B ATTERIES : R ISKS AND R EALITIES DAV I D RAH E, CRE R EALITY : B - PowerPoint PPT Presentation

B ATTERIES : R ISKS AND R EALITIES DAV I D RAH E, CRE

R EALITY : B ATTERIES P OWER O UR L IVES Portability is reality ……always moving toward greater mobility Battery energy is the means to power portability, but what are the risks ? Li I on Battery Projected Growth This isn't your grandpa’s battery! 5/ 9/ 2014 2

C HALLENGES Meet these demands: Under these conditions:  Longer Runtime  Temperature  Greater Charge / Discharge Cycle Life  Temperature shock  Lower Cost  Vibration  Smaller Size  Humidity  Quick Charge Time  Altitude • Secondary cells  Random Drops  More Power  Impacts  Green – Environmentally Friendly  Immersion  AND Safe & more Batteries rely on an electrochemical process … limitations will prevail. How to get the most out of the electrochemical device? New Chemistries 5/9/2014 3

R EALITY : C ELL C HEMISTRIES Lead Acid • Developed in 1890 • Larger power applications where weight is of little concern; car starter battery, hospital equipment, wheelchairs, emergency lighting and UPS systems. Nickel Cadmium (NiCd) • Developed in 1947 • Mature and well understood but relatively low in energy density • Contains toxic metals • Periodic full discharge is critical, if omitted, large crystals form on the plates • Long life, high discharge rate and economical • Two-way radios, biomedical equipment, video cameras and power tools Nickel-Metal Hydride (NiMH) • Developed in 1990 • 50% higher energy density compared to the NiCd • Reduced cycle life • High self discharge • Contains no toxic metals • Digital cameras with LCDs and flashlights Lithium Ion (Li-ion) • Developed in 1991 • Fastest growing battery system • Li-ion is used where high-energy density and lightweight is of prime importance • The technology is fragile and a protection circuit is required to assure safety • Notebook computers, EV cars Lithium Ion Polymer (Li-ion polymer) • Developed in 1994 • Offers the attributes of the Li-ion in ultra-slim geometry and simplified packaging • Mobile phones, tablets 5/ 9/ 2014 4

R EALITY : C ELL C HEMISTRIES Best Solution: Lithium Ion 5/ 9/ 2014 5

B EST S OLUTION : L ITHIUM I ON Highest Energy densities (smaller and lighter), Higher Voltage, no Memory Expected to dominate the market by 2017. 18650 Can Technology : • Lithium-ions move through an electrolyte from the negative electrode (“anode”) to the positive electrode (“cathode”) during battery discharge, and from cathode to anode during charging. • The electrochemically active materials in lithium-ion batteries are typically a lithium metal oxide for the cathode and a carbon for the anode. • Cathode options: Li-cobalt, Li-manganese, Li-iron phosphate, Nickel-manganese-cobalt, Lithium Thionyl Chloride (high temp), others • Electrolytes can be liquid, gel, polymer or ceramic. Technology improvements are expected to further increase cell performance. 5/ 9/ 2014 6

R ISKS : L ITHIUM I ON Request to Stop Using VAIO Fit 11A/Flip Personal Computer Posted: 4/11/2014 Dear Valued Sony VAIO Customers, It has come to our attention that some of the internal, non-removable battery packs provided to us by a third-party supplier and included in 368 units of VAIO Fit 11A/Flip PC released in February 2014 have the potential to overheat resulting in partial burns to the housing of the PC. If you have one or more of the VAIO Fit11A/Flip PC model listed below, please immediately discontinue use, shut down and unplug the PC. We are currently identifying…………… Lenovo was forced to recall over 150,000 battery packs for its popular ThinkPad line earlier this year after discovering systems can overheat, posing a fire hazard, said the U.S. Consumer Product Safety Commission Boeing 787 Dreamliner's first year of service, at least four aircraft suffered from electrical system problems stemming from its lithium-ion batteries. HP Expands Recall of 280,000 Notebook Computer Batteries Due to Fire Hazard Sony 6 million recalled BatteriesPlus Expands Recall of Battery Packs used with Cordless Tools Due to Tesla Model S; road debris punctures Explosion Hazard. The replacement battery undercarriage, crash. 6,500 LIBs in 16 pack can explode unexpectedly, posing a modules. Tesla S & Chevy Volt sitting in a risk of injury to consumers. garage 7

S AFETY : H OW TO M ITIGATE R ISK Pack a lot of chemical energy into a small space and if something goes wrong, fire or explosions are the inevitable result. Can it fail safely? Anode short to • Cell Safety features Cathode • PTC (Positive Temp Coefficient) thermistor • Over charge pressure sense, CID (Current Interrupt Device) • Over discharge sleep • Pressure relief vent • Battery Management Systems • Communicates with other components, to limit the current they source or draw • Manages charge 5/ 9/ 2014 8

S AFETY : H OW TO M ITIGATE R ISK Pack a lot of chemical energy into a small space and if something goes wrong, fire or explosions are the inevitable result. Anode How does the industry test for safety? short to • Numerous Test Standards that focus on specific risk from Cathode electrical , mechanical and environmental conditions Tests: • External short circuit • Abnormal charge • Forced discharge • Impact • Shock • Vibration • Heating • Temperature Cycling • Low Pressure (Altitude) • Drop • Penetration • Immersion 5/ 9/ 2014 9

S AFETY : T ESTS Underwriters Laboratories • UL 1642: Lithium Batteries • UL 1973: (Proposed) Batteries for Use in Light Electric Rail (LER) Application and Stationary Applications • UL 2054: Household and Commercial Batteries • UL Subject 2271: Batteries For Use in Light Electric Vehicle Applications • UL 2575: Lithium-Ion Battery Systems for Use in Electric Power Tool and Motor Operated, Heating and Lighting Appliances • UL Subject 2580: Batteries For Use in Electric Vehicles Institute of Electrical and Electronics Engineers • IEEE 1625: Rechargeable Batteries for Multi-Cell Mobile Computing Devices • IEEE 1725: Rechargeable Batteries for Cellular Telephones National Electrical Manufacturers Association • C18.2M: Part 2, Portable Rechargeable Cells and Batteries — Safety Standard Society of Automotive Engineers • J2464: Electric and Hybrid Electric Vehicle Rechargeable Energy Storage Systems (RESS), Safety and Abuse Testing • J2929: Electric and Hybrid Vehicle Propulsion Battery System Safety Standard — Lithium-based Rechargeable Cells International Electrotechnical Commission • IEC 62133: Secondary Cells and Batteries Containing Alkaline or Other Non-acid Electrolytes — Safety Requirements for Portable Sealed Secondary Cells, and for Batteries Made from Them, for Use in Portable Applications • IEC 62281: Safety of Primary and Secondary Lithium Cells and Batteries During Transportation United Nations (UN) • Recommendations on the Transport of Dangerous Goods, Manual of Tests and Criteria, Part III, Section 38.3 Japanese Standards Association • JIS C8714: Safety Tests for Portable Lithium-Ion Secondary Cells and Batteries For Use In Portable Electronic Applications Battery Safety Organization • BATSO 01: (Proposed) Manual for Evaluation of Energy Systems for Light Electric Vehicle (LEV) — Secondary Lithium Batteries 5/ 9/ 2014 10

T ESTS : P ERFORMANCE Safety tests are critical but in the product…the OEM’s design controls the battery! The choice of battery in an application is driven by: • Application requirements for power and energy • Cost • Physical characteristics (i.e., size, shape, weight, etc.) • Life required by the application • Anticipated environment in which the product will be used • Anticipated duty cycle of the product (continual or intermittent) • Maintenance and end-of-life considerations Test for the Application: mimic electrical, mechanical and environmental conditions Life Cycle Tests (electrical) • Battery Manufacturer provides test data at 25C • Single charge/discharge is generally defined as one cycle. The process is repeated until state of charge fades to a predetermined level (80% of initial capacity). Target ≈400+ cycles or EOL. • Other stresses applied 5/ 9/ 2014 11