Building a Common Battery

Architecture

Dr. John Warner

Chief Customer Officer
American Battery Solutions
 Agenda

1 ABS Company Overview

2 What is a Common Architecture?

3 Cells

4 Module and Pack

5 Systems

© American Battery Solutions, Inc. Proprietary and Confidential Page 2

 Established Manufacturing Capacity with Footprint Ready to Scale

2018 Manufacturing Facility – Springboro, OH

60,000 Established 300k sq. ft.
Battery pack
of innovation and
systems delivered
manufacturing facilities
through existing facilities
~245
Team Members
across all locations

Ex-Bosch Facility Zero PPM

Acquired ready-to-scale ~120 quality performance
Battery engineers for FCA, BMW,
facility
across all locations Daimler and GM

170k sq. ft. 2 GWh 8 GWh

Key Competencies Current building
Expandable to 213k 2023 installed capacity
capacity

Innovation Centers
Expertise

Lake Orion, MI Hudson, MA

Raw Module Pack Reuse and
materials production assembly recycling

Cell
Cell technology
Battery Integration Finished
technology know-how management know-how products

120k sq. ft. Pilot line

Engineering, test Flexible semi- ~16k sq. ft.
and validation automatic prototype ESS design center in MA
facility build facility

© American Battery Solutions, Inc. Proprietary and Confidential Page 3

 What is a common architecture?
 The goal of developing a common architecture is to have the ability to leverage common
designs, parts, sourcing and manufacturing processes to meet the needs of multiple
customers/applications
 Common doesn’t necessarily mean identical
 Aspects of a common architecture:
 Common cell type – Choose one or a limited number of cell types (2170 cylindrical) but allow for different
chemistries
 Common module design
 Common pack design
 Common system design
 Common manufacturing process
 Common sourcing of components

© American Battery Solutions, Inc. Proprietary and Confidential Page 4

 Common Cell Form Factor
Base architecture on an industry standard cell type 2170 to 4680

Pack Energy Roadmap

75
Pack Energy (kWh) Nominal

70 68

65  30%
61
59
60
55  17%
55 52  13%
 6%
50

45
5.0Ah 5.2Ah 5.6Ah 5.8Ah 4680

2170
© American Battery Solutions, Inc. Proprietary and Confidential Page 5
 2170 Cell Chemistries
Wide range of chemistries and power availabilities

2170 Cells
350 High Energy NMC, NCA, NMCA

325
300
Different Energy
Capabilities 275
250
225
High Power NMC
Different Power 200
Capabilities
175
Different 150 Same From Factor
LFP
Chemistries 125
2.5 3.5 4.5 5.5 6.5 7.5

© American Battery Solutions, Inc. Proprietary and Confidential Page 6

 ProLiance High Voltage Packs
Standardized, flexible high voltage battery packs
ProLiance ™ T350-50
2023 2025
Characteristic Unit
Specification* Specification*
Voltage, Nominal V 354 354
Voltage, Range V 288 - 394 288 - 394
Energy, Total kWh 52 55
Capacity Ah 150 156
Continuous Current A 180 185
Peak Current (10 sec) A 440 455
Power, Continuous (@50% SOC, 24°C) kW 63 66
Peak Power (10 sec) (@50% SOC, 24°C) kW 157 165
Volume L 296 296
Mass Kg 313 313
Energy Density Wh/L 175 187
Specific Energy Wh/kg 166 175
Dimensions (L x W x H) mm 1,360 x 769 x 283
Operating Temperature °C -30 to 55
Start of Production May 2023 *All specifications are preliminary and subject to change

© American Battery Solutions, Inc. Proprietary and Confidential Page 7

 Visual Bill of Materials
T350-50 pack

Enclosure Cover
2170 Li-ion Cells
Cross Module Bracket
Cell Voltage Temperature
Battery Module Node (CVTN)
Battery Management
Thermal Coolant Hoses System (BMS)

Battery Disconnect Unit

Mica TR Barrier (BDU)
Module Mounting Bracket Pyro Fuse
LV Communications
Aux Power
Mounting Bracket
Common DC Fast Charge Connector
Identical Enclosure Cover Base High Power
Cooling In/Out
© American Battery Solutions, Inc. Proprietary and Confidential Page 8
 Common Architecture Definition
Module Scalability

 Fixed Design Features

• Module depth (fixed cold plate depth)
• Cell Type (Manufacturer/model specific)
• Thermal Interface (Fitting type, size)
• HV Interfaces (Module side-to-side, module-to-BDU)
• LV Interfaces (V/T sense-to-CVTN, 1 CVTN/module) Height
• Voltage Sense (attachment method, location)
• Temperature Sense (attachment method)
• Symmetrical Brick S/P Configuration on each side of cold plate
• Standard Fasteners

 Scalability
• Common sourcing and manufacturing for economies of scale
• X-Y flex, capacity flex, voltage flex
• Module Height and Width
 Accommodate app-specific S/P configurations
• Max. S-configuration constrained by CVTN (# of Voltage inputs)
• P-configuration determined by app-specific energy requirement
• S/P configuration options dependent on overall pack geometry, # of modules, current collector layout

© American Battery Solutions, Inc. Proprietary and Confidential Page 9

 Common Module Architecture
Core Architecture Flexibility and Scalability

Height is scalable
Length is scalable

Width is fixed

© American Battery Solutions, Inc. Proprietary and Confidential Page 10

 Common Pack Architecture
Pack Assembly DFM and Scalability

 Fixed Features/Design Constraints

• Enclosure materials and structural features
• Module assembly orientation (CVTN on top) and standard mounting features
• Module HV and Coolant connections on same (depth) side
• Standardized coolant system plumbing components and quick-disconnects
• Modular BDU Assembly
• Standard bulkhead connections (including coolant) mounted to housing interface plate
• V/T sense (module-to-module and module-to-BMS, ISO SPI jumper harness) Height
• Application Mounting Bracket attachment features and internal structure
• Process compatible module and pack lift and handling features
• Standardized fasteners
Width

 Scalability
• Common sourcing and manufacturing for economies of scale
• Pack Width, Depth (dependent on app-specific Voltage and Energy Density
Requirements)
 BDU Assembly Layout/Form Factor
 Bulkhead Connector Interface locations (i.e. coolant and HV/LV electrical)

© American Battery Solutions, Inc. Proprietary and Confidential Page 11

 Scalabile Pack Architecture
Possible future configurations based on a single pack architecture

Add modules to increase Voltage & Energy

Increase pack length

T410-60
(7) 480-Cell
T470-69
modules, T530-78
(8) 480-Cell
410V-60kWh (9) 480-Cell
modules,
470V-69kWh modules, T590-87
530V-78kWh (10) 480-Cell T650-95
modules, (11) 480-Cell T700-100
590V-87kWh modules, (12) 480-Cell
T350-50
650V-95kWh modules,
(6) 480-Cell modules,
700V-104kWh
350V-50kWh
© American Battery Solutions, Inc. Proprietary and Confidential Page 12
 ProLiance High Voltage Packs
Standardized, flexible high voltage battery packs ProLiance ™ T700-100
2023
Characteristic Unit
Specification*
Voltage, Nominal V 708
Voltage, Range V 576 - 797
Energy, Total kWh 104
Capacity Ah 150
Continuous Current A 180
Peak Current (10 sec) A 440
Power, Continuous (@50% SOC, 24°C) kW 126
Peak Power (10 sec) (@50% SOC, 24°C) kW 314
Volume L 594
Mass Kg 626
Energy Density Wh/L 180
Specific Energy Wh/kg 170
Dimensions (L x W x H) mm 2,425 x 769 x 283
Target Start of Production 2024 Operating Temperature °C -30 to 55

*All specifications are preliminary and subject to change

© American Battery Solutions, Inc. Proprietary and Confidential Page 13
 Common Pack Architecture Design Flexibility
Potential Configurations based on one design
Customer 1 (10 612-Cell modules, 665V-
110kWh)

T350-50 (6 480-Cell modules, 350V-50kWh)

Customer 2 (9 576-Cell modules, 400V-94kWh)

T700-100 (12 480 Cell-modules, 700V-100kWh)

• Common Module Design

• Common Enclosure
• Common HVFE
• Common BMS
• Common CVTN
• Common BDU

© American Battery Solutions, Inc. Proprietary and Confidential Page 14

 Common architecture with a new cell format
Architecture concept extends to different cell form factors

Prismatic Prismatic
Cell-to-Pack Cell-to-Pack
Concept 1 Concept 2
Based on 12-cell module stacks Based on a pure CTP concept without modules
Common enclosure design Common enclosure design
Common BMS, BDU, CVTN, HVFE, Common BMS, BDU, CVTN, HVFE, connectors
Connectors

© American Battery Solutions, Inc. Proprietary and Confidential Page 15

 Architectural System Scalability
Parallel / Series Connection Configuration
Veh CAN

Parallel connection to vehicle junction box

+
+

+
BATT CAN

Batt CAN
Series 1 Series 2 Series n
Int CAN

Int CAN

Int CAN
-

-
+

+
-
-

-
Parallel connection to vehicle junction box

© American Battery Solutions, Inc. Proprietary and Confidential Page 16

 Common architecture can serve a wide
variety of applications…

© American Battery Solutions, Inc. Proprietary and Confidential Page 17

 Benefits of using a common architecture
Enabling market growth

 Minimize non-recurring engineering and tooling costs

 Common design strategy:
 Reduce engineering time and cost
 Reduce validation time
 Shared set of components (BMS, BDU, HVFE, etc)
 Common enclosure design
 Common manufacturing processes – economies of scale
 Sourcing of common components – economies of scale
 Access to higher volume cell sourcing
 Address a wide range of customer applications

 All of these provide the benefit of improving costs for inherently low volume markets,
giving them the advantages experienced by higher volume applications

© American Battery Solutions, Inc. Proprietary and Confidential Page 18

 Dr. John Warner
jwarner@americanbatterysolutions.com
More Info
www.americanbatterysolutions.com