eReport

April 2008

Battery Manufacturing e-Report Premiere

Welcome to the premiere issue of Battery Manufacturing e-Report, a monthly newsletter that focuses on battery manufacturing, materials and components, as well as R&D. Click here to subscribe: http://www.infowebcom.com/newsletters_form.php.

Do you have company news or a product you would like featured in the May issue of the Battery Manufacturing e-Report? Contact Shannon Given at shannong@infowebcom.com.

Interested in advertising in the Battery Manufacturing e-Report? Contact Jeremy Fleming at jeremyf@infowebcom.com.

Sandia Researchers Damage Batteries to See How Much Abuse They Can Take

Researchers in the Power Sources R&D group at Sandia National Laboratories have been driving nails into batteries, heating them to extreme temperatures, overcharging them and putting them into some of the most adverse conditions possible to see how much abuse they can take before they blow up. For certain types of lithium-ion batteries the answer is a lot.

The research is part of the DOE-funded FreedomCAR program that is looking at lithium-ion batteries to be part of hybrid electric-gasoline powered vehicles and eventually plug-in hybrids.

Current hybrid vehicles run on gasoline and use nickel-metal hydride batteries as the energy storage device for the electric motor. The intent of the battery portion of the FreedomCAR program is to replace the older type batteries with safe lithium-ion batteries that have six times the energy density of lead-acid batteries and two to three times the energy density of nickel-metal hydride batteries.

“Lithium-ion batteries, generally found in laptop computers and power tools, have greatly improved over the past few years,” said Peter Roth, lead researcher for Sandia’s FreedomCAR battery efforts. “In fact, they have improved so much that we expect to see them in hybrids later this year and possibly even in short-range plug-in hybrids within two years.”

He notes the battery industry has made great strides in manufacturing safe, long-lasting, and affordable batteries. Sandia has played a role in assuring that the lithium-ion batteries are indeed safe and can operate for long periods of time. Sandia is a National Nuclear Security Administration (NNSA) laboratory.

One way Sandia researchers have helped determine how safe and long-lasting batteries are is by testing them in adverse situations to determine when and how they can fail or leak their electrolyte.

The Sandia research group obtains batteries and battery materials from research laboratories, like Argonne National Laboratory, and companies that manufacture and sell batteries. They then study the stability of the materials, their flame-retardant performance, high-temperature integrity of separators between the cathode and anode, and general thermophysical properties.

“We look at fundamental chemistry, wanting to discover the kinds of gases they emit when they are heated and explode,” Roth said. “We also build smaller prototype batteries that once we get the chemistry right may eventually be built full size to go into vehicles.”

Roth said that some of the newer batteries, like the new lithium/iron phosphate ones used in handheld power tools, are extremely resilient and less reactive when subjected to extreme conditions, unlike other types of batteries.

These are the type of batteries the FreedomCAR program is seeking, particularly for plug-in hybrid electric vehicles (PHEV). A PHEV is a regular hybrid that operates both on gas and a battery but has an extension cord. It can be filled with gas at the gas station and also can be plugged into any 120-volt outlet for all-electric driving. It’s almost like having a second fuel tank that is used first — only it is filled up at home.
Industry experts predict that plug-ins that can run 10 miles on all electric are two to three years away while plug-ins that can run 40 miles on all electric are three to four years away.

Continental Launches Production of Lithium-Ion Battery

The international automotive supplier Continental will launch first-time volume production of a high-performance lithium-ion battery for hybrid vehicles at the end of 2008. It will be used in the Mercedes S 400 BlueHybrid.

"This marks an important breakthrough for Continental as supplier of battery systems. In the next few years we will be launching production of further lithium-ion energy storage devices for mild- and full-hybrid and electric-powered vehicles," says Continental executive board member Dr. Karl-Thomas Neumann.

“Lithium-ion technology is viewed as the key to the success of the hybrid and electric drive systems in motor vehicles. Lithium-ion batteries have a higher energy density, and thus a wider range, than those based on conventional nickel metal hybrid technology. The power output of the battery determines the overall performance of the vehicle as well as the potential for lower emissions and for possible fuel savings. In so far it also has a significant role to play in reducing CO2," said Dieter Rogge, head of Continental's Powertrain division, which has developed and will supply ultramodern and innovative technology.

Inspired Energy Launches a New High Power Density Battery Optimized for use in Robotics and 24 Volt DC Motor Applications

Inspired Energy has launched their first in a new range of high power density smart lithium ion batteries packs; the seven-cell, 25 V, 2.9 Ah, 73 Wh, PG3665A29. Developed primarily with the needs of 24 V DC motor applications in mind, the PG3665 harnesses the high power density of the latest technology Li Ion cells to create a 25 volt lithium ion battery pack with the capability to continuously deliver 20 amps with 30 amp peaks.

 “The success of the new breakthrough lithium ion cell technologies as used in power tools, along with demand from customers led us to develop the new PG3665,” said Inspired Energy managing director, Lex Jacobs.

The PG3665 is designed for use in rugged environments, featuring an aluminum extruded case with molded end-caps which recess the D-sub connector, fuel-gauge window and the stainless, spring-steel pull handle. If required, the battery can be physically located in place by sliding M4 nuts along the included “T-tracks” to bolt it to a chassis. With a nominal voltage of 25.2 V the PG3665 is perfect for use with 24 V DC electric motors - its high discharge current capability enables it to easily handle large current spikes during start-up. The use of a high-current D-Sub connector with optional screw-mounting posts also enables the use of a cable battery connection, effectively creating a version with “flying leads”.

Miyachi Unitek Introduces a New Mini Wire Welder and Compactor

As demands have increased for compacting smaller gauges of stranded wires, Miyachi Unitek Corporation recently released a new “Mini Compactor.” Based on the popular Miyachi Unitek 180A/EZ weld head, the compactor may be paired with an inverter welder or a conventional AC welder depending on the demands of the application. Miyachi Unitek designs and manufactures a full range of resistance welding and reflow soldering power supplies, heads, monitors and accessories for both large scale and fine spot applications requiring precision metals joining, lasers and laser systems for welding and marking, and hermetic sealing systems, Gloveboxes and environmental enclosures. 

Water-Cooled 20 kW FCTS

Arbin Instruments has unveiled its new water-cooled 20 kW stack tester.  Water-cooled e-loads offer a more compact, cooling option versus traditional air-cooled e-loads. Since the heat dissipation is more efficient than air cooled e-loads, the advantages are significant for high power applications.  This 20 kW Fuel Cell Testing System coupled with Arbin’s patented dew point humidifier provides precise and accurate control of gas humidification. Specific customer requirements can be integrated with Arbin’s flexible design and plug-and-play modules. Safety features include leakage interlocks, manual emergency stop, water level control and programmable sensors/alarms.

The flexibility of this system lies not only in the hardware, but with Arbin’s Mits Pro Control Software.  Mits Pro offers several built in control types, as well as other dynamic modes that can be set by the operator.  Measurements, data logging and data conversion are all performed quickly by the software.  The software is also capable of running simulation of current, voltage and power for applications with a non-formulated profile. With its high power capabilities, efficient heat dissipation, compact e-load module, and exceptional performance-price ratio, the new 20 kW FCTS can meet the industries needs in a variety of testing environments. 

Stabilized Lithium Metal Powder (SLMP):  Material for a New Generation of Lithium-Ion Batteries
Marina Yakovleva
FMC Corp.

Global concerns over the climate change, traffic congestions, rising fuel costs and fuel's availability are prompting the governments to issue fuel efficiency regulations and the carbon footprint reduction requirements for the automotive industry. New approaches are necessary to make the step change in the types and the ways energy is being utilized to meet both regulations targets and consumer expectations.
Lithium chemistry provides the best chance for the highest energy batteries and not surprisingly, it currently dominates the power supply for portable electronics. Recent developments in Li-ion battery technology have advanced its application into the area of large format batteries, for example HEV/PHEV/EV automotive markets. This, in turn, has heightened the need for research on higher capacity, safer and less expensive battery materials.

Click here to read the entire article

Battery Power 2008
Battery Power 2008, September 4-5 in New Orleans, will feature presentations from industry-leading companies. Register by May 9th and save $500.

Presentations include:
• Market Trends – Markets, Technologies and Major Players, Lux Research, Inc.
• Venture Capitalist Investor Panel, Moderated by Ardour Capital Investments, LLC
• International Regulatory Issues, Motorola Product Testing Services
• Key Roles of Carbon Materials in Power Sources, Timcal Graphite and Carbon
• Technology to Prevent Counterfeiting in the Battery Industry, Eastman Kodak Company
• Cathode Materials for Lithium Ion Batteries, Toda Kogyo Europe GmbH
• New Non-Metallic High Electron Flow Plastic Materials for Capacitors and Anodes, Engineered Materials, Inc.
• Domestic Manufacturing of Lithium Ion Cells, Electro Energy, Inc.

Click here to view the entire preliminary program, including presentation descriptions: http://www.batterypoweronline.com/bp08_program.htm.

May
4-7 - UTC, Orlando, Fla.

5-7 - BATTCON 2008, Marco Island, Fla.

6-8 - EDS 2008, Las Vegas, Nev.

12-16 - The 8th International Advanced Automotive Battery and Ultracapacitor Conference, Tampa, Fla.

18-23 - Electrochemical Society Spring, Phoenix, Ariz.

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