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CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Future Trends of Batteries for E-Mobility
Dr.-Ing. Horst Muenzel Bosch Research and Technology Center, Palo Alto
Baden-Wuerttemberg Forum “E-Mobility”
Stanford University October 24, 2011
1
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Market Trend and Portfolio for e-mobility
The Battery System is a Key Component
Battery Technology Challenges and Trends
Conclusions
Outline
2
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Market for electric-powered vehicles will grow long-term Total market:
Uni
ts [M
illio
n ve
hicl
es]
and
0
5
10
15
20
2008 2012 2020
EV and PHEV
Hybrid vehicles (HEV)
Other (FlexFuel, CNG, LPG)
Uni
ts [m
illio
n ve
hicl
es]
4.8
19.2
7.2 10.2
6.0
3.0
0.002
4.2
1,9
*) Estimated total production
*)
0.6
0.3 1.9
9.4
Total market: 70 M 82 M 103 M
3 -10 units
3
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
“The future belongs to e-mobility.
By 2050 2% or less of power trains will be internal combustion engines” Dr. Bernd Bohr, Robert Bosch
Chairman of the Automotive Technology Business Sector 2011
Our view for 2050
4
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Bosch is involved in many areas of e-Mobility
Charging Stations for Electric Vehicles
Power Train for E-Bikes
FUTU
RE
Research and Advanced Engineering for futureElectric Vehicle Concepts
Battery of SBLimotive A Joint Company ofSamsung and Bosch
E-Machines andPower Electronics forHybrids and EV
ABS, ESP, Break-Booster
Starter and Generatorsfor Start/Stop Systems
Software for Infra-structure Integration
Charger EV and PHEV
Hydraulic Hybrid Systems & Industrial Drives
Navigation Systems
5
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Battery tailoring for electrified vehicle segments
Mild Hybrid Strong Hybrid Plug-In Hybrid Electric Vehicle Battery type Medium Power High Power High Energy
Power 5 kW – 15 kW 20 kW – 60 kW 40 kW – 80 kW 15 kW – 150 kW
Energy 0.6 kWh – 1.8 kWh 5 kWh – 15 kWh > 15 kWh
Cell size 5 Ah 20 Ah – 40 Ah 40 Ah – 66 Ah
Power Energy
Dedicated battery cells and systems for each vehicle segment required
6
Typical car segments:
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Battery System Design: Scalable, flexible, modular
Cell
Module
Battery System
Subunit
7
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Integrated Engineering along the Value Stream
Chemistry Cell Battery System Automotive Integration Aftermarket
• Materials for AnodeSeparator, Electrolyte, Cathode
• Electrode- & cell manufacturing
• Prismatic cell design
Pack manufacturing:• Thermal Management• Electrical components• Housing• Battery assembly
• Layout of electrical system• Expertise in system tailoring • Strong validation• Vehicle integration
• Spare part supply/logistics• Diagnostics (software/test
equipment)• Repair & maintenance• Training for automotive
workshops
Features Safe materials Ceramic layer to prevent
inner short circuits Shut down function
of separator Flame retardant additives Active materials with
improved inherent stability
High quality manufacturing Safety proved cell-design Balancing of electrodes Clean room conditions
Flexible construction kitbased on modular concept for different customers & applications
Packaging optimized w/ reduced weight & size
Lifetime optimized cell bracing, integration of automotive qualified materials & parts
Serviceability
Common specification Aligned system quotations
• Electrical machine • Power electronics • Battery
Common customer approach
Worldwide network High quality spare parts
and diagnostics Original equipment
know-how in all automotive technologies
8
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Hardware and Software Integration is important
BMS HardwareCooling System BMS Software PackCells & Modules
Products & Engineering Services Engineering Services
High Power
High Energy
Internal liquid cooling system
Valve, Pump & Chiller, Heater
Interface to vehicle refrigerant circuit, or environment
Battery Management ECU
SCS Units,Safety & Fuse Box
Relays, Fuses, Safety plug,
Sensors, Cell monitoring& Balancing
State of Charge and Health Monitor
Safety Functions
Thermo-management
Communication & OBD System
Cells/Modules
Cooling System
BMS HW&SW
Wiring harness
Degassing structure-plugs
Housing and external interfaces
9
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
A Li-ion battery is a complex chemical and physical system.
Optimization takes long and is difficult.
The specific energy needs to be increased to improve the range of the vehicle.
The lifetime of automotive batteries needs to be verified.
The cost needs to be reduced to increase market penetration and customer acceptance.
Battery Research and Development Challenges
10
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Example: Li-ion battery cell cross section
Cathode materials Li(Ni,Co,Mn)O2, LiFePO4, HV-NCM Anode materials Graphite, soft carbon, hard carbon, Si and Sn alloys Binder & Solvents PVDF variants, NMP, acetone, MEK, DMSO Electrolytes EC, PC, DMC, DEC, EMC, DME, THF, mixtures Conducting salt LiPF6, new salts e.g. LiBOB, LiBF4
Additives SEI improver e.g. VC, overcharge protection, Al-corrosion inhibitor, wetting agents Separator PE, PP, PET, inorganic composite, other Packaging Coating, drying, sealing, process control Cell formation
Sources: Tiax, Exponent
11
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Challenge: Specific energy needs to be increased
12
0
50
100
150
200
250
300
350
0 100 200 300 400
Veh
icle
rang
e (k
m)
Battery system weight (kg)
Target window for full range EV
GM Volt (electric range only)
BMW Mini E
Tesla Roadster
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
New Battery Cell Designs: Research ongoing
Lead Acid
NiMH Li-Ion Li/Sulfur Li/Air
Specific energy (Wh/kg)
800
700
600
500
400
300
200
100
0
800
700
600
500
400
300
200
100
0
Shift to advanced Li-ion anodes and cathodes
Achieved
Future Potential
Technology change; need to overcome fundamental barriers
13
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Li/air research in early stages, but rapid progress
Top research challenges
Demonstrate excellent chemical reversibility.
Achieve a high practical capacity.
Determine if it’s necessary to separate oxygen from air; if so, find a way to do so.
Achieve a high energy efficiency.
Accommodate volume changes.
…
14
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Challenge: Lifetime needs to be verified
Complex aging mechanisms Carefully designed experiments and modeling required for lifetime predictions
Some examples:
Li+
Particles can lead to fracture and subsequent battery cell capacity loss
Aging of standard CE battery cells at different temperatures
15
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Example: Advanced simulations to predict cell behaviour
Goal: Prediction of critical thermal reactions
SIMULATED CELL CAN T
SIMULATED JELLYROLL T
EXPERIMENTAL INFRARED CAN T
Goal: Battery performance simulation to determine temperature distributions within cells
Model can be used to improve cooling strategy and to improve cell design for longer lifetime
16
CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Challenge: Cost of Li-ion batteries needs to be reduced
Energy per mass (Wh/kg)
Cost per energy ($/kWh)
Today’s values:
Nissan Leaf (small passenger car)
Tesla Roadster (performance car)
24 kWh, 150 km range
53 kWh, 400 km range
$18k pack
$35k pack
75 to 130 (battery system)
750 (battery system)
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CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
Cost Trend
Sources: Tiax, Institute of Information Technology, SB Limotive
Battery system cost ($/kWh)
2011 2015 2020 0
250
500
750
0
250
500
750 At this price a 25 kWh pack (150 km range) would cost about $7500
Increasing production, increasing energy per mass / volume
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CR/RTC-NA | 10/1/2011 | © 2011 Robert Bosch LLC and affiliates. All rights reserved.
Future Trends of Batteries for E-Mobility
Research and Technology Center North America
The market for electric powered vehicles grows significantly. However
internal combustion engines will still dominate the market for many years.
The battery is the key component in electrical vehicles and is a complex system with many subcomponents.
Batteries for HEV and PHEV have reached series production status. First EV-solutions with limited driving range are enabled by batteries.
Among the top R+D Challenges of batteries are the increase in specific energy, cost reduction, safety aspects and lifetime verification
Li/S and Li/air battery systems are in research focus. They may offer a longer range and lower cost in future.
Conclusions
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