1. Predicting Heat Release
Where:
U= open circuit potential
V= cell potential
I= current
Heat Generation
during discharge Reversible heat generation
or thermal related to entropy change
runaway Loss due to due to all chemical
overpotentials reactions occurring in cell
and ohmic
potential drop
Mechanisms and Interactions Between
Heat Transfer and Chemical Reactions
heat accumulation
in cell creates
additional chemical
heat accumulation reactions
in cell creates
burden on cooling
Heat Net Heat Heat
accumulation
in Cell
= Entering/Leaving
Cell
+ Generation
Insufficient heat
transfer causes
heat accumulation
in cell Heat from
Chemical reaction
accumulates in
cell
How do we break the cycle?

2. Li-ion Battery Safety Methods
Pack Level Cell Level
Active Cooling Passive Cooling
Cell Design Cell Chemistry
Air Liquid Cooling Phase Change
See Next Slide
Cooling (refrigerant) Material (PCM)
Electrode Shutdown Safety Safety Positive Thermal
Coatings Separators Vents Circuits Coefficient Devices
Ceramic Conductive
Materials Polymer
Cell Chemistry
Electrode Electrolytes Electrode Materials
Additives
SEI Anode Cathode
Gel
Protecting
Polymers
Carbon Lithium
Overcharge Solid
Titanate
Protecting Polymers
(redox Shuttles)
Molten
Shutdown Salts Graphite
Nano-
Graphine
Flame Retarding Platelet
Composites
Flammability LiCoO2 LiMn2O4 LiFePO4 LiNiO2
Oxygen “Eating”
Lowering

3. Case Study
Preventing Thermal Runaway Propagation
Using Phase Change Material (PCM)
What is PCM cooling?
Thermal management
using phase change
material (PCM) – latent
heat of fusion
Excess heat absorbed
into latent heat of
melting wax
No pumps, radiators,
piping, or controls
Prevents propagation of
thermal runaway
Case Study
Air Cooling Simulation
Thermal runaway propagation occurs due to a
single cell run-away in an air-cooled module

4. Case Study
PCM Cooling Simulation
Module of 12 high energy Type 18650 cell
Case 1: thermal runaway trigger of a single cell
Pack Heat Generation Liquid Fraction
Propagation of thermal runaway due to a single cell run-away is
prevented by interstitial PCM microencapsulated in graphite
Case Study
PCM Cooling Simulation
Module of 12 high energy Type 18650 cell
Case 2: thermal runaway trigger of 2 cells
Pack Heat Generation Liquid Fraction
Can not prevent propagation of thermal runaway when more than
2 cells are triggered simultaneously (i.e. more PCM material or
higher latent heat is needed)

5. Summary
Safety of Li-ion batteries is a major concern
Thermal Management is essential for successful
commercialization of hybrid/electric vehicles
Combination of various methods may be needed
to optimize system design and cost
Thermal amanagement with phase chnage
material (PCM) is an effective alternative solution
for Li-ion battery packs
Discussion and Questions
Acknowledgement
Carrie Okma for preparing presentation slides.
Contacts:
Said Al-Hallaj, Chairman & CEO
Tel: +1-312-235-3705
salhallaj@allcelltech.com
Karen Orlich, CFO/COO
Tel: +1-312-235-3702
korlich@allcelltech.com
All Cell Technologies
IIT University Technology Park
3440 S. Dearborn Street Suite 117N
Chicago, IL 60616

7. EV Li-ion Battery Forum Shangai Sept. 2, 2009
Rome and Lyon Case study:
Evaluating the Sodium Nickelchloride Battery
value for electric urban bus transport
Pres MES-DEA
Lyon:
Mission of ALTRA-IVECO
electric buses
‡ Service 7:00AM - 10:00PM – 5 days a week
‡ Down town line 91,10 km,1 h round trip, 15’ frequency
‡ Public service on urban bus line in Lyon (F) downtown.
‡ Urban service with many stops and starts cycles charges on
downtown traffic
‡ 120 Km per day for each vehicle with a complete daily service
of about 50 complete trips. Energy consumption 1.1 kWh/km.
Pres MES-DEA

8. Main Europolis BUS features
‡ 7400 x 3750 x 3100 mm
‡ Kerb weight 8740 kg
‡ GTT 12280 kg
‡ Capacity 48 Passengers
‡ Energy on board 17KWh
‡ Chargers on board with 8
hours charging time
‡ Top speed 60 km/h
‡ Max slope starting 16 %
Pres MES-DEA
Improvement 1: Lyon Remote Diagnostic system
Pres MES-DEA

9. Improvement 2: New MBS software
Multi Balancing Algorithm
Pres MES-DEA
Improvement 3: new three-phases Charger
+ power, - charging time, + efficiency
Furthermore different BMI/MBS software
improvements have been introduced.
Pres MES-DEA

10. Lyon case study result:
Dec. ’04 ~ July ’09 = 500’000Km
Average = 130’000Km/year
Pres MES-DEA
15 Europolis EVbus in Sorrento Italy
‡ Public service for tourists between Sorrento
port and city centre.
‡ Urban service with many stops and starts
cycles charges on downtown traffic
‡ 70 km per day for each vehicle
‡ 100% bus availability
‡ 102000Km covered up to July 2009
Pres MES-DEA

11. Rome: Mission of TECNOBUS and MES-DEA
52 electric Gulliver bus already travelling in
Rome powered by lead acid battery
+
Other 100 electric Gulliver bus powered by
ZEBRA® batteries
=
Rome will became one of the city with the
largest electric bus fleet in Europe.
Pres MES-DEA
Tecnobus Gulliver vehicles:
The “Gulliver” zero-emission
electric bus, equipped with
ZEBRA® high technology
batteries, has been in regular
urban service for many years
further than in Italy also in
several countries as England,
France, Portugal, Spain,
Germany and Canada with
excellent results.
This specific bus version works with about 70KWh and can
cover about 130 km during a daily duty service even using air
conditioning system.
Pres MES-DEA

12. Gulliver capabilities in urban conditions with
ZEBRA® batteries
Many Gulliver bus are
working in urban streets and in
severe winter climatic
conditions (Canada T=-40°C).
Pres MES-DEA
ZEBRA® Charging Efficiency
Pres MES-DEA

13. ZEBRA® Expected Life
Pres MES-DEA
Battery price target
For reference:
If fuel price is
1.5 /l and a low
fuel consumption
for such a car of
4,5l/100km,
a battery price of
413 /kWh or 8260
is calculated.
Pres MES-DEA

14. Thanks for your attention!
www.mes-dea.ch
info@mes-dea.ch
* References:
- Li or Na_Full_paper_iamf 2009-Cord-Henrich Dustmann
- Pure electric buses fleet in Lyon: mission, battery, energy, maintenance-
Giorgio Mantovani, Fabio Nicora, Renato Manzoni
Pres MES-DEA

15. CONFERENCE DAY TWO
3 September 2009

16. Examining The Li-ion Battery Needs Of
Small Size City Cars For City Mobility
Chetan Kumar Maini
Deputy Chairman & Chief Technical Officer
REVA ELECTRIC CAR
India