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Safety and Thermal Management for
Li-ion Batteries in Transportation
Applications
Said Al-Hallaj
Presented at:
EV Li-ion Battery Forum 2012
AllCell Technologies LLC
2321 W. 41stStreet
Chicago, IL 60609
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Presentation Outline
Overview of lithium-ion batteries
Importance of thermal management
Safety
Performance
Passive thermal management with phase
change material (PCM)
Concluding remarks
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Lithium-ion chemistry has large
power/energy range
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HEV
EV
PHEV
Cycle l i fe and co st per kWh general ly
increase with sp ecif ic power
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Automotive applications require full
range of lithium-ion batteries
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LEV0.5-10 kWh
Hybrid0.5-1.5 kWh
Plug-in Hybrid4 -16 kWh
Full EVs20-70 kWh
Priority Not
Power Energy Density
Shallow/Cycle life
Priority Not
Cost Power
Deep cycle life
Priority Not
Energy Density Power
Cost
Deep/ cycle life
Priority Not
Energy Density
Cost
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Divas of the EV world
Li-ion batteries have high performance, but very
temperamental
Key problem: dealing with heat generated by cellsduring charge, discharge and ambient conditions
If cells get too hot, three problems:
Decreased battery life Decreased performance
Risk of fire or explosion
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Thermal degradation is a hot button issue
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Thermal management of lithium- ion battery
systems is cr i t ica l to th e suc cess o f al l -e lectr ic
vehic les because extreme temperatures can
affect perfo rmance, rel iabi l i ty, safety and
durability. V. Anand Sankaran, Executive technical leader, Ford Energy Storage& High Voltage Electrical Systems
The di f ferent chemis tr ies
have different thermal
characteristics and so weve
been able to incorp orate howto make sure from a thermal
perspective that weve got
i t... - Denise Gray, Advanced Battery Director of GM
As a result, the LEAF pack wil l h ave
temperatures all over the place,
causing i t to suf fer huge degradation in
cold environments and b asically shut
off in hot environments. Elon Musk, CEOTesla
Thermal management of the system...all of
those l i t t le details go into effect to take it to
the next levelJay Iyengar, Global Director & ChiefEngineer for Electrified Powertrains, Chrysler
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Chemical reactions inside cell add
complexity to the heat problem
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Heat
accumulation in
Cell
Net Heat
Entering/Leaving
Cell= +
Heat
Generation
Insufficient heattransfer causes heat
accumulation in cell
heat accumulation in
cell creates burden
on cooling
Heat from Chemical
reaction
accumulates in cell
heat accumulation in
cell creates additional
chemical reactions
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AllCellsPCM Solution
Phase change material (PCM) andconductive matrix used to absorb andconduct heat to and from lithium-ionbatteries
PCM improves battery cost, efficiency,and weight when compared to activesystems
Phase change materials have a long trackrecord in other applications: Vehicle HVACDelphi, Behr
Building thermal systems
Spacecraft thermal systems
Medical supply shipping
Chemical reaction exotherm smoothing
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Cell
PCM
Cell
Why not apply PCM to
batteries?
PCM
Cell
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Safety issues still exist
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Source: A. Pesaran/USDOE-NREL
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Safety reputation bad for industry,
but...
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Auto safety chief denies sitting on
Chevy Volt warnings in heated
hearingFox News
Chevy Volt Fire Prompts
Federal Investigation Into
Lithium-Ion Batteries NY Times
Fisker Karma recall is official, 239 cars will
need their battery packs swapped - engadget
Fisker Recalling 239 Karma Plug-In
Hybrids for Fire Hazard
NY Times
Fire deals new setback to Navy's heralded
mini-sub navyseals.com
PC Notebook Computer Batteries Recalled
Due to Fire and Burn Hazard -http://www.cpsc.gov/
http://www.cpsc.gov/http://www.cpsc.gov/8/10/2019 2_10AllCellTech_Said AlHallaj_Safety and Thermal Management for Lithium Ion Batteries in Transport Applications
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...its really about lives
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Lithium Ion Batteries Faulted for
Jet Crash - Gigaom
2 Die as Asiana Cargo Plane
Crashes Off South Korea NYTimes
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Safety improvements are being made on
multiple fronts
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Cell LevelPack Level
Cell Design Cell Chemistry
Active Cooling Passive Cooling
Liquid Cooling
(refrigerant)Air Cooling
Phase Change
Material
Safety CircuitsSafety VentsShutdown
Separators
Positive Thermal Coefficient
DevicesElectrode Coatings
Conductive
Polymer
Ceramic
Materials
Electrolytes AdditivesAnode/
Cathode
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AllCell PCM prevents thermal
runaway propagation
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Operational performance must evolve to
achieve mass adoption
Gen 1Product
Introduction
Gen 2Mass market/cost
sensitive
Safety Must Must
Low Cost Good to have Must
Performance Good to have Must
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Gen 1 Chevy Volt uses 16 kWh battery to achieve 25-50 mi AER11 kWh go to vehicle propulsion
+ 3.5 kWh oversize to limit SOC window and heat generation
+ 1.5 kWh oversize for thermal management power requirements
16 kWh
Gen 2 must meet more difficult technical goals at a lower cost11 kWh still required for propulsion
+ 2.5 kWh oversize to limit SOC window and heat generation
+ 0.2 kWh thermal management (cabin air/PCM system)
13.7 kWh (2.3 kWhr or 14% battery size reduction)
battery downsize translates to significant savings in vehicle cost
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Optimal solution balances multiple
methods
Oversize battery
Curtail performance
Effective thermal management
Must consider cost, efficiency, life and
customer satisfaction when evaluating options
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When is liquid cooling used?
HEV
(Prius)
PHEV
(Volt)
EV
(Leaf)
Low
High
Air coolingAir cooling Liquid cooling
Without
PCM With
PCM
C-rate
Energy Density
Heat Removal
Intensity
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Hybrid air/PCM cooling for hybrid and EV
normal operationPCM eliminates the need for active cooling and heating during the majority
of operating time combined with cabin air system for remainder ofsituations
Ambient EV HEV
Cold Delays cool down. Adds minimal
heating time/energy.
Delays cool down. Heat with engine
heat.
Moderate No active management required Peak shaving of heat removal
requirement
Hot Keeps battery below ambient
during hot days
Peak shaving of heat removal
requirement
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AllCell system simplifies design
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Al air channel
PCM-graphiteCopper mesh
Copper mesh enhances
heat transfer to air
500 Wh LFP battery
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Battery can be used more aggressively
without needing liquid cooling
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10 m/s air flow 0.4 m3/s
45
40
35
30
25
20
Air only
PCM+Air2 m/s air
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Concluding Remarks
One size does not fit all...variety of cell typesand applications necessitates customized
solutions
Chemistry advances are only one piece of
solution...thermal management and intelligent
electronics play significant role
Safety problems still exist...high energy and
toxic chemicals pose real risk
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Company Contacts
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Said Al-Hallaj, Chairman & CEOTel: (+1) 773-922-1155 x201
AllCell Technologies LLCCorporate Headquarters
2321 West 41stStreet
Chicago, IL 60609 USA
mailto:[email protected]:[email protected]
