the fraunhofer battery alliance - ller.pdf2012 > 2030 short-term 2015 mid-term 2020 long-li s...

© Fraunhofer

Dr. Kai-Christian Möller

The Fraunhofer Battery AllianceFrom Material Research to Cell Production, Testing and

System Integration

http://www.ecartec.com/

© Fraunhofer Allianz Batterien

The German Research LandscapeBasic and Application-oriented Research

0%

25%

50%

75%

100%

Fraunhofer Helmholtz Leibniz Max-Planck

Drittmittel aus derWirtschaft**

Drittmittel aus Wettbewerb(ohne Wirtschaft)*

Institutionelle Förderung

Source: Paktbericht 2013, Daten aus 2012

base funding

industrial revenue

public sector revenue


The Fraunhofer GesellschaftLocations in Germany

66 institutes

23 786 employees

total budget: 2.060 billion €

contract research: 1.716 billion €

(industrial 37 %, public sector 36 %)

patent applications: 564

active patent famailies: 6618

International cooperation via affiliated offices

in Europe, USA, Asia and Near East institutes

further locations

Status 2014

München

Holzkirchen

Freiburg

Efringen-

Kirchen

FreisingStuttgart

PfinztalKarlsruheSaarbrücken

St. IngbertKaiserslautern

DarmstadtWürzburg

Erlangen

Nürnberg

Ilmenau

Schkopau

Teltow

Oberhausen

Duisburg

EuskirchenAachen

St. Augustin

Schmallenberg

Dortmund

PotsdamBerlin

Rostock

LübeckItzehoe

Braunschweig

Hannover

Bremen

Bremerhaven

Jena

Leipzig

Chemnitz

Dresden

Cottbus

Magdeburg

Halle

Fürth

Wachtberg

Ettlingen

Kandern

Oldenburg

Freiberg

Paderborn

Kassel

GießenErfurt

Augsburg

Oberpfaffenhofen

Garching

Straubing

Bayreuth

Bronnbach

Prien

Hamburg

Leuna


Ernst-Mach-Institute EMI

Electron Beam and Plasma Technology FEP

Chemical Technology ICT

Manufacturing Techn. and Appl.Materials Research IFAM

Integrated Circuits IIS

Ceramic Technologies and Systems IKTS

Laser Technology ILT

Silicate Research ISC

Systems and Innovation Research ISI

Integrated Systems and Device Technology IISB

Silica Technology ISIT

Solar Energy Systems ISE

Techno- und Industrial Mathematics ITWM

Transportation and Infrastructure Systems IVI

Mechanics of Materials IWM

Material and Beam Technology IWS

Structural Durability and System Reliability LBF

Wind Energy and Energy System Technology IWES

Manufacturing Engineering and Automation IPA

München

Holzkirchen

Freiburg

Efringen-

Kirchen

FreisingStuttgart

PfinztalKarlsruheSaarbrücken

St. IngbertKaiserslautern

DarmstadtWürzburg

Erlangen

Nürnberg

Ilmenau

Schkopau

Teltow

Oberhausen

Duisburg

EuskirchenAachen

St. Augustin

Schmallenberg

Dortmund

PotsdamBerlin

Rostock

LübeckItzehoe

Braunschweig

Hannover

Bremen

Bremerhaven

Jena

Leipzig

Chemnitz

Dresden

Cottbus

Magdeburg

Halle

Fürth

Wachtberg

Ettlingen

Kandern

Paderborn

Kassel

GießenErfurt

Augsburg

Oberpfaffenhofen

Garching

Straubing

Bayreuth

Bronnbach

Prien

Hamburg

LeunaSCAI

Oldenburg

Freiberg

EMI, ISE, IWM

ICT

IFAM

ICT

IIS, IISB

FEP, IKTS, IVI, IWSILT

ISC

ISIT

ITWM

LBF

ISI

IPA

Sulzbach-

Rosenberg

IWES

Fraunhofer Battery Alliance

Members



Employees and Budget

Material

System

Simulation

Zellfertigung/-design

Testung

Employees

0

5

10

15

20

25

30

35

2012 2013 2014 2015 2016

2012

2013

2014

2015

2016

Budget in Mio €

270


Materials and Cells

Systems

Testing and Evaluation

Simulation


Competences

► + Trainings and Seminars, Studies, Roadmaps, Strategies

../../Presentations/generalBatteryPresentation/BEST_GeoDict2Geometry_longRun2.avi


Material development

Synthesis of electrode materials

inorganic-organic hybride polymers (ORMOCER®s)

Sol-gel- or solvothermal synthesis of cathode materials

Carbon compounds as electrode materials

Particle modification

Core-shell-structures

Functional coatings

Realisation of partical morphologies

Development of electrolytes and separators

Solid & polymer electrolytes, gel-type electrolytes

Ceramic separators


Material & Cell



Material & Cell

> 20302012short-

term2015

mid-

term2020

long-

term

4.3 V

LIB

5 V

LIB

4.4 V

LIB

High Voltage Cathodes


Core-shell Materials

Inorganic-organic coating of high voltage cathodes materials

Protected electrode/electrolyte interface

High charging end voltages

Good rate capability

Improved cycling stability

Up scaling to kg batches

Cost-saving coating process


Material & Cell

Galvanostatic cycling of pristine and coated LiNi0,5Mn1,5O2-electrode

► „5 V“ battery w/ commercial available electrolytes50 nm

LiNi0,5Mn1,5O2

ORMOCER®

Coated LiNi0,5Mn1,5O2-particle


Gas Deposition Methods

Coatings

Protected electrode/electrolyte interface

Passivation layers

Electrode materials, e.g. Si


Material & Cell

► Stable cycling of a bulk Si anode with reasonable

electrode loading

LiNi0,5Mn1,5O2

2 µm

Columnar structure of a Si anode

0 10 20 30 40 500

2

4

6

8

10

Are

al cap

acit

y / m

Ah

cm

-2cycle number

0

10

20

30

40

50

60

70

80

90

100

CE


> 20302012short-

term2015 mid-term 2020

long-

term

Li S


Material & Cell

Next Generation Lithium-based Technologies


► Li-S cells are interesting for their potential high gravimetric energy density

Grav. and vol. energy density of various electrochemical storage systems


Material & Cell

Li-S cells and Li2S-Si cells


Lithium metal deposition (Plating, dendrites)

Charging rate limitations at low temperatures

Ageing effect: irreversible Li deposited on the anode

Safety risk: short circuits caused by dendrite growth

Reasons for plating

Cell operating conditions (Temperature, charge rate)

Cell design factors

Non-uniformities within stack

► Plating is initiated locally: non-uniformities

Overcharged graphite electrode

In-Operandi microscope

investigations on graphite

electrodes


Material & Cell


Evaluation of new electrolytes in high energy Lithium-Sulfur-cells (Li-S)

Testing liquid electrolytes for Li-S

Specifications for Li-S cells

Adaption of cathode structure

Evaluation in prototype pouch cells

Gel-type polymer barrier films for Li-S

Development of coating technology (R2R)

Testing of polysulfide retention

Electrochemical characterization

Prototype cell evaluation


Material & Cell

Polymer barrier (Nafion) film on separators:

Demonstration of polysulfide retention and 3 Ah

prototype Li-S-cell at Fraunhofer IWS► Nafion-coating on polyolefin separator


Lithium conducting glass ceramics for solid electrolytes and separators

LATP-System (Li1+xAlxTi2-x(PO4)3

application in, e.g., lithium sulfur batteries

Stable in aqueous environments

Conductivities up to 0,4 mS/cm at 25°C

Process technology and applications

Monolithic substrates by tape casting

Films on porous substrates by screen printing

Conducting fillers in polymer based separators


Material & Cell

Sintered LATP glass ceramic micro structure

with conductivity of 0,3 mS/cm@25°C

► Material synthesis, powder processing and

development of sintering routes


High requirements for sulfur cathodes


Material & Cell

► Only high sulfur loads, high sulfur utilization and a low electrolyte/sulfur ratio may push

the energy density above the level of commercialized cells!


Tailored Carbon Support for Sulfur Cathodes

Target: high specific energy on cell level:

> 350 Wh kg-1

Cathode concept:

Tailored porous carbons for cathodes

with enhanced sulfur-utilization

Solvent-free dryfilm-process for cathode

production


Material & Cell

► High specific capacity through tailored

cathode

Sulfur / carbon nanocomposite for cathodes in Li-S

batteries

Dryfilm-process for electrode production


Li-S pouch cell production

Proof of concept – tests in pouch cell

Evaluation of new material concepts in 3

Ah pouch cells

Pouch cell production

3 Ah cells with energy density up to 250 Wh kg-1 are available

New concepts for high energy density > 350 Wh kg-1 are in progress


Material & Cell

► High energy Li-S pouch cells in development

► Target specific energy: > 350 Wh kg-1

Performance example of developed Lithium-Sulfur-

cells

Dryfilm electrode and Li-S pouch cells (200-250 Wh kg-1)


Prototype Cell Production

Electrode production

Dryfilm process and roll-to-roll

coating

Fast cutting by remote laser

“on the fly”

Electrode stacking

Flexible in type

Flexible in shape

Flexible in capacity


Material & Cell

► Automated (Li-S) cell processing line (stacked pouch cell)

► Integrated laser cutting and welding technologies

Samples of

laser welded tabsStacking machine with laser welding of tabs

Test channels from 40 up to 300 A


Punching

Lamination

Ultrasonic welding

Heat sealing station

Electrolyte addition


Material & Cell

Process technologies

Coating


Cell and battery prototype production

Batteries for different applications (Automotive, Stationary, UUV, Hearings aids, …)

Batteries for different requirements (e.g. high temperatures, flexible batteries)

Test cells for material development


System


Battery management, battery monitoring, modeling and simulation

Development and realization of optimized charge strategies for different battery chemistries and applications

Techniques for multi-cell systems (single cell protection, cell balancing)

Compatible solutions with standards, like SBS, SMBus, PMBus

Methods, systems and software for charge state and capacity determination and battery management

Battery characterization and parameter determination formodels

System software and hardware for automotive BMS-devices

Model based software development and simulation

Simulation based calendar life and life cost analyzes


System


Battery characterization and tests

Electrical characterization, temperature behavior, aging behavior and mechanisms

Electrical, mechanical and thermal abuse tests (VDA specifications for lithium Ion

Batteries for hybrid electric vehicles, tests for storage and transport (UN Regulations on

Transport of Dangerous Goods)


Test



Simulation

Material research

Electrode and cell design

Safety and durability

Battery system and

battery management

electrochemical

continuum simulations

quantum-chemical

simulationsmolecular dynamics

battery network modelsstructural mechanics

simulations

../../Presentations/generalBatteryPresentation/BEST_GeoDict2Geometry_longRun2.avi



Simulation



Applications 2015

Battery Simulation

Software

for Hardware-in-the-

Loop- Stands

fast and

inexpensive

simulation

Fraunhofer IWES

Laser-drying

Module

implemented into a

R2R electrode

coating machine

cuts energy

consumption into

half

Fraunhofer ISIT / IIS

EV Battery module

with automotive-

qualified 3 Ah-

18650-Cells

high energy

density (160 Wh/kg),

low-cost electronic

for monitoring

Fraunhofer IISB

Oscillation Laser

Welding

for safe electric

contacting of battery

cells

ultra fast and low

energy input

Fraunhofer ILT

Fraunhofer ILT / IKTS

Lithium-Booster-

Battery Modul

with12 high-power

cells and integrated

electronic

enhanced safety

with ceramic sepa-

rator, effective cell

balancing



► www.batterien.fraunhofer.de/en.html

Dr. Kai-Christian Möller


Fraunhofer-Gesellschaft Headquarter

Corporate Business Development

Hansastraße 27c, 80686 München, Germany

phone: +49 89 1205 - 4417

email: [email protected]

https://de.linkedin.com/in/kaichristianmoeller

the fraunhofer battery alliance - ller.pdf2012 > 2030 short-term 2015 mid-term 2020 long-li s...

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