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© Fraunhofer
Dr. Kai-Christian Möller
The Fraunhofer Battery AllianceFrom Material Research to Cell Production, Testing and
System Integration
© 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
© Fraunhofer Allianz Batterien
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
© Fraunhofer Allianz Batterien
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
© Fraunhofer Allianz Batterien
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
Materials and Cells
Systems
Testing and Evaluation
Simulation
Fraunhofer Battery Alliance
Competences
► + Trainings and Seminars, Studies, Roadmaps, Strategies
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
Material & Cell
© Fraunhofer Allianz Batterien
Fraunhofer Battery Alliance
Material & Cell
> 20302012short-
term2015
mid-
term2020
long-
term
4.3 V
LIB
5 V
LIB
4.4 V
LIB
High Voltage Cathodes
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
Gas Deposition Methods
Coatings
Protected electrode/electrolyte interface
Passivation layers
Electrode materials, e.g. Si
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
> 20302012short-
term2015 mid-term 2020
long-
term
Li S
Fraunhofer Battery Alliance
Material & Cell
Next Generation Lithium-based Technologies
© Fraunhofer Allianz Batterien
► Li-S cells are interesting for their potential high gravimetric energy density
Grav. and vol. energy density of various electrochemical storage systems
Fraunhofer Battery Alliance
Material & Cell
Li-S cells and Li2S-Si cells
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
Material & Cell
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
High requirements for sulfur cathodes
Fraunhofer Battery Alliance
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!
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
Material & Cell
► High specific capacity through tailored
cathode
Sulfur / carbon nanocomposite for cathodes in Li-S
batteries
Dryfilm-process for electrode production
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
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)
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
Punching
Lamination
Ultrasonic welding
Heat sealing station
Electrolyte addition
Fraunhofer Battery Alliance
Material & Cell
Process technologies
Coating
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
System
© Fraunhofer Allianz Batterien
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
Fraunhofer Battery Alliance
System
© Fraunhofer Allianz Batterien
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)
Fraunhofer Battery Alliance
Test
© Fraunhofer Allianz Batterien
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
Fraunhofer Battery Alliance
Simulation
© Fraunhofer Allianz Batterien
Fraunhofer Battery Alliance
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
© Fraunhofer Allianz Batterien
Fraunhofer Battery Alliance
► www.batterien.fraunhofer.de/en.html
Dr. Kai-Christian Möller
Fraunhofer Battery Alliance
Fraunhofer-Gesellschaft Headquarter
Corporate Business Development
Hansastraße 27c, 80686 München, Germany
phone: +49 89 1205 - 4417
email: kai-christian.moeller@zv.fraunhofer.de
https://de.linkedin.com/in/kaichristianmoeller
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