Quallion Lithium-ion Material & Cell Status

NASA Battery Workshop

November 17th - 19th 2015

Topics
Title III Cathode/Anode Material Production

DLA Strategic Stockpile Delivery Status

Qualification Lot Small Cell Life Testing

75Ah production with Title III materials for USG life testbed

Satellite Cell Electrochemical Testing

Zero-Volt Capability

Life Test Battery Testing

Future 18650 Space Cell Product Status

Production Equipment Status

18650 Proof of Concept Testing

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Title III Cathode/Anode Material Production

DLA Strategic Stockpile Delivery Status

Qualification Lot Small Cell Life Testing

75Ah production with Title III materials for USG life tested

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Material Production Update

MaterialProductionVolumes
1400

1277.5

1217.4

1276.4

1200

Amount(kg)

1000
LCO

800

NCA
MCMB

600
400
200

263.3
183.5

231.5

0
QualificationPeriod(kg)

ProductiontoDate
November2015(kg)

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Future DLA Delivery Updates

Planned LCO Deliveries (Last Updated September 2015)
LCOMonthlyBuildPlanTotals(kg)

Period
Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Annual
Total
(kg)

BaseYear
1Oct14

91

91

150

150

30Sep15
OptionYear
1
1Oct15
30Sep16
OptionYear
2
1Oct16

90

119

209

90

60

150

90

60

150

30Sep17
OptionYear
3
1Oct17
30Sep18
OptionYear
4
1Oct18
30Sep19

OverallTotal

Deliveries highlighted in green have been completed

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750

Future DLA Delivery Updates

Planned NCA Deliveries (Last Updated September 2015)
NCAMonthlyBuildPlanTotals(kg)

Period
Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

80

80

80

80

80

120

80

80

80

80

80

80

80

80

80

80

80

80

80

80

Jun

Jul

Aug

Sep

Annual
Total
(kg)

BaseYear
1Oct14

290

450

30Sep15
OptionYear
1
1Oct15

80

20

540

80

70

630

80

80

60

540

80

80

60

540

30Sep16
OptionYear
2
1Oct16

80

30Sep17
OptionYear
3
1Oct17
30Sep18
OptionYear
4
1Oct18
30Sep19

OverallTotal

Deliveries highlighted in green have been completed

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2700

Future DLA Delivery Updates

Planned MCMB Deliveries (Last Updated September 2015)

Sep

Annual
Total
(kg)

169.3

88.7

618

MCMBMonthlyBuildPlanTotals(kg)

Period
Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

BaseYear
1Oct14

180

180

30Sep15
OptionYear
1
1Oct15

180

180

180

108

648

180

180

180

138

678

180

180

180

108

648

180

180

180

108

648

30Sep16
OptionYear
2
1Oct16
30Sep17
OptionYear
3
1Oct17
30Sep18
OptionYear
4
1Oct18
30Sep19

OverallTotal

Deliveries highlighted in green have been completed

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3240

Electrochemical Performance
LCO Electrochemical Long Term Cycling, Qualification Lots, BTE
Medical Cells

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Electrochemical Performance
NCA Electrochemical Long Term Cycling, Qualification Lots, BTE
Medical Cells

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Electrochemical Performance
MCMB Electrochemical Long Term Cycling, Qualification Lots, BTE
Medical Cells

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Electrochemical Performance
MCMB Electrochemical Long Term Cycling, Qualification Lots, BTE
Medical Cells

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75 Ah Cell Production with Title 3 Materials

for USG Life Test Bed
12 MCMB/NCA Production Cells Using Standard Production Equipment/Processes
Shipped 12 June 2015 (3 weeks ahead of schedule)

2nd Production Lot of 75 AHr Cells due for Delivery by 13

Nov 2015
3rd Production Lot for Delivery by 5 Feb 2016
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Satellite Cell Electrochemical Testing

Zero-Volt Capability
Life Test Battery Testing

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14
Zero VoltTM Capability
Capacity Retention and Cell Voltage after low voltage Storage (49 months)
(QL015KA cell, 40% DOD LEO Cycle Performance)
Cell Voltage
Discharge Capacity / Ah
during
Storage
After Storage
After 5000
Before Storage
/ Volts
(49 months)
cycles

Discharge Capacity

X06H532

0.656

14.6

14.6

14.9

X06I004

0.180

14.7

14.4

14.5

Cell Voltage @ End of Discharge

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Zero VoltTM Capability

Capacity Retention after 0V Storage (40 months)
(QL075KA cell, 20% SOC Storage Performance)

0 volt storage

20 % SOC storage on going

After 0 volt storage

- No capacity fade
- Same storage capability
to fresh cell

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8S-1P 200mAh 0V Battery Test

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8S-1P 200mAh 0V Battery Test

Cell and Battery Voltages During 0V storage

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8S-1P 200mAh 0V Battery Test

Capacity Checks after 0V Storage

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1
8

8S-1P 200mAh 0V Battery Test

20% LEO Cycling after 0V Storage

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Life Test Pack Status

15Ah cell (small feedthrough), 1P-8S, 20% DOD LEO, 80,860 cycles,
104 months (8.7 yrs)

75Ah cell, 8S-1P, 20% DOD LEO, 67,564 cycles, 84 months (7 yrs)

15Ah cell, 2P-8S, TacSat IV replica: HEO, 15th seasons, 4 yrs

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8S-1P 15Ah Life Test Pack

Accelerated LEO 20% DOD (8.7 yrs)

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8S-1P 75Ah Life Test Pack

Accelerated LEO 20% DOD (7 yrs)

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2P-8S 15Ah TacSat IV Replica

Accelerated HEO (4 yrs)

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Future 18650 Space Cell Product Status

Production Equipment Status

18650 Proof of Concept Testing

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18650 New Sub-Assembly Dry Room

Winder
Bottom Tab
Weld Station
Beading
Station
Sealant
Dispensing
Station

Final Crimping
Station

Filling Station

Top Tab Weld

and Taping
Station

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EnerSys Proprietary - Title III Data Rights

Winding Station

1
1
:
4
0

Cathode/anode patch
coating (vs continuous for
satellite cells) are fed into
the winder that
automatically winds and
welds the positive and
negative tabs

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Beading Station

The case and jellyroll

assembly is manually
inserted into the collet of the
beading station. Once the
operator triggers cycle start,
the case is beaded along the
top of the case.

Start 11:2

Bead/Groov
e

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Crimping Station

St

The cell assembly is manually

inserted into the pre-crimp or final
crimp collet of the crimping station.
Once the operator triggers cycle
start, the cell is pre-crimped or final
crimped to complete the
mechanical cell assembly before
going into formation.

Final
Crimp

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Equipment Validation Status

Insitu:Finaltooling,Prelimlimits

BottomTabWeld

Beading/Grooving

Sealant

Filling

PositiveTabWeld

Crimp

Qty:30samples
PullStrength
Dimensions

Qty:30samples
Dimensions

Qty:30samples
Beaddimensions
Weight

Qty:30samples
Weight(electrolytestandin?)

Qty:30samples
PullStrength
Dimensions

Qty:30samples
Dimensions

EquipmentAccepted

FinalToolingandProcessLimits
BottomTabWeld
Qty:50samples
2Operators
PullStrength
Dimensions

Beading/Grooving
Qty:50samples
2Operators
Dimensions

Sealant
Qty:50samples
2Operators
Beaddimensions
Weight

Filling
Qty:50samples
2Operators
Weight

Equipment installation
COMPLETE

Equipment Acceptance testing

COMPLETE

Equipment Validation
COMPLETE

Final criteria COMPLETE

Process Capability COMPLETE

Cell Qualification IN PROCESS

PositiveTabWeld
Qty:50samples
2Operators
PullStrength
Dimensions

Crimp
Qty:50samples
2Operators
Dimensions

ProcessCapability
Analysis

EquipmentReleasedforUse

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18650 Upcoming Milestones

MILESTONE

DATE

Equipment Qualification/ValidationmBuilds

Complete

Qualification Cells Long Life chemistry

12/4/15

Long Life Testing Start (Best Case w/ 1st Build)

11/19/15

Long Life Testing Start (2nd Build)

12/05/15

UN/UL Test Start

12/16/15

UN Test Complete (Best Case w/ 1st Build)

02/24/16

UL Test Complete (Best Case w/ 1st Build)

03/16/16

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Table Top Equipment Built

Prototype 18650 Cell Testing
Rate Test (6 samples)
Charge : 0.5C to 4.1V, C/20 CV cutoff at 25 5C
Discharge : 0.2, 0.5, 1, 2, & 5C to 2.7V at 25 5C
Rest : 10 minutes after each charge and discharge step
C/2 Charge/Discharge Cycling (2 samples, started 6/20/14)
Charge : C/2 to 4.1V, C/20 CV cutoff at 25 5C
Discharge : C/2 to 2.7V at 25 5C
Repeat : 200 Cycle increments
40% DOD Chg/Dchg Cycling (4 samples, started 6/20/14)
Charge : C/2 to 4.1V, C/20 CV cutoff or 96 minutes at 25 5C
Discharge : C/2 to 2.7V or 48 minutes at 25 5C
Repeat : 400 Cycle increments; Capacity check each 400 cycles
For all testing 1C = 1500mA
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C/2 Rate Discharge Curve Comparison

Both the 1.5Ah 18650 and 75Ah prismatic cells show

similar discharge curves at a C/2 rate

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C/2 Charge/Discharge Cycling to 40% DOD

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Cycling to 40% DOD Comparison

QL1500: C/2 to 40% DOD (4.1V EOCV)

Based on the trendline, QL1500 cells should
reach 80% remaining capacity >25000
cycles (~95Wh/kg).

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Cycling to 100% DOD

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Cycling to 100% DOD Comparison

QL1500: C/2 to 100% DOD (4.1V EOCV)

Sony HCM: 0.66C Charge to 4.2V, 0.47C
Discharge to 95% DOD
Based on the trendline, QL1500 cells should
reach 80% remaining capacity at
approximately 2200 cycles (~95Wh/kg).

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THANK YOU

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