eNewsletter

February 2010

Nextreme and Infinite Power Solutions Announce Thin-Film Thermal Charger Application
Nextreme Thermal Solutions, a provider in microscale thermal and power management products for the electronics industry, and Infinite Power Solutions, Inc. (IPS), a manufacturer of solid-state, rechargeable, thin-film micro-energy storage devices, have developed a thermal charger with the ability to continuously recharge the IPS THINERGY Micro-Energy Cell (MEC) using an eTEG thermoelectric power generator from Nextreme. Thin-film thermoelectric technology enables thermal charging where energy scavenging from thermal sources is combined with solid-state, rechargeable thin-film battery technology to provide an alternative energy source for a variety of autonomous, self-powered applications.

The prototype thermal charger uses an array of 16 HV14 modules in power generation mode to provide the 4.1 volts of electricity needed to charge the MEC to a fully charged state in approximately 20 minutes. At 0.5 millimeters high and each smaller than a sunflower seed, four of these tiny HV14 power generators can replace a AA battery.

With modules measuring just 1.8 mm by 1.5 mm, the eTEG HV14 has corresponding output power densities of ~ 0.6 and 1.6 W/cm². Nextreme’s eTEG devices generate electricity via the Seebeck Effect, where an electrical current is produced from a temperature gradient across the device.

Unlike conventional batteries, these ultra-thin and rechargeable MECs can be solder attached directly to printed circuit boards (PCBs), or deeply embedded (buried) within the layers of a PCB. The MECs can also be embedded into integrated circuit (IC) packaging and multi-chip modules, as well as systems in package. The THINERGY MEC is provided to supply stored energy for use by the application during periods when the heat source is not available or is intermittent. Applications for thermal charging from waste heat include scavenging heat from a solar panel as a supplemental source of electricity, using heat produced by an engine during combustion to charge a battery, or providing power for a remote sensor.

Hitachi Develops Lithium-Ion Batteries for Plug-In Hybrid Electric Vehicles
Hitachi, Ltd. and Hitachi Vehicle Energy, Ltd. have developed lithium-ion batteries for plug-in hybrid electric vehicles, a first for the Hitachi Group. These new batteries were developed in response to the growing demand for environment-friendly vehicles resulting from the increasingly strict regulations on automobile exhaust emissions around the world. Starting from the spring of 2010, the company will begin shipping samples to automobile manufacturers in Japan and overseas.

Plug-in hybrid electric vehicles (PHEVs) have two running modes: an EV (electric vehicle) mode, in which the vehicle runs on a motor alone, and an HEV (hybrid electric vehicle) mode, in which the vehicle is driven by both the engine and the motor. PHEVs offer dramatically improved gas mileage and reduced exhaust emissions, and so are considered a strong contender among environment-friendly vehicles of the future. The newly developed lithium-ion batteries offer the high performance and reliability required for use in PHEVs, achieving both high energy (durability; contribute to gaining cruising distance) and high output (instantaneous force) performance. In the future, Hitachi will make preparations for the shift to volume production, incorporating the expertise that it has accumulated over many years through its Monozukuri technologies and its experience in global markets.

The newly developed lithium-ion batteries have an electric capacity of 25Ah, so can run for about 20 km in EV mode, using the motor alone. This represents four to five times the capacity of the lithium-ion batteries for hybrid electric vehicles (HEVs) that Hitachi has been developing up to now.

The  batteries incorporate a heat-resistant separator that prevents internal short-circuits and dramatically improves safety. The separator is a key component of lithium-ion batteries that separates the cathode and the anode, and at the same time maintains ionic conductivity. Because the electric capacity of PHEV batteries is considerably higher than that of HEV batteries, consideration for safety becomes even more important. The heat-resistant separator adopted in these new batteries was specially designed and developed for automotive applications, based on ceramic separator technologies.

To accommodate larger battery sizes, a variety of simulation technologies, including structural analysis and vibration analysis, have been utilized to increase battery strength and enhance the collector structure. In collaboration with Hitachi Research Laboratory and the Mechanical Engineering Research Laboratory, Hitachi has achieved a battery structure with an even higher level of reliability than previous units.

Battery Stack Fault Monitor Provides Independent Supervision of High Voltage Li-Ion Strings
Linear Technology has introduced the LTC6801, a high voltage battery stack fault monitor that operates without a microprocessor, and without the need for optocouplers or isolators. An LTC6801 can monitor up to 12 series-connected battery cells for overvoltage and undervoltage conditions. Multiple LTC6801 devices can be daisy chained, providing a method to monitor each individual cell in very long battery strings. When connected in a daisy-chain, a single differential clock output confirms that all cells in the stack are within the defined operating range. This clock interface provides high noise immunity and ensures that fault conditions are not hidden by frozen bits or short circuit conditions. The result is a reliable and simple design that can serve as a complete monitoring or redundant circuit. The LTC6801 is a low cost companion to the LTC6802 precision battery measurement and cell balancing IC, providing a backup circuit for hybrid electric battery packs, battery backup systems, and other high powered Li-Ion battery systems.

A wide range of overvoltage and undervoltage thresholds can be set via pin connections and the LTC6801 offers selectable threshold hysteresis and adjustable update rates. The LTC6801 is fully specified for operation from -40°C to 85°C and two temperature sensor inputs are monitored for over-temperature faults.

Samples, demonstration boards and the data sheet for the LTC6801 are now available. Prices start at $4.48 each in 1,000-piece quantities.

Battery Data Acquisition Made Easy
The new DataCell from Merlin Equipment uses unique technology to analyze the battery and determine actual capacity remaining without the need of a shunt, greatly reducing installation time and complexity. The unit then continuously outputs battery voltage and state of charge (SoC) information via a standard RS232 output, which can be interpreted remotely by any windows based PC running Merlin software.

As well as reducing installation time dramatically and the obvious cost savings of not needing a battery monitor display and RS232 converter, DataCell provides a massive improvement in long term accuracy compared to conventional shunt based battery monitors. All shunt based units count ampere hours to determine capacity remaining but due to inherent inaccuracies, they require regular manual synchronization. As Data-Cell does not have a shunt (and the inherent inaccuracy of counting amp hours), it never runs out of synchronization. This makes it much more attractive for applications where regular maintenance is not possible (such as in many telemetry based installations), or for use by untrained operators.

Merlin’s DataCell software provides a wealth of important battery data including voltage and remaining capacity.  Low voltage and capacity alarms can also be set. For each active bank, it displays a moving ‘heart monitor style graph’ where voltage and SoC can be viewed over time to provide trend information.

Designed for either 12 V or 24 V systems, DataCell can be purchased in either single bank format or for monitoring two, three or four banks simultaneously. Each battery bank can consist of either a single mono-block or several batteries in series/parallel configuration.

GM Builds First Lithium-Ion Battery for Chevrolet Volt
Exactly three years since the day the Chevrolet Volt concept car debuted, GM manufactured the first advanced lithium-ion battery for a mass-marketed electric vehicle at GM’s Brownstown Battery Pack Assembly Plant. GM announced last August a $43-million investment to prepare the 160,000-square-foot, landfill-free facility for production of lithium-ion battery packs for the Volt and other electric vehicles with extended-range capabilities. The plant is part of a wholly-owned subsidiary of General Motors called GM Subsystems Manufacturing LLC.

In just five months, the Brownstown plant was converted from an empty facility to a production-ready battery manufacturing site. New machinery and specialized equipment have been installed and three primary assembly areas have been completed: battery module pre-assembly, final assembly and the battery pack main line.

The Volt’s battery pack is made up of multiple linked battery modules and more than 200 battery cells. The initial assembly area is where the prismatic-shaped cells are processed and installed by state-of-the-art flexible automated equipment into modules, which are then delivered to the battery pack main line.

The battery pack main line area features an Automated Guided Cart (ACG) system that includes operations for thermal and electrical assembly, along with quality and dimensional checks. The main line is also where battery pack final testing, verification and packaging for shipment take place.

Initial battery production at Brownstown will be used to validate the plant’s equipment and processes, and batteries will be sent to GM’s Global Battery Systems lab in Warren, Mich., for testing. This spring, GM will begin shipping batteries to GM’s Detroit-Hamtramck plant, the assembly location for the Volt, for use in production validation vehicles.

GM is investing $700 million in eight Michigan facilities for Volt-related production, including $336 million in the Detroit-Hamtramck plant, which will benefit from battery research conducted at the battery lab in Warren.

EnerDel Plans to Invest $237 Million in New Indiana Lithium-Ion Battery Plant, Creating 1,400 New Clean Tech Jobs
Lithium-ion battery manufacturer EnerDel will invest $237 million in a new manufacturing plant near its Indianapolis headquarters in order to meet anticipated demand for advanced battery systems used in both automotive and stationary smart grid applications. Backed by a mix of private funds and public incentives, the new facilities will more than double EnerDel’s US production capacity and create 1,400 new jobs.

“Demand for high-performance lithium-ion battery systems is expanding dramatically, for vehicles of all sizes as well as the utility grid, and we are going to be fully prepared to meet it with a product stamped ‘Made in America’,” said Charles Gassenheimer, Chairman and CEO of EnerDel parent company Ener1, Inc.

The new plant will give EnerDel the capacity to produce battery packs for approximately 600,000 hybrid electric vehicles, or 60,000 battery electric cars. It will be financed through a $118.5 million grant awarded under the federal stimulus package under a 50:50 cost-share program, of which EnerDel plans to spend $60 million in 2010. The project represents just the first stage of the company’s expansion plans in the Indianapolis area.

EnerDel will immediately begin to occupy more than 211,500 square feet of newly-constructed space in the Axcess70 industrial park in Mt. Comfort, Indiana, with a two year option to purchase the entire facility which is comprised of 423,000 square feet. The company is currently in the process of hiring new engineers, production associates and other staff as build-out progresses.

EnerDel has commercial and strategic partnerships with industry leading companies including Volvo, THINK, Nissan and Mazda, and is supplying batteries for a prototype hybrid version of the Humvee being tested by the US Army. EnerDel batteries have recently been chosen for smart grid projects in the US and Japan.

Orocobre and Toyota Tsusho Announce JV to Develop Argentine Lithium Project
Orocobre Limited has reached  an agreement to establish a joint venture with Toyota Group Company, Toyota Tsusho Corp., to develop its flagship Salar de Olaroz Lithium-Potash Project in Argentina.

The agreement sets out the terms under which the parties will develop the Salar de Olaroz project. In the current feasibility study phase, Toyota Tsusho will provide $4.5 million to fund the completion of the Definitive Feasibility Study and other associated pre-development activities. This is expected to be completed in the third quarter of 2010.

Toyota Tsusho’s interest in the Project stems from the desire to increase its exposure to reliable and diversified lithium supplies as global demand for lithium batteries in the automotive sector continues to grow. Toyota Tsusho said the company had a strategy to invest in the Olaroz Lithium-Potash Project in order to secure access to competitive, low-cost lithium carbonate production in a timeframe closely aligned with worldwide lithium requirements for hybrid and electric vehicles.

A123 Systems Signs Multi-Year Battery System Supply Agreement with Fisker Automotive
A123 Systems has announced a battery supply agreement with Fisker Automotive, a new American automaker building green vehicles. The supply agreement is for battery systems for the Fisker Karma Plug-in Hybrid Electric Vehicle (PHEV). The Karma is scheduled to be launched in late 2010 and expected to be one of the cleanest, most fuel-efficient cars in the world while still offering industry-leading style and performance.

A123 Systems will provide Fisker Automotive with advanced automotive battery systems that combine high power and energy density with excellent safety and life performance, characteristics required to meet Fisker’s stringent technical specifications. Fisker Automotive and A123 will also collaborate on Fisker’s Project Nina platform, with the intent of having A123 supply batteries for that vehicle based on meeting the automaker’s performance and delivery requirements. Project Nina is expected to launch in 2012.

The multi-year agreement provides that A123 is the selected battery system supplier for the Fisker Karma. A123 plans to manufacture the cells and systems at its Livonia, Mich. facility with production slated to commence later this year.

The Fisker Karma is expected to have a range of 50 full-electric miles on a charge of A123’s lithium ion battery system and a total range of 300 miles with an on-board generator turned by a traditional but efficient four-cylinder gasoline engine. The Karma features 403hp and is designed to go from 0 to 60 mph in about six seconds, reaching a top speed of 125 mph.

In addition to entering into the supply agreement, A123 also announced its intent to invest up to $23 million in Fisker Automotive’s current funding round in order to establish a strategic relationship with the car company. The contemplated investment would consist of $13 million in cash and $10 million in A123 common stock and would be subject to the completion of certain terms and conditions. This investment would closely align the interests of both companies in delivering innovative technologies for safe and reliable PHEVs. This investment would also allow Fisker Automotive and A123 to work closely together to optimize the performance of future vehicles.

Battery Power 2010 Call for Presentations
The Battery Power 2010 conference committee is currently accepting abstracts. Being held October 19-20 in Dallas, Texas, the 2010 event will explore the important topics impacting battery power technology from design issues in battery packs and emerging charging technologies to predicting battery failure and battery hybrid technologies. Other topics include cell design and manufacturing, power management, testing, materials, market trends and end-user requirements for new applications. Presentations will cover the portable/mobile, automotive/EV and stationary/onsite power markets.

With more than 500 attendees, the conference provides an excellent forum to discuss new developments in technology, market conditions and end-user requirements that are driving innovation, capabilities and features, application trends and performance improvements today and in the future. Attendees will include top executives, technical managers and engineering professionals from original equipment manufacturers, system developers and integrators, dealers and component providers.

There are a limited number of speaking slots in each track, so it is imperative that you submit an abstract before the deadline of February 9th, 2010.

For details on submitting an abstract, please visit the Call for Presentations page.

March

3-5 - 1st International Rechargeable Expo Battery Japan, Tokyo, Japan

15-18 - The 27th International Battery Seminar & Exhibit, Fort Lauderdale, Fla.

April

27-28 - 3rd China & Global Lithium Battery Industry Summit 2010, Beijing, China

APEC 2010
February 21-25
Palm Springs, Calif.

As The Premier Event in Applied Power Electronics, APEC focuses on the practical and applied aspects of the power electronics business. This is not just a designer's conference, APEC has something of interest for anyone involved in power electronics:

• Equipment OEMs that use power supplies and dc-dc converters in their equipment
• Designers of power supplies, dc-dc converters, motor drives, uninterruptable power supplies, inverters and any other power electronic circuits, equipments and systems
• Manufacturers and suppliers of components and assemblies used in power electronics
• Manufacturing, quality and test engineers involved with power electronics equipment
• Marketing, sales and anyone involved in the business of power electronics
• Compliance engineers testing and qualifying power electronics equipment or equipment that uses power electronics.

Battery Japan
March 3-5
Tokyo, Japan

Register Now! World’s Largest Expo for Rechargeable Battery!
BATTERY JAPAN is the world’s largest exhibition dedicated to rechargeable battery held at Tokyo, Japan from March 3-5, 2010.
For those interested in expanding business in rechargeable battery industry, BATTERY JAPAN is the place to be!

Exhibitor Profile: www.batteryjapan.jp/bj_en/01_outline/index_04.html

1. Rechargeable Battery
2. Material/Component
3. Manufacturing Equipment
4. Inspection/Testing/Evaluation
5. Related Apparatus

Conference Details: www.batteryjapan.jp/bj_en/04_seminar/index.html
• Mr. Keisuke Saito, Director-General, Energy Conservation and Renewable Energy Dept., Agency for Natural Resources and Energy, Ministry of Economy, Trade and Industry (METI)
• Mr. Naoto Noguchi, Executive Officer, President, Energy Company, Panasonic Corp.
• Mr. Insang Jeon, Vice President, Samsung SDI Co., Ltd.
And more!

Concurrent Events:
FC EXPO 2010
PV EXPO 2010
PV SYSTEM EXPO 2010
1st Processing Technology Expo

In order to participate, please visit us online.

IWCE 2010

IWCE is the pre-eminent integrated communications systems event for the working world. Having the ability to receive the right information has never been more important. If you are responsible for the dependability, reliability and interoperability of your organization’s communication system, then IWCE is your must attend event.  IWCE provides the applications and systems you need in order to communicate anytime, anywhere. Make connections with 360+ leading edge exhibitors and collaborate in an educational environment that delivers meaningful information that allows you to do a better job. 

From Land Mobile Radio…to Wireless Mobility…Voice…Video…Data…and everything in-between…Communications Technology is Changing…and so is IWCE.

Register by February 5, 2010 and SAVE!

Aviation Industry Expo
March 16-18
Las Vegas, Nev.

Aviation Industry Expo focuses on what matters most in the aviation industry and is the industry’s ONLY annual event focused on Ground Support, FBO/Aviation Services and Aircraft Maintenance.

Attendees come from all 50 states and over 35 countries looking for products and services like: aircraft maintenance equipment; auxiliary power & ground power units; batteries; communication devices; engine parts and components; forklifts; surface carts; transfer vehicles; trucks/vans/scooters; tugs & tractors; wheels and brakes

AIE is host to NATA Spring Training, AMTSociety’s Annual Symposium, the U.S. Department of Defense JPAVSE Annual Gathering, and a wide variety of ground support and business seminars.

Join us March 16-18, 2010, at the Las Vegas Convention Center. For information on exhibiting or attending, call 800.827.8009 or visit www.AviationIndustryExpo.com.  Use priority code WCNew to register and the $25 exhibit hall fee will be waived!

International CTIA WIRELESS
March 23-25
Las Vegas, Nev.

The International CTIA WIRELESS® show represents a $1 trillion global marketplace that brings together every component of the wireless and broadband ecosystem. For 25 years, International CTIA WIRELESS® has been THE premier marketplace for all things wireless and 2010 is guaranteed to be another crucial and groundbreaking event for the industry. Join us in Las Vegas, March 23-25. Early bird pricing ends February 16 -- register now at www.ctiawireless.com!

Battcon 2010 International Stationary Battery Conference
May 17–19
Hollywood, Fla.

The Battcon Stationary Battery Conference is a three day, noncommercial, technical event for storage battery users from the power, telecom, UPS and other industries.

This well-established event brings over 500 end-users, engineers, battery and battery test equipment manufacturers, installers, and standards and safety experts together to discuss storage battery innovations and solutions for existing systems.

Presentations by users and manufacturers address everyday battery applications, technical advances, and industry concerns. The dialogue between the audience and the presenters make Battcon a truly interactive experience. A two evening trade show featuring storage power related vendors is also part of the conference.

For more information contact Jennifer Stryker, Albér, 3103 N. Andrews Ave. Ext., Pompano Beach, FL 33064. (954) 623-6660 or visit www.battcon.com.

Sensors Expo & Conference
June 7-9
Rosemont, Ill.

For 24 Years, Sensors Expo & Conference Has Been the Leading Industry Event Focusing Exclusively on Sensors & Sensor-Integrated Systems! The in-depth conference program features the world's leading authorities, in a carefully designed program, including topics such as: Energy Harvesting, Wireless Networking, Low-Power Sensing, Bio-Sensing, MEMS & MCUs, Monitoring Tools & Applications, Novel Approaches to Measurement, Power/Smart Grid Monitoring & Control, and more!  PLUS – save months of time researching, by examining solutions to your toughest sensing challenges from best-in-class vendors on the Expo floor!  Whether you're looking to find the latest sensing solutions, evaluate emerging standards, find and compare suppliers, or solve new design challenges, you can't afford to miss Sensors Expo & Conference! 

Visit www.sensorsexpo.com for details!

INTELEC 2010
June 6-10
Orlando, Fla.

Register Online Now for INTELEC 2010 at www.intelec.org

INTELEC 2010 will be held June 6 - 10, 2010 at the brand new Hilton Bonnet Creek Resort in Orlando, Florida.  This year’s theme is “Energy doesn’t just mean telephony anymore.”

In light of the theme, a broad agenda covering all areas of communications and energy use is scheduled including technical papers and interactive panel sessions which will provide you detailed insight and information into the latest trends in communications energy systems.  There are also several technical tutorial sessions that provide additional expertise to attendees which offer continuing education units (CEU’s).

A concurrent exhibition will feature industry leaders that will display the latest energy systems and related equipment designed to support communications.

Register online now at www.intelec.org.

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