Intertek Group plc · LSE:ITRK
Intertek — The Battery Show 2012
38 slides from Intertek's conference presentation, November 2012
Slide 1: Overstress Safety Evaluations of Consumer/Automotive Li-Ion Batteries Near End-Of-Life
Overstress Safety Evaluations of Consumer/Automotive Li-Ion Batteries Near “End-Of-Life” The Battery Show November 2012 2012, Novi MI Tom O’Hara, Håken Carlberg 1 www.intertek.com
Slide 2: Global Presence – Energy Storage
Global Presence – Energy Storage v v USA v vv D t it MI Detroit, Grand Rapids, MI v v v San Antonio, TX EMEA Kaufbeuren, Germany Leatherhead, UK Kista, Sweden APAC Shanghai Global Centers of Excellence Taipei 2 www.intertek.com
Slide 3: An Idea
An Idea Overstress Safety Evaluations of Consumer/Automotive Li-Ion Batteries Near “End-Of-Life” End Of Life 3 www.intertek.com
Slide 4: A Perspective on Battery Safety Standards
A Perspective on Battery Safety Standards • Intertek sits on many Battery Safety Standards Committees: ANSI, UL, UN/DOT, IEC, IEEE (CTIA), SAE 4 www.intertek.com
Slide 5: A Perspective on Battery Safety Standards
A Perspective on Battery Safety Standards • Intertek sits on many Battery Safety Standards Committees ANSI, UL, UN/DOT, IEC, IEEE (CTIA), SAE • Each Organization and Standard has its own charter and focus • SAE – Automotive A t ti • UN/DOT – Transportation/Shipping • ANSI, UL, IEC, IEEE – Consumer B
Slide 6: A Perspective on Battery Safety Standards
A Perspective on Battery Safety Standards • Intertek sits on many Battery Safety Standards Committees ANSI, UL, UN/DOT, IEC, IEEE (CTIA), SAE • Each Organization and Standard has its own charter and focus • On a test by test basis, there is much overlap across safety standards • Harmonization effort
Slide 7: A Perspective on Battery Safety Standards
A Perspective on Battery Safety Standards • Intertek sits on many Battery Safety Standards Committees ANSI, UL, UN/DOT, IEC, IEEE (CTIA), SAE • Each Organization and Standard has its own charter and focus • On a test by test basis, there is much overlap across safety standards • Real world Li-Ion ba
Slide 8: A Perspective on Battery Safety Standards
A Perspective on Battery Safety Standards • Intertek sits on many Battery Safety Standards Committees ANSI, UL, UN/DOT, IEC, IEEE (CTIA), SAE • Each Organization and Standard has its own charter and focus • On a test by test basis, there is much overlap across standards • Real world Li-Ion battery “
Slide 9: Program Overview
Program Overview On-going O i evaluation l ti off “Near-End-Of-Life” “N E d Of Lif ” Li-Ion Battery Safety Purpose: Evaluate E l t the th safety f t performance f off “Fresh” “F h” andd “Near-End-Of-Life” Li-Ion batteries using both standard and overstress safety test metrics • Are older batteries m
Slide 10: Program Overview
Program Overview Phase I – Consumer • Aged (replaced) Li-Ion Notebook Computer B tt i Batteries • Aged (replaced) Li-Ion Cell Phone Batteries Phase II – Automotive EV/HEV • Details TBD 10 www.intertek.com
Slide 11: Technical Approach – Phase I (Consumer)
Technical Approach – Phase I (Consumer) Sampling: Our sampling procedure consists of replacing aged notebook computer battery packs from Intertek staff. We call these batteries “Near-End-Of-Life” as judged by the staff member requesting the replacement. Rather R th ththan di disposing i off th these
Slide 12: Technical Approach – Phase I (Consumer)
Technical Approach – Phase I (Consumer) State-Of-Health (SOH) Assessment: Our SOH assessment consists of measuring battery and individual cell capacities, impedance, and conducting an elevated temperature soak while monitoring OCV for signs of low grade internal shorting. This sorting Thi ti by b ce
Slide 13: Technical Approach – Phase I (Consumer)
Technical Approach – Phase I (Consumer) Safety Testing: Initially, Intertek will assess performance using industry standard safety tests as defined by ANSI, IEC, IEEE, UL, UN/DOT and SAE (for automotive). Overstress evaluations will follow. Intertek plans to query industry leaders in order to genera
Slide 14: Technical Approach – Phase II (Automotive)
Technical Approach – Phase II (Automotive) Details TBD 14 www.intertek.com
Slide 15: Test Selection – Phase I (Consumer)
Test Selection – Phase I (Consumer) A Number of Industry Standards exist for evaluating Li Li-Ion Ion safety safety. Those considered for this program include: ANSI C18 IEEE 1625 & 1725 IEC 62133 UN/DOT 38.3 UL 1642 & 2054 SAE J2464 / J 2929 Although the various test standards listed above vary in s
Slide 16: Test Selection – Phase I (Consumer)
Test Selection – Phase I (Consumer) The following series of slides presents an overview of the various safety tests contained in the standards listed above. Presentation is made from an SAE J 2464 perspective 16 www.intertek.com
Slide 17: 4.3.1 Shock Tests
4.3.1 Shock Tests • Cells: follow UN/DOT 38.3 • small cells/batteries (150g/6ms, 3 axis, +/-, 3X repeat) • large cells/batteries (50g/11ms, 3 axis, +/-, 3X repeat) • Packs: 25g, g 18 ms, 3 axis, +/- directions, 3X repeat p SAE J2929 Criteria: No rupture, fire, explosion, or loss of isolation -------
Slide 18: 4.3.2 Drop Tests
4.3.2 Drop Tests •Pack level only •2 meter drop SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a) UL 1642 (n/a) IEC 62133 (same as UL 2054) 18 www.intertek.com
Slide 19: 4.3.3 Penetration Tests
4.3.3 Penetration Tests • Cell • 3mm steel rod, sharp point, 8cm/s, through the cell • Module/Pack • 20mm steel rod, rod sharp point point, 8cm/s 8cm/s, through 3 cells / 100mm SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a) UL 1642 (n/
Slide 20: 4.3.4 Roll-Over Tests
4.3.4 Roll-Over Tests • Module and Pack level • One full roll, 1 minute duration; repeat 90 degrees SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a) UL 1642 (n/a) IEC 62133 (n/a) 20 www.intertek.com
Slide 21: 4.3.5 Immersion Tests
4.3.5 Immersion Tests • Module or Pack • Submerge in ambient temperature salt water (5% NaCl in water) for 2 hours SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a) UL 1642 (n/a) IEC 62133 (n/a) 21 www.intertek.com
Slide 22: 4.3.6 Crush (Impact) Tests
4.3.6 Crush (Impact) Tests • Cell level or above • Textured platen (radiused “cylinders”) • Crush to 15%, hold 5 minutes, crush to 50%, max force = 1000X DUT weight SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (Impact Test: 15.8mm bar, 9.1
Slide 23: 4.4.1 High Temperature Hazard Tests
4.4.1 High Temperature Hazard Tests • Pack Module and above • 890C (within 90s) for 10 minutes, indirect heat, fuel fire simulation SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a) UL 1642 (Projectile Test: “Bunsen Burner” blue flame tes
Slide 24: 4.4.2 Thermal Stability Tests
4.4.2 Thermal Stability Tests •Cell level •Thermal ramp 5C/min to 300C above max operating temp •Repeat at 2C/minute and 1 hour hold to determine thermal stability limit •Several additional repeat conditions (overcharge, (overcharge cells at mid-life mid life, etc.) etc ) SAE J2929 Criteria: N evide
Slide 25: 4.4.3 Cycling Without Thermal Management Tests
4.4.3 Cycling Without Thermal Management Tests •Module and Pack level •20 full cycles, no rest SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a, conditioning of samples requires 25 or 50 cycles) UL 1642 (n/a, conditioning of samples requi
Slide 26: 4.4.4 Thermal Shock Cycling Tests
4.4.4 Thermal Shock Cycling Tests • Cell level or above • Cycle between +70C to -40C (<15 minute per transition) • 5 thermal cycles, cycles 1 hour hold at extremes for cells cells, 6 hours for packs • 3X C/3 charge/discharge cycles before and after thermal cycling y g SAE J2929 Criteria: No evidence
Slide 27: 4.4.5 Passive Propagation Resistance Tests
4.4.5 Passive Propagation Resistance Tests • Module or Pack level • Heat to +55C or max operating temperature • Rapidly heat one cell to +400C to thermal runaway SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (n/a) UL 1642 (n/a) IEC 62133 (n
Slide 28: 4.5.1 Short Circuit Tests
4.5.1 Short Circuit Tests • Cell and Module or Pack level, at Room Temp. • Hard Short (Cell, Module, and Pack) – 5 mOhm or less, hold 1 hour • Soft Short (Cell) – over 10 mOhm (DUT DC resistance), hold 1 hour SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compar
Slide 29: 4.5.2 Overcharge Tests
4.5.2 Overcharge Tests • Cell (both 1C continuous and max regen breaking / charging current, est. 3C) • Module or Pack (1C continuous) • Charge to 200% SOC or event SAE J2929 Criteria: No evidence of fire or explosion ------------------------------- Compare: UN/DOT 38.3 (2X up to 22V for 18V system,
Slide 30: 4.5.3 Overdischarge (Forced Discharge) Tests
4.5.3 Overdischarge (Forced Discharge) Tests • Fully discharged cell cell, discharge at max current to 2X Ah capacity capacity, hold 30 min • Module – fully discharged cell in series with charged module cells, discharge configuration at maximum current to 0.2V SAE J2929 Criteria: No evidence of fire
Slide 31: 4.5.4 Separator Shutdown Integrity Tests
4.5.4 Separator Shutdown Integrity Tests • Cells C ll which hi h hhave a shutdown h td separator t • Heat cell to shutdown temperature plus 5 C • Apply 20V over voltage potential (current limited to <1C), 30 minutes SAE J2929 Criteria: No evidence of fire or explosion -------------------------------
Slide 32: Miscellaneous Additional Evaluations
Miscellaneous Additional Evaluations • SAE: 4.2 Hazardous Substance Monitoring • Battery Enclosure Tests (UL & IEC) • Altitude Simulation (UN/DOT, UL, IEC) • Vibration (UN/DOT, UL, IEC) • Forced Internal Short Circuit, Nickel Particle (IEC) • Cell Safety Vent (IEEE) 32 www.intertek.com
Slide 33: Initial Test Results
Initial Test Results Two 6 cell Notebook Computer packs were evaluated: • Packs are approximately 30 months old • Pack A: Code Date April 2010 • Pack B: Code Date February 2010 Clearly, we have • Both packs were in service approximately 2 years a distinction! • Packs are rated at 4910 mAh • Pack A m
Slide 34: Initial Test Results
Initial Test Results First tests conducted were IEC 62133’s Overcharge and Thermal Abuse: Overcharge Thermal Abuse 2 Cells per Pack 2 Cells per Pack All Cells Passed All Cells Passed It is obvious that more aggressive overstress tests are needed! 34 www.intertek.com
Slide 35: Conclusions and Recommendations
Conclusions and Recommendations Planning and initial testing for Intertek’s ongoing overstress safety evaluation of aged Li-Ion batteries was presented. Much more will follow. Stay tuned… 35 www.intertek.com
Slide 36: Global Automotive Depth
Global Automotive Depth Engine Airbag Brake Hose EMC Certification Dynamometer Deployment Testing (Type Approval) Development & Durability Testing Exhaust & Fuel Certification Fuel handling & Evaporative Failure Analysis - including Hazardous Area Emissions biofuels Classification Analysis Fuel Syst
Slide 37: Why Intertek?
Why Intertek? Experienced Team Global reputation World-Class Test recognized for 200+ years of collective Facilities uncompromised experience and independence and well- academic advanced Unique scope and founded advice– the degrees in the field of breadth of testing “Sagentia Catella” battery techno
Slide 38: Valued Quality. Delivered.
Valued Quality. Delivered. 38 www.intertek.com