Cedric Weiss, PhD

A2Mac1, EV/Hybrid Department

Electric Vehicle Battery Chemistry

and Pack Architecture

Charles Hatchett Seminar

High Energy and High Power Batteries for e-Mobility
Opportunities for Niobium
London, England
July 4, on2018
Updated Mar. 2015
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 GLOBAL PRESENTATION
A2MAC1 presentation - Key figures

6 benchmarking centres worldwide

600+ full teardowns
600 000 parts in storage
28 Mio photos
170+ customers
2.8 Mio pages viewed/month
• Trusted partner to all major OEMs worldwide and suppliers, including steel makers and material producers

• Key reference for competitive analysis in the automotive industry

• Industry leading data management software solution

• Best in class processes for effective data capture

 GLOBAL PRESENTATION
A2MAC1 presentation - Locations

Belleville – US Hary – FR Shanghai – CN

FRANCE - Hary Benchmarking site Headquarter Benchmarking site
North America Benchmarking site China
Europe

USA - Belleville

CHINA - Shanghai
Tokyo – JP
Representative
office
THAILAND - Bangkok

Chennai – IN
Benchmarking site
INDIA - Chennai India

Frankfurt – DE Bangkok – TH Seoul – KR

Representative Benchmarking site Benchmarking site
office ASEAN Korea
KOREA - Hwaseong-si
Slide 1/6
 GLOBAL PRESENTATION
A2MAC1 presentation – Scope of Analysis

AUTOVISION VEHICLE RECEIVING 3D VEHICLE INNOVATION BENCH ACOUSTICS PARTS PARTS STORAGE WORKSHOP

FASTENERS
ANALYSIS

MEDIA PACK TRIM COMPARISON HMI NVH AUTOREVERSE VIRTUAL REALITY CONSULTING & EXPERTISE
eHPV

BIW SCAN
NEW VEHICLE 3D SCAN DATA
ANNOUNCEMENT CLEARANCES FUNCTIONAL
MEASUREMENTS VIDEO

2D INTERIOR 2D EXTERIOR LIGHTING SEAT ANALYSIS

ADVANCED ANALYSIS BENCHMARKING SOFTWARE

ENGINE ANALYSIS BIW ANALYSIS

CHASSIS ANALYSIS EV/HYBRID ANALYSIS ELECTRICAL ARCHITEC. ELECTRONICS COSTING ELECTRONICS

CONTACTS
 GLOBAL PRESENTATION
New 3D Innovation Bench database

Video
 Electric Vehicle Battery Chemistry
and Pack Architecture
EV/Hybrid at A2Mac1
EV/Hybrid perimeter Cell Analysis Report BMS Report Functional Schematics
Teardown & properties
• High Voltage Battery Pack • Performance testing • Bill of materials • Cabin Heat/Engine Thermal
• Power electronic: Inverter / • Structural analysis • Functional Layout detail • HV components Heat
Charger • Chemical analysis • Block Diagram exchanger
• High voltage cables • Electrolyte • Battery Architecture • HV components & cabling
• HVAC and Cooling system analysis Observations systems
• E Machine: EV Drive and • Separator analysis • Battery external cooling
Transmission • Electrodes • Battery thermal
• ECU System management analysis • Battery pack electrical
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
A look back in history
1960s-1970s: Renewed interest
in electric cars by several
manufacturers
(1 oil crisis, growing
st

environmental concerns…)
1859: invention of the
lead–acid battery (1st
rechargeable battery) 1902: 1st “mass-
by French physicist produced” electric car
Gaston Planté (Studebaker Electric) Today

1899: The Jamais 1997: The Toyota Prius I

Contente sets first launch is the beginning
speed record over of a new era for hybrid
100 km/h and electric vehicles

1910s-1920s: Gasoline Today, the EV/Hybrid car market is growing thanks to:
 Better road infrastructure: longer distances to travel powered cars take
 Emissions regulations
 ICE prices went down with Ford’s mass production over the market
 Battery chemistry/performance improving
 More petroleum discovered, ICE with less noise,
smell, vibrations…  New players like Tesla challenging traditional carmakers
 Electric Vehicle Battery Chemistry
and Pack Architecture
Types of Electric Vehicles
PHEV REEV
Micro Mild (Plug-In Hybrid (Range Extended
Hybrid Hybrid Electric Vehicle) Electric Vehicle)
ICE
(Internal HEV
Combustion (Hybrid Electric Full EV, or BEV
Engine) Vehicle) (Battery Electric
Vehicle)

Conventional Start/stop An electric motor Combustion engine High voltage Vehicle runs on Electric motor
gasoline/diesel system supports the combined with battery can be electric motor powered by high
engine combustion engine electric motor charged externally Combustion engine voltage battery
for various features Full electric mode charges the battery
available
Range/Mileage
on pure electric 0 km ≈ 8 km ≈ 50-80 km ≈ 150 to 500 km
motor

Size of the
battery ≈ 1 kWh ≈ 0,5 to 2 kWh ≈ 4 to 20 kWh ≈ 20 to 100 kWh
10-50 kg ≈ 20-60 kg ≈ 100-200 kg ≈ 200-700 kg
(Usually 48 V) (≈ 100-300 V) ≈ 200-400 V (≈ 350-400 V)
 Electric Vehicle Battery Chemistry
and Pack Architecture
Weight of the Battery Pack
Contribution to the total weight

200-700 kg

Battery weight fraction in the vehicle:

1 to 3 % for HEV (Hybrid Electric Vehicle)
4 to 12 % for PHEV (Plug-in Electric Vehicle)
17 to 32 % for EV (full Electric Vehicle)

80-180 kg

20-60 kg

Source: A2Mac1 database

 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture

Tesla Model 3

Weight = 460 kg (26 % of 1766 kg)

Length = 2.15 m
Width = 1.47 m
4 modules, 4416 battery cells
Nominal Voltage = 355 V
Capacity = 217 Ah
Energy = 75 kWh
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture
What’s inside the Battery Pack ?
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture
Enclosures

Housing,
Enclosure

Metal or plastic “box”

Can be reinforced against impact crash

Housing,
Enclosure
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture
Battery Modules

3.6 V

7.2 V

3.6 V
Battery modules

46 cells/brick in parallel, 96 bricks in series

(96 S 46 P)
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture
Thermal Management System (TMS)

TMS
(Thermal Management
System)
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture
Electrics/Electronics

Electronics
 Electric Vehicle Battery Chemistry
and Pack Architecture
The Battery Pack Architecture
Weight Distribution

Mercedes GLE 550e (PHEV) Tesla Model 3 (EV)

Elec. Elec.
5.5 kg (5%) Housing Cooling 11.7 kg (3%) Housing
Cooling
15.4 kg (14%) 21 kg (5%) 65.1 kg (14%)
8.2 kg (7%)

Total Weight
Total Weight
460 kg
113 kg

Modules Modules
86.4 kg (76%) 363 kg (79%)
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Battery Cells Form Factors
Cylindrical cell Pouch Cell Prismatic Cell

 Standard sizes: 18650, D, AA…  No standard size, each manufacturer  No standard size, each manufacturer
 Steel casing designs its own designs its own
 Low manufacturing cost  Laminated bag  Aluminum or steel casing
 High specific energy (Wh/kg)  High energy density (Wh/L)  Good energy density (Wh/L)
 Good mechanical stability  Requires stacking pressure  Commonly used in electric vehicles
 Sensitive to moisture and high
pressure
 Electric Vehicle Battery Chemistry
and Pack Architecture
Battery Cells (Li-ion): Chemistry and Materials
Anode Materials Cathode Materials

Carbon (graphite, hard carbon) → Most common anode LCO: LiCoO2 → High specific energy but
material expensive because of the cobalt
(mostly used in portable
electronics)
Graphite with ≈ 1-3 % silicon : C + Si → Silicon brings better → No cobalt but low specific
LMO: LiMn2O4
specific energy energy and cycle life. Usually
blended with NMC (Nissan Leaf,
Chevy Volt…)

LTO (Lithium Titanate Oxide) : Li4Ti5O12 → High power, high NMC : LiNi1/3Mn1/3Co1/3O2 → High specific energy but high
cycle life, safe cobalt content. Most common
Low voltage, low cathode material in EVs
specific energy NCA : LiNi0,8Co0,15Al0,05O2 → Highest specific energy, high
specific power. Lower cobalt
Major battery cells manufacturers:
content than NMC but less safe.
Panasonic (Tesla) NCA has Tesla’s preference
Samsung SDI (BMW, VW…) (reduced cobalt content in
A123 (GM, Mercedes…) Model 3)
LG Chem (Renault, GM, Volvo…) LFP : LiFePO4 → Long cycle life, high power, very
Sanyo, Hitachi, Lithium Energy Japan, Toshiba, CATL… safe but low specific energy
 Electric Vehicle Battery Chemistry
and Pack Architecture
Battery Cells (Li-ion):
The Cobalt Issue
Problem with cobalt:
 Expensive (almost 100 $ / kg)
 Low reserves (7 million tons)
Tesla Model 3  Geopolitics
69 g
17 Wh
4416 Cells/vehicle

In previous models, cathode material (NCA) was: LiNi0,9Co0,05Al0,05O2

LiNi0,8Co0,15Al0,05O2

8 kg Li/vehicle ≈ 3.5 kg Co/vehicle (As compared to ≈ 10 kg

(0.1 g/Wh) (0.04 g/Wh) with: LiNi0,8Co0,15Al0,05O2)

Today’s trend is to reduce amount of cobalt in EV batteries

(NCA and from NMC 111 to NMC 811)
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Outline

1) Global Presentation of A2Mac1

By Fabrice Robert, European Sales Engineer

2) History and types of EVs

Hybrids, full electric…

3) Battery Pack Architecture

Battery pack components (housing, cooling, modules, BMS…)

4) Focus on Battery Cells

Battery chemistry and materials

5) Future of Electric Vehicle Battery

What’s beyond Lithium-Ion for tomorrow’s cars?
 Electric Vehicle Battery Chemistry
and Pack Architecture
Battery Cells for Electric Vehicles: Beyond Li-ion and/or better Li-ion
Several new battery chemistries are being studied and developed in laboratories worldwide

Solid-state Li-ion → Replaces highly flammable liquid electrolyte by solid electrolyte

Higher energy density and safer
Could be the next generation of EV battery:
Among the major players working on this technology are Toyota, BMW, Saft in partnership with
Solvay, Siemens…

Titanium Niobiate (TNO) → TNO is being developed by Toshiba to replace LTO as the anode in Li-ion
Higher energy density, fast charging

Lithium Sulfur → Uses sulfur as the cathode

Higher specific energy
Main issues: cycle life, sulfur has low conductivity and expands during discharge
Companies like Oxis energy or Sion Power try to commercialize Li-S batteries

Lithium air → Uses air (oxygen) as the cathode

Highest specific energy
Main issues: cycle life, low power, water and nitrogen filtering
Samsung and many research labs work on this technology

Other → Na-ion, Mg-ion…

Other improvements in Li-ion: use of graphene, high capacity cathodes, high voltage cathodes…
 Electric Vehicle Battery Chemistry
and Pack Architecture

Thank you very much for

your attention !

Any question ?

Please don’t hesitate to contact us:

Cedric Weiss
[email protected]