the negative electrode of a Lithium Ion battery called?

Scene Number: 75021280 - Assessment

What is the largest unit of measure in a Lithium Battery System?

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