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.
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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...