The Handbook of Lithium-Ion Battery Pack Design: Chemistry, Components, Types and Terminology offers to the reader a clear and concise explanation of how Li-ion batteries are designed from the perspective of a manager, sales person, product manager or entry level engineer who is not already an expert in Li-ion battery design. It will offer a layman’s explanation of the history of vehicle electrification, what the various terminology means, and how to do some simple calculations that can be used in determining basic battery sizing, capacity, voltage and energy. By the end of this book the reader has a solid understanding of all of the terminology around Li-ion batteries and is able to do some simple battery calculations.
The book is immensely useful to beginning and experienced engineer alike who are moving into the battery field. Li-ion batteries are one of the most unique systems in automobiles today in that they combine multiple engineering disciplines, yet most engineering programs focus on only a single engineering field. This book provides you with a reference to the history, terminology and design criteria needed to understand the Li-ion battery and to successfully lay out a new battery concept. Whether you are an electrical engineer, a mechanical engineer or a chemist this book helps you better appreciate the inter-relationships between the various battery engineering fields that are required to understand the battery as an Energy Storage System.

Figure Captions ix

Preface xiii

Acknowledgments xv

Acronyms List xvii

Chapter 1: Introduction 1

Factors Influencing Consumer Adoption of Electric Vehicles 2

Evolving Vehicle Technology Needs 3

Purpose of the Book 4

Chapter Outline 6

Chapter 2: History of Vehicle Electrification 9

The History of the Modern Storage Battery 10

An Electrical Industry Emerges 14

Early Electric Vehicle Development 14

Modern Vehicle Electrification 16

Chapter 3: Basic Terminology 23

Vehicle and Industry Terms 23

Stationary and Grid Terminology 27

Battery Terms 28

Chapter 4: Battery Pack Design Criteria and Selection 35

Ohm’s Law and Basic Battery Calculations 38

Converting Customer Requirements into Pack Designs 45

Power to Energy Ratios 47

Large Stationary and Grid Systems 48

Quick Formula Summary 48

Chapter 5：Design for Reliability/ Design for Service 51

Design for Reliability/Design for Service 52

Quality and Reliabil ity 53

Failure Modes Effects Analysis 54

Design for Service 56

Chapter Summary 57

Chapter 6: Computer: Aided Design and Analysis 59

Organizations and Analysis Products 59

Analysis Tools. 6 1 Battery Sizing Tools. 62

Chapter 7: Lithi11m-lon and Other Cell Chemistries 65

Lead Acid 66

Nickel Metal-Based Chemistries 72

Sodium-Based Chemistries 74

Lithium-Ion Cells 75

Cathode Chemistries 78

Anode Materials 80

Separators 81

Electrolytes 82 Safety Features 83

Lithium-Jon Cell Types and Sizes 84

Lithium-Jon Cell Manufacturers. 86

Chapter 8: Battery Management System Controls 91

BMS Typologies 92

BMS Hardware 93

Balancing 95

Active versus Passive Balancing 98

Additional BMS Functionality 99

Software and Controls 100

Chapter 9: System Control Electronics 103

Contactors/Relays 104

High-Voltage Interlock Loop 106

Fuses 106

Battery Disconnect Unit 108

Connectors 109

Charging 110

Chapter 10: Thermal Management 115

Why Cooling? 119

Why Heating? 122

Active Thermal Management Systems 123

Passive Thermal Management Systems. 127

Temperature一Protection and Insulation 128

Thermocouples and Meastumement 129

Chapter 11: Mechanical Packaging and Material Selection 131

Module Designs 132

Use of Metals in Battery Design 133

Use of Plastics and Composites in Battery Design 135

Sealed Enclosures 135

Chapter 12: Battery Abuse Tolerance 139

Failure Modes of Lithium-Ion Batteries 141

Characterization and Performance Testing 142

Safety and Abuse Testing. 146

Certification Testi ng 148

Chapter 13: Industrial Standards and Organizations 153

Voluntary Standards 155

Research and Development and Trade Groups 163

Mandatory Standards Organizations 165

Chinese Standards and Industry Organization s 166

European Standards and Industry Organizations 166

Chapter 14: Second Life and Recycling of Lithium-Ion Batteries 169

Repairing and Remanufacturing 170

Refurbishing, Repurpo sing , and Second Life 170

Second Life Partnerships 173

Recycling 174

Chapter 15: Lithium-Ion Battery Applications 177

Personal Transportation Application s 177

Automotive Applications 183

Bus and Public Transportation 194

HD Truck Applications 196

Industrial Applications 196

Robotics and Autonomous Applications 198

Marine and Mariti me Applications 199

Grid and Stationary Application s 200

Aerospace Application s 206

Chapter 16: The Future of Lithium-Ion Batteries and Electrification 211

Major Trends 211

Technological Trends 212

Future Trends in Battery Technology 214

Conclusion 216

References 217

Appendix A: USABC 12-V Stop/ Start Batte吃y Pack Goals 223

Appendix B: USABC 48-V BatteηF Pack Goals 225

Appendix C: USABC H EV Battery Pack Goals 227

Appendix D: USABC PH EV Battery Pack Goals 229

Appendix E: USABC EV Batteη，Pack Goals 231

lndex 233

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