Electric Battery Actual and future Battery Technology Trends

Transcription

1 Electric Battery Actual and future Battery Technology Trends Peter Birke Senior Technical Expert Battery Systems Business Unit Hybrid Electric Vehicles Continental AG Co-authors: Michael Keller, Michael Schiemann Prague, May 6 th, / Peter Birke / May 2010 Continental AG

2 Introduction and short historical overview Batteries first steps Luigi Galvani Alessandro Volta Johann Wilhelm Ritter Experiments with frogs legs Battery with alternating one upon the other stacked Copper and Zinc plates (Cu/Zn). The plates were separated by cloths, which have been soaked by acid. Ritter s column (first secondary battery) In 1802 he built the first accumulator with 50 copper discs separated by cardboard disks moistened by a salt solution. 2 / Peter Birke / May 2010 Continental AG

3 Introduction and short historical overview Batteries Walk Of Fame 2004 Introduction LiFePO 4 cathode material 2002 Introduction of NMC cathode material 1999 Lithium ion polymer 1996 Manganese based Lithium-Ion batteries cost optimized Energy density E [Wh/kg] 1991 Introduction of Lithium Ion batteries (Sony): Cobalt based 1972 Development of NaS (Sodium-Sulphur batteries) high temperature batteries 1990 Introduction of NiMH batteries (Sanyo) with higher energy density and banned Cadmium 1983 Lithium metal rechargeable - Moli Begin of 80er CSIR Laboratory development of NaNiCl (Sodium-Nickelchloride) ZEBRA battery 1950er serial production of sealed Nickel Cadmium production 1930 Nickel Zinc battery - Drumm 1901 Thomas Alva Edison Nickel Iron battery 1899 Waldemar Jungner - first Nickel Cadmium battery (pocket plates) 1859 Gaston Planté first lead acid battery 3 / Peter Birke / May 2010 Continental AG

4 Battery types - historical overview Comparison of energy densities Theoretical energy density Practical energy density High temperature battery Wh/kg 161 Wh/kg Wh/kg 240 Wh/kg Wh/kg 320 Wh/kg Wh/kg 300 Wh/kg Wh/kg Wh/kg Wh/kg Wh/kg 435 Wh/kg 450 Wh/kg 720 Wh/kg 720 Wh/kg 795 Wh/kg Pb NiCd NiZn NiMH 4 / Peter Birke / May 2010 Continental AG ZnBr NaNiCl NaS Li-Ion

5 Introduction short historical overview Electrode reaction principle of different battery types The active material of the lead acid system reacts with the electrolyte (the sulphur of sulphuric acid is inside the plates after discharge reaction). As a result the active material electrode structure becomes disoriented due to active mass displacement resulting in decreased cycle life time. Modern battery systems like Li-Ion and NiMH cells base on principle of intercalation (both electrodes), NiCd was the first system showing up one intercalation electrode (Ni(OH) 2 ). The active material is intercalated inside the grid structure and back (swing principle), the electrolyte is not a part of chemical reaction (thus a high cycle life time results). breakthrough 5 / Peter Birke / May 2010 Continental AG

6 Batteries for hybrid and electric vehicles Future development trends powered by vehicle requirements Hybrid vehicle Power density [Whkg] Electric vehicle Energy density [Wh/kg] 6 / Peter Birke / May 2010 Continental AG

7 Lithium-Ion batteries trends Electric Battery 20xx, quo vadis? Higher current densities (e.g. HEV, PHEV, power tools) Higher energy density (EV, Consumer-Market, especially portable devices) Lower costs for Low end products Alternative active materials, which require less supervising hardware (e.g. less sophisticated voltage control) Low cost active materials for applications with reduced demands (e. g. less capacity, power) Due to increasing different demands there will be a larger variety in cell types and also different electrochemistries. 7 / Peter Birke / May 2010 Continental AG

8 Lithium-Ion batteries the challenges are also on system level Energy density [Wh/kg] High integrated electronics, new electro-mechanical components and new package design 2015 give potentials for future energy increase on system level 100 % 20 C 50 Ah cell Cell level System level 8 / Peter Birke / May 2010 Continental AG

9 Energy Storage Systems - Components Electromechanical components and electronic components Fuses and current sensing Protection against electrical overload Switches and Service disconnect HV disconnect in service case Support emergency shut-off Software + BMC Calculation general condition of battery Input of max. charge / discharge current Monitoring of isolation Control of main relay, pre-charge device Isolation of control voltage and battery voltage HV Connectors and wiring Vehicle power interface Modular Li-Ion Energy Storage System Concept CSC Active balancing of Li-Ion cells Measuring of temperature 9 / Peter Birke / May 2010 Continental AG

10 Lithium-Ion batteries Challenges on cell and on system level Weight [%] 100% 80% 60% 40% 20% 0% Weight distribution Mild hybrid battery (H7 packaging) HEV battery (20 C 10 sec) 7 % 13 % 70 % Electronics & Electromechanical components (fuses, HV connectors, wiring) Packaging 10 % Cooling Cell pack High integration Customized Customized Modular 10 / Peter Birke / May 2010 Continental AG

11 Successful weight reduction on system level Jump from first to second generation 100% 80% High integrated Electronics Improved housing -2% Optimized internal -4% -2% accomplishment -10% optimized cell design Reduced sealing compound Weight [%] 60% 40% Outlook 20% 0% / Peter Birke / May 2010 Continental AG

12 Li-Ion battery system Power density and energy density development is necessary but. Power density [W/l] Energy density [Wh/l] 10,000 HEV cells EV cells HEV cells EV cells ,000 10,000 [W/kg] [Wh/kg] 100 % 20 C (typical SOC HEV 50 % - 60 %) - Cell volume without tabs - Cell volume without tabs 12 / Peter Birke / May 2010 Continental AG

13 Lithium-Ion batteries Cathode materials future potential of Phosphates for Li-technology LiNiPO 4 5,1V LiCoPO 4 LiMnPO 4,1V 4 4,8V tomorrow LiFePO 4 LiNi 1/3 Co 1/3 Mn 1/3 O 2 3,6 V 3,2V High energy and high intrinsic safety LiAl 0,05 Co 0,15 Ni 0,8 O 2 3,6 V today LiCoO 2 LiMn 2 O 4 3,9V 3,6V Theoretical spec. energy [Wh/kg] 13 / Peter Birke / May 2010 Continental AG Source: Dr. Wohlfahrt-Mehrens, ZSW

14 Future cell systems Development of energy Future development direction Theoretical energy density Practical energy density Laboratory samples Future evelopment of energy Energy density [Wh/kg] Wh/kg 320 Wh/kg Wh/kg 450 Wh/kg 130 Wh/kg 650 Wh/kg 2000 Wh/kg 3500 Wh/kg 3500 Wh/kg Wh/kg NiZn Li-Ion Li/S x Li/MeF y Li/F 2 Li/MeO z Li/O 2 14 / Peter Birke / May 2010 Continental AG

15 New Battery trends Lithium + Sulfur Negative Electrode: Lithium metal (electrodeposited and sandwiched between current collector and stabilization layers Electrolyte: Organic based Positive Electrode: Sulphur with carbon Negative electrode Negative conductor Separator Positive conductor Positive electrode Separator Challenges: Safety and life time (especially over cycles) 15 / Peter Birke / May 2010 Continental AG

16 New Battery trends Lithium + Fluorine Negative Electrode: Lithium metal (electrodeposited and sandwiched between current collector and stabilization layers Electrolyte: Solid State, Polymer Positive Electrode: Me x F y (Me: Metal) in Matrix Challenges: High temperature required Excellent material distribution within the matrix 16 / Peter Birke / May 2010 Continental AG

17 New Battery trends Lithium + Air Air Oxygen permable membrane Composite carbon electrode on Ni current collector (Cathode) Solid polymer electrolyte Li on Ni current collector (Anode) Metallized plastic envelope Challenges: Safety and life time (especially over cycles) 17 / Peter Birke / May 2010 Continental AG

18 Outlook cell technologies Cell technologies in dependence on applications EV Plug In HEV Mild HEV Micro HEV VRLA & FLA VRLA / Li-Ion VRLA & Li-Ion / other VRLA & Li-Ion / VRLA & DLC VRLA & ECCAP / Li-Ion ECCAP / other Li-Ion / NiMH Li-Ion Li-Ion / other Li-Ion / NiMH Li-Ion Li-Ion / Li Li-Ion Li-Ion Li-Ion / Li VRLA sealed lead acid batteries with immobilized electrolyte (absorbed glass mat batteries AGM)), FLA vented lead acid batteries with fluid electrolyte UCAP double layer capacitor, ECCAP double layer capacitor with extended capacity, NiMH Nickel-metal hydride battery Li-Ion Lithium-Ion battery, Li e.g. Lithium-air, other e. g. Nickel tin battery Li-Ion Li-Ion Li-Ion DLC FLA VRLA NiMH HEV Cell PHEV Cell EV Cell 18 / Peter Birke / May 2010 Continental AG

19 System Comparison Vision of electrical energy storage systems and operating range Operating range [km] per weight of energy carrier [kg] EV has weight advantage 1) Li-Air Li- Fluorine Li-Ion for almost all driving scenarios up to 1,500 km operating range up to 120 km operating range Gasoline 0% 25% 50% 75% 100% [ ] km/kg km/kg 1) Basis for comparison: Weight of powertrain + weight of energy carrier/storage ICE: Vehicle with Internal Combustion Engine, EV: Electric Vehicle 19 / Peter Birke / May 2010 Continental AG

20 System Comparison Vision of electrical energy storage systems and operating range 20 / Peter Birke / May 2010 Continental AG

21 Summary The Li-Ion technology will become more and more the dominant technology for electro mobility. The Li-Ion technology has not yet reached its full potential, further improvements are still possible. For high end applications Li (metal) technology may be the follower of Li-Ion For low-end applications also electrochemistries such as Lead acid or Nickel-Zinc will still be interesting options. Parallel to the evolutions on cell level, the development on system level such as electronics, electromechanical components, software, battery algorithms, thermal management, housing will lead to decrease in volume, weight and system costs. 21 / Peter Birke / May 2010 Continental AG

22 Thank you for your Attention 22 / Peter Birke / May 2010 Continental AG