November 2005November 2005
GAIA Li-Ion Batteries: Evolution GAIA Li-Ion Batteries: Evolution
or Revolution?or Revolution?GAIA EuropeGAIA Europe
Company SecretaryCompany Secretary
Tim Tim SchäferSchäfer
Akkumulatorenwerke GmbH, Akkumulatorenwerke GmbH, NordhausenNordhausen, Germany, Germany
Lithium Technology Corporation, Plymouth Meeting, PA, USALithium Technology Corporation, Plymouth Meeting, PA, USA
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Overview
Company Overview
Technology
Manufacturing Process
Product Portfolio
Target Markets
Hybrid Electrical Vehicle Battery• Cell Level
- Discharge Performance
- Cycle Life
- Calendar Life and Self Discharge
- Safety Aspects
• Battery Management System
• Battery Level- Design of 288V Battery and Prototype
- Pulse Power Performance
• Applications
Developments
Summary
Company Company OverviewOverview
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History
April 1996 Founding of GAIA
1997 Proprietary extrusion process
1998 Arch Hill, a Dutch venture capital
company, acquires majority share of GAIA
1999 Installation of three pilot extrusion lines
2000 Refinement of battery production facilities
2002 Merger of GAIA and LTC
2003 Market entry with large format Lithium
ion cells
2005 Market entry with Lithium ion batteries
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Lithium Technology Corporation is a Public US Corporation
traded on the OTC Bulletin Board (LTHU.OB)
LTC and GAIA were merged in 2002 combining twosynergistic technologies
(US Operations)
Plymouth Meeting
Pennsylvania (USA)
GAIA Akkumulatorenwerke, GmbH
Nordhausen
Thuringia (Germany)
Lithium Technology Corporation
Plymouth Meeting
Pennsylvania (USA)
Corporate Structure
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Facilities
US Operations(LTC - Plymouth Meeting)
• Corporate Headquarters
• US Government/MilitaryDevelopment Contracts
• R & D and cooperativeprograms with US rawmaterial suppliers
• US Sales
• Battery design and assemblyusing GAIA cells
• Limited contract productionof specialty flat cells
European Operations(GAIA - Nordhausen)
• European DevelopmentContracts
• R & D and cooperativeprograms with EU rawmaterial suppliers
• European Sales
• Commercial Production ofcylindrical cells
• Battery design andassembly
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Small Production/Large Pilot Scale Operation
•57 Employees (17 in US, 40 in Germany)
•FACILITIES• 176,000 ft2 facility in Nordhausen, Germany• 13,000 ft2 facility in Plymouth Meeting, PA, USA
• PRODUCTS:• Custom engineered batteries• Development contracts• Cylindrical and prismatic Lithium-Ion cells - from 5 Ah to 120 Ah
Current Operations
GAIA TechnologyGAIA Technology
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e-
e-
e-
Copper
neg. Collector
(Anode)
Li+ conductive
Electrolyte
Li+
Li+
Li+
Li+
Li+
e-
e-
e-
Aluminium
pos. Collector
(Cathode)
LixC6 Li1-xMO2
A– +Discharge Current I Charge Current I
Principle of Lithium Ion Batteries
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Technological Advantages of Lithium-Ion over otherChemistries
Low
(3.6V per cell)
High
(1.2V per cell)
Medium
(2V per cell)Battery Complexity
(Number of Cells)
Very WideWideNarrowOperational
Temperature Range
Very LowLowHighHeat Generation
Very GoodGoodPoorFast Charge
3 to 10 x3 to 6 x1Power per Volume
5 to 15 x5 to 10 x1Power per Weight
2 x1.5 x1Energy per Volume
3 x2 x1Energy per Weight
Li_IonNiMHLead Acid
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Proprietary cell design IP• Low internal resistance allows for high power output and
rapid charging with limited heat generation
Proprietary manufacturing process• Lower cost extrusion and assembly allows scalability and
opportunity for high gross margins
• Environmentally friendly (no solvents)
Patents
• Issued 33
• Applications Pending 42
LTC Differentiators
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Li-Ion Technology
I II III IV V
I: Al-Collector (18-25 m)
II: Positive Electrode (40-200 m)
III: Separator (16 – 35 m)
IV: Negative Electrode (30-150 m)
V: Cu-Collector (12-20 m)
Manufacturing ProcessManufacturing Process
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Process - Extrusion
electrolytedry blend
cathode
electrolyte
dry blend
anode
graphit, polymers
and carbon black
LiCoO2,
polymers and
carbon black
mixing and drying of
cathode materials
mixing and drying of
anode materials
polymer anode
on carrier foil
polymer cathode
on carrier foil
y g g y y
No emission of solvents Safe and environmental
No ex-proof installation Cost-effective Co-extrusion of polymer blends
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Process - Lamination
anode
material on
carrier foil
1
lamination of
anode laminate of
anode / Cu / anode
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Processing Technology - Winding & Assembling
cathode currentcollector "Al"
anode currentcollector "Cu"
tab and lidassembly
housing
laser welding
lid withterminals
anode polymer electrolyte
cathodepolymer electrolyte
cell winding machine
GAIA Product PortfolioGAIA Product Portfolio
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GAIA Product Portfolio
Present cylindrical cells
range in capacity from 5 Ah to
60 Ah
GAIA offers two basic types
of products taylored to
different applications• The HE product series is optimized towards high energy content
with moderate rate capability (continuous discharge up to 2C)
• The HP and UHP series are designed to deliver maximum power
(continuous discharge up to 10C)
GAIA has developed battery packs of up to 600V to customer
specifications
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Battery Systems Comparison - Ragone Plot
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GAIA cells offer the highest power of any commerciallithium ion cell in the western hemisphere* (most amperesor watts per kilogram)
• GAIA UHP product achieves 2400 W/kg (pulse)
GAIA cells are the largest lithium ion cells produced in thewestern hemisphere (most energy capacity - watt-hours oramp hours)
• GAIA HE-602050 has 60 Ah or 216 Wh corresponding to 150Wh/kg
• 120 Ah cell is in development
LTC specializes in working with the customer to engineersolutions using standardized cells in customizedconfigurations
• Custom engineered battery packs including electronic batterymanagement systems
* US and EU companies have an advantage selling the western hemisphere being
domestic suppliers and it is unrealistic for US and EU companies to sell into Asia.
Large, High Power Engineered Lithium Ion Is LTC’s CoreExpertise
GAIA GAIA MarketsMarkets
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Transportation
Applications require rapid
charging rates and long
life in safe, durable high
power storage for HEV, EV
and fuel cell powered
vehicles. Military, heavy
duty and niche vehicle
OEMs are early adopters.
Immediate niches exist.
Stationary Power
Growing dependence on
electrical power worldwide
drives the demand for high
quality high-reliability power
for telecommunications,
computers, mission critical
applications, remote mobile
and renewable power
applications. Very large
potential market.
Markets with Projected Growth in Advanced Batteries
Military/National
Security
Applications require
flexibility in design, wide
ranges of power output,
broad operating
temperatures, low weight
and thousands of recharge
cycles. Performance is more
important than price.
Market need is growing
quickly. Development
funding is available.
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The US and its allies are changing the militarylandscape. The trend is to many small, rapidly deployedunits using extensive power-intensive electronics.
Applications already exist in this market and continueto grow rapidly.
• Unmanned reconnaissance and combat support systems
-- airborne, ground, underwater
• Satellite surveillance and communications systems
• Remotely controlled surveillance, detection and demolition robots
• Manned combat support vehicles -- land-based and underwater
• “Silent Watch” (stealth operations on battery power only)
• Night goggles, communications equipment, GPS, computers,
handheld spotlights, etc.
Military/ National Security Market
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American and European auto manufacturers are nowtaking the Japanese HEV effort seriously
•Existing applications (lithium ion SLI [starting, lighting & ignition] batteries)
- Motorcycles
- Racing cars
- Certain very high end automobiles – dual battery systems
•Developing applications / trends (HEVs,EVs)
- Wheelchairs
- Taxies
- City delivery vans
- All terrain vehicles (ATVs) & snowmobiles for national parks
- Professional lawn and garden
- Neighborhood electric vehicles (NEVs)
Transportation Market
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Growing dependence on digital devices for missioncritical applications drives demand for uninterrupted(distributed) power and backup power. Life cycle valueof lithium ion over lead acid is a key market advantage.
• Existing applications
- Telecom: lower cost of cooling/heating the facilities; less maintenance;
remote monitoring
- Solar: less maintenance, longer battery life
- UPS: space/weight savings, higher reliability, less maintenance,
longer life and lower life cycle cost
• Developing applications / trends
- New wireless network installations with lower cost infrastructure
- Heightened awareness of need for backup systems following storms and
blackouts
- Wind and solar power
Stationary Power Market
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Sources: Frost & Sullivan, LTC investigations
Continuous growth of the advanced market over 700% in 8 years
Within the advanced market, lithium ion will grow faster than competing
chemistries
Conventional Advanced Total Conventional Advanced Total
Transportation 8,000$ 50$ 8,050$ 7,400$ 1,400$ 8,800$
National Security 2,000$ 200$ 2,200$ 2,200$ 500$ 2,700$
Stationary Power 5,000$ 50$ 5,050$ 6,500$ 250$ 6,750$
Total 15,000$ 300$ 15,300$ 16,100$ 2,150$ 18,250$
2003 2011
Conventional: Lead-Acid
Advanced: Li-Ion, NiCd, NiMH
Rechargeable Battery Market Size for National Security,Transportation, and Stationary Power
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Partnerships that have Developed as a Result of OurDemonstrated Capabilities
GAIA GmbH has entered into a contract with a
European submarine manufacturer to jointly develop
and supply very large lithium ion cells for
underwater non-nuclear submarine propulsion
LTC has signed a contract with a major US battery
company to develop and supply rack-mounted
backup power supplies
LTC is discussing a joint venture arrangement with a
small European EV/HEV manufacturer to supply
batteries for inclusion in the drive train for HEVs/EVs
HP-341450 Cell forHP-341450 Cell for
Hybrid Electrical Vehicle BatteryHybrid Electrical Vehicle Battery
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Cells for HEV Batteries
DD cell UHP341450 "7.5Ah"
Diameter 34 mm
Height (w/o terminals) 145 mm
Weight 320 g
Volume (w/o terminals) 132 cm3
Case material Stainless steel
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GAIA 7.5Ah DD HEV CellsDischarge Curves: 20°C at Different Rates
2
2.5
3
3.5
4
4.5
0 2 4 6 8
Discharge Capacity / Ah
Vo
lta
ge
/ V
0.4 1 2 3 5 7 9 10
12 14 15 17 19 21
C-Rate
DD646
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Discharge Curves: C/2 at Different Temperatures
2
2.5
3
3.5
4
4.5
0 2 4 6 8
Discharge Capacity / Ah
Vo
lta
ge
/ V
temperature during test / °C
DD646
~40°C200-20-30
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HP341450: 250A Pulse for 500ms
-300
-200
-100
0
100
200
300
400
500
44000 44500 45000 45500 46000 46500 47000 47500 48000
Test_Time(s)
Cu
rre
nt(
A)
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Vo
lta
ge
(V)
1-001 Current(A)
1-001 Voltage(V)
~2400W/kg
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0%
20%
40%
60%
80%
100%
0 200 400 600 800 1000
Cycle
Ca
pa
cc
ity
/ %
of
C i
ni
Charge: C/2 to 4.2V, taper to C/10
Discharge: 1 min @ 4C, than 1C to 3V
Cycle Performance at 100% DoD
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Cycling Experiments (Summary)
100
1000
10000
100000
1 10 100
DOD / %
Ca
pa
cit
y /
x-f
old
C n
om
Min
Maxextrapolated, no fade
after 300k 1% cycles
extrapolated after 22k cycles
C/2 CHR and ~1C DCH
3C CHR and 3C DCH
4.5C CHR and 3C DCH
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Calendar Life & Self Discharge
0
1
2
3
4
5
6
0 50 100 150 200 250 300
Time / days
Ca
pa
cit
y /
Ah
0
10
20
30
40
50
60
rev. C
ap
. lo
ss / %
per
mo
nth
20°C 40°C
Capacity
rev. Capacity loss
LiNiCoO2/MCMB System
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Safety Tests on Cell Level
Summary of tests on
7.5 and 60Ah cells
*small variation to
the standard
** not a requirement
on the cell level
According
to UL1642
and ADR
**
Altitude Simulation
Heating*
Temperature Cycling
Environmental Tests
small dentsFall
Vibration
de-contactingShock*
small dentImpact
small deformationCrush
Mechanical Tests
Abnormal Discharge
sparks and smokeAbnormal Charge
Short Circuit at60°C*
temperature riseShort Circuit at RT
Electrical Tests
BatteryBattery Management System Management System
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Justification for the Battery Management System
The recommended battery charging method is IU-
charging (const. current, const. voltage)
But:
• In a serial string the charger can not control individualcell voltages.
• Li-Ion cells do not tolerate overcharging with“elevated” voltages for balancing the cells
(e.g. “float or boost charging”)
• Abuse or operation out of range could result in safety
issues by thermal runaway
Li-Ion Batteries require a battery management
system (BMS) or an electronic protection circuit
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Block Diagram of BMS
Data acquisition
SOC
SOH
Comm. unit
CAN
U I T R
Thermal management
Safety management
Fan, etc..
Contactor
Battery
Load & Charger
Energy management
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Example of 10S BMS Hardware
Master Slave (10S)Current sensor
OpticallydecoupledRS485 bus
RS232 forflashingMaster
CANinterface
Sensors& mainswitch
P
P
MUX
to cells
40 cm2130 cm2
288V Hybrid Electrical Vehicle Battery288V Hybrid Electrical Vehicle Battery
with 80S HP-341450 Cellwith 80S HP-341450 Cell
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288V HEV Battery with 2kWh
Weight of cell 0.32 kg
Number of cells 80
Packaging 30 %
Weight today 42 kg
Weight 33 kg
Length 700 mm
Width 292 mm
Height 195 mm
Volume 40 L
Power (18s) 25 kW
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“Peukert” Plot of a Simulated HEV Battery
of 288V HEV batteryPower calculated with BSF=80
1
10
100
1000
10000
1 10 100
Power / kW
Co
nt.
dis
ch
arg
e t
ime
/ s
40°C
20°C
0°C
-20°C
-30°C
PN
GV
Pow
er
Assis
t DC HEV Spec
Cold Cranking
Power
PNGV
Dual Mode
FreedomCar
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Hybrid Pulse Power Test
Hybrid Pulse Power Characterization(HPPC)
PNGV Battery Test Manual, Feb., 2001
FreedomCAR Battery Test Manual For Power-
Assist HEV, Oct., 2003
-1
0
1
0 10 20 30 40 50 60 70
Time / sec
Cu
rren
t /
Im
ax
Regen
Discharge
OCV
DM PA
PADM
OCV
Discharge
Regen
C/1
HPPC Profiles
Time
10%C/1
10%
C/1
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Cells: Resistance and OCV
BSF = 80
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Battery 288V: HPPC Profile
measurement by ZSW
0
10
20
30
40
50
60
020406080100
State of Charge / %
Ch
arg
e P
ow
er
/ kW
0
10
20
30
40
50
60
70
Dis
ch
arg
e P
ow
er
/ kW
10 s CHR
18 s CHR
10 s DCH
18 s DCH
FreedomCAR Requirements
=> ca. 20..80% SOC, >1kWh
CHR
10s
18s
10s
18s
~ 1600W/kg
~ 1400W/kg
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Gap Analysis to USABC requirements
PNGV FreedomCar
Chara cteristi c Unit PA PA Min 42V SS achieved
Pulse Discharge kW 18sec@25 10sec@25 2sec@6 70
Pulse Charge (regen) kW 2sec@30 10sec@20 N/A 55
Available Energy kWh 0.3 (@ C/1) 0.3 (@ C/1) 0.25 (@3kW) 1
Efficiency round-trip % 90 (25Wh) 90 (25Wh) 90 95
Cold Cranking @ –30°C (3x 2sec, 10 sec. rests)
kW 5 5 8 (21V Cold Start Profile)
10
Cycle Life Cycles 300k total 7.5MWh
300k total 7.5MWh
150k ZPA 450k Starts
>300k
Calendar Life Years 15 6-8
Weight / Volume kg / L 40 / 32 40 / 32 10 / 9 42/40
Max. Voltage V 440 400 48 (OCV) 336
Min. Voltage V 0.55*V max 0.55*V max 27 185
Max. Self Discharge Wh/Day 50 20 5%/m=4
Operation Temperature °C -30 to +52 (-30 to 40°C) -30..40
Storage Temperature °C -46 to +66 (-40 to 60°C)
Cost $ 300/kWh 500/unit 150/unit more
28
8 V
/ 2.1
kW
h H
EV
Ba
ttery
Hybrid Electric Vehicle ProfileHybrid Electric Vehicle Profile
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Specification for HEV-Bus: 100kW with 45Ah Cells
kg290Weight%25Packagingkg232Weight Cellsl171Volume
mm1070Lengthmm500Widthmm320Height
160Cells
1C Cycle
single 27Ah cell
DevelopmentsDevelopments
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Cycling Data of LiFePO4 System
0
1
2
3
4
5
6
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Cycles
Ca
pa
cit
y /
Ah
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
Re
sis
tan
ce
/ O
hm
cycling after deep discharge
Cycle profile:
CHR: 0.8C rate to 4.0V taper to C/20
DCH: 0.8C rate to 2.5V
Ri DCH
Ri CHR
Ri Test:
U/ I with
5s pulse @
C/10 and C/1
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Ragone Plot DD-size Cell
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500 600 700 800 900 1000
spec. Power / W/kg
sp
ec. E
nerg
y / W
h/k
g
GAIA UHP
GAIA HE
-30°C
0°C
20°C
40°C
LiFePO 4
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0
50
100
150
0 50 100 150 200 250 300
SOC / %
Ch
an
ge in
Tem
p. / K
0
5
10
15
20
Vo
ltag
e / V
U>20V
LiN
iCoM
O2
LiF
eP
O4
Overcharging
LiNiCoMO2
LiFePO4
Charging with 3x of the recommended charging current (1.5C-rate)
SummarySummary
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Summary
Large format, high power engineered Lithium Ion batteries areLTC's core expertise• Specific pulse power up to 2400 W/kg
• Specific energy up to 150 Wh/kg
• Cell energy content up to 216 Wh (60 Ah)
LTC delivers customers with engineered battery packs from pilotfacilities in Germany and the US• Military, transportation and stationary markets
• Batteries up to 600 V
Batteries with LTC's DD High Power cell meet the performancetargets for Hybrid Electrical Vehicles• Power
• Cycle life
• Low temperature performance
