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This manual defines a complete body of abuse tests intended to simulate actual use and abuse conditions that may be beyond the normal safe operating limits experienced by electrical energy storage systems used in electric and hybrid electric vehicles. The tests are designed to provide a common framework for abuse testing various electrical energy storage systems used in both electric and hybrid electric vehicle applications. The manual incorporates improvements and refinements to test descriptions presented in the Society of Automotive Engineers Recommended Practice SAE J2464 "Electric Vehicle Battery Abuse Testing" including adaptations to abuse tests to address hybrid electric vehicle applications and other energy storage technologies (i.e., capacitors).These (possibly destructive) tests may be used as needed to determine the response of a given electrical energy storage system design under specifically defined abuse conditions. This manual does not provide acceptance criteria as a result of the testing, but rather provides results that are accurate and fair and, consequently, comparable to results from abuse tests on other similar systems. The tests described are intended for abuse testing any electrical energy storage system designed for use in electric or hybrid electric vehicle applications whether it is composed of batteries, capacitors, or a combination of the two. 4 AcknowledgementsSandia National Laboratories would like to acknowledge and thank Tien Duong of U.S. Department of Energy's Office of FreedomCAR and Vehicle Technologies for the support and funding of this work. Appreciation is extended to Randy Wright, Jeff Belt, and Gary Hunt (retired) of Idaho National Engineering and Environmental Laboratory and to Terry Unkelhaeuser (retired) of Sandia National Laboratories. We gratefully acknowledge the many useful comments concerning abuse of capacitors received from Mike Everett of Maxwell Technologies, Inc. and the contributions of his staff. We thank E. Peter Roth, Brad Hance and J. Anthony Romero for reviews and improvements of the manuscript as well as test method development. We also thank all of the contributing organizations that participated in this project and contributed to its success. For further information, the technical contact is Daniel H. Doughty, Lithium Battery Research and Development Department, Sandia National Laboratories, phone (505) 845-8105, email: dhdough@sandia.gov.5

This paper describes the development and qualification of a method capable of analyzing inorganic ions as salts and counter-ions of both active pharmaceutical ingredients and other compounds such as lysine. The use of a polymeric zwitterionic column with a binary high-performance liquid chromatography gradient enables the separation of several anions and cations in a single run. A generic gradient (method #1) was developed and validated with respect to specificity, correlation, intermediate precision, accuracy, and sensitivity (limits of quantitation and detection) for four anions and two cations. Furthermore, the ability to alter chromatographic selectivity by simple gradient manipulation (without altering the mobile phase composition or column type) is demonstrated for nine anions and three cations (method #2). The simultaneous measurement of cations and anions at the parts per billion level using the Corona charged aerosol detector with zwitterionic chromatography-polymeric hydrophilic interaction chromatography is a viable alternative to traditional techniques used for ion analysis.

Li-ion cells are being developed for high-power applications in hybrid electric vehicles currently being designed for the FreedomCAR (Freedom Cooperative Automotive Research) program. These cells offer superior performance in terms of power and energy density over current cell chemistries. Cells using this chemistry are the basis of battery systems for both gasoline and fuel cell based hybrids. However, the safety of these cells needs to be understood and improved for eventual widespread commercial application in hybrid electric vehicles. The thermal behavior of commercial and prototype cells has been measured under varying conditions of cell composition, age and state-of-charge (SOC). The thermal runaway behavior of full cells has been measured along with the thermal properties of the cell components. We have also measured gas generation and gas composition over the temperature range corresponding to the thermal runaway regime. These studies have allowed characterization of cell thermal abuse tolerance and an understanding of the mechanisms that result in cell thermal runaway. 4This page intentionally left blank. 5 Executive SummaryThe use of high-power Li-ion cells in hybrid electric vehicles is determined not only by the electrical performance of the cells but by the inherent safety and stability of the cells under normal and abusive conditions. The thermal response of the cells is determined by the intrinsic thermal reactivity of the cell components and the thermal interactions in the full cell configuration. The purpose of this program has been to identify the thermal response of these constituent cell materials and their contribution to the overall cell thermal performance. We have investigated commercial cell chemistries (Sony) as well as custom cells (Gen1 and Gen2) designed to achieve high levels of performance as well as safety. Calorimetric techniques such as Accelerating Rate Calorimetry (ARC) and Differential Scanning Rate Calorimetry (DSC) were used as a sensitive measure of the thermophysical properties. The program objectives, approach and accomplishments are summarized below. Objectives• Develop abuse methods which can establish cause and effect relationships between variations in abuse tolerance, thermal instabilities, or reduced lifetimes to changes in cell design or materials • Identify mechanisms and chemical constituents leading to reduced thermal tolerance, reduced thermal stability, or reduced operational lifetime in Li-ion cells.• Identify chemical mechanisms resulting in gas generation that leads to cell venting.• Determine factors affecting flammability of cell vent products under abusive conditions. • Characterize the thermal response and gas generation products of cells under various overcharge conditions. • Develop a knowledge base of cell thermal properties leading to improved cell designs. Approach• Test full size cells by the method of Accelerating Rate Calorimetry (ARC) to determine cell properties leading to cell thermal runaway. • Measure gas generation in full cells a...

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