In Pursuit of More Energy:

Equipping our Armed, Security and

Emergency Services

Tony JefferyTony Jeffery

July 2003July 2003

l History of Secondary Military Batteries

l The Lithium-ion Advantage

l Military Drivers

l The Evolution of Intelligence & Impact on Logistics

l The Search for More Energy & the Digital Battlefield

Agenda

The Pursuit of More Energy: Equipping Our Armed,Security and Emergency Services

ll 1799 First Battery1799 First Battery

ll 1859 1859 First Lead Acid BatteryFirst Lead Acid Battery

ll 1898 1898 First Commercial BatteryFirst Commercial Battery

History of Military Batteries

First Battery in the armed forcesFirst Battery in the armed forcesll 19101910

History of Military Batteries

ll 1970 NiCd adapted for military use1970 NiCd adapted for military use

PRC351-1 (Clansman)

History of Military Batteries

ll 1970 NiCd adapted for military use1970 NiCd adapted for military use

ll 1979 AEA Lithium-ion materials patented1979 AEA Lithium-ion materials patented

History of Military Batteries

ll 1970 NiCd adapted for military use1970 NiCd adapted for military use

ll 1979 AEA Lithium-ion materials patented1979 AEA Lithium-ion materials patented

ll 1994 AEA grants Licenses1994 AEA grants Licenses

History of Military Batteries

ll 1970 NiCd adapted for military use1970 NiCd adapted for military use

ll 1979 AEA Lithium-ion materials patented1979 AEA Lithium-ion materials patented

ll 1994 AEA grants Licenses1994 AEA grants Licenses

ll 2002 AEA Lithium-ion BOWMAN2002 AEA Lithium-ion BOWMAN

(replacement for Clansman batteries)(replacement for Clansman batteries)

• Norway Jan-Mar 02

• 6 day patrol

2 Li-ion vs 4 Ni-Cd(2.7 kg vs 13.9 kg)

• Base station radio trialLi-ion : 30 hrs at -32oCNi-Cd: no performance

Li-ion Clansman Arctic Field Trials

Operational Advantages

• Operational benefits confirmed:

Li-ion Clansman Trials – 3 Para (16 Air Assault Brigade)

Operational Advantages

Ø Sept – Oct 02: 10 Day Eagle Lift Exercise

Li-ion NiCd

— LIFE: 48 hours Vs 18 hours

— WEIGHT: 4kg Vs 20.8kg

— Space savings

— No conditioning required

— Rapid deployment due to instant availability

The Cell Company

• Location:

• Formed:

• Purpose: Manufacture of HighTechnology Li-ion Cells

Thurso, Caithness, Scotland

1998

l Joint Venture:

60%

18%

22%

The Cell Company

Manufacturing Equipment

• Coating

• Calendering

• Winding

• Electrode fabrication control

- coating to ±1.5% by weight

- calendering to ±1% by thickness

• Jelly roll winding control

- electrode alignment to ±1%

over 6 feet length

Manufacturing Control

D Cell Features

Energy 5.6Ah

Cycle Life 1,100

Safety Meets UN TransportationRegulations

TemperatureRange

+75ºCto

-51ºC

Cycle Life

Cycle Life

0102030405060708090

100

0 200 400 600 800 1000 1200

Cycle Number

Cap

acit

y (%

D1)

C/2.5 Rate Discharge

ICR346002 Amp Discharge

2.0

2.5

3.0

3.5

4.0

4.5

0.0 1.0 2.0 3.0 4.0 5.0 6.0

Capacity (A h)

Cel

l V

olt

age

(V)

+55°C +20°C -30°C -40°C

2C Rate Discharge

ICR3460010 Amp Discharge

2.0

2.5

3.0

3.5

4.0

4.5

0.0 1.0 2.0 3.0 4.0 5.0 6.0

Capacity (A h)

Cel

l V

olt

age

(V)

+55°C +20°C -20°C

12A –40oC Discharge

0

1

2

3

4

0 5 10 15 20 25 30 35

Time / min

Cel

l Vol

tage

/ V

0

2

4

6

8

10

12

Cur

rent

/ A

9151 9152 9153

9151 9152 9153

Currents

Voltages

4 Pressure vent, shut-down separator

4 Internal fuse - over-current protection

4 Safety cap options - over-charge and

re-settable over-current

4 Passes all new UN transportation tests

Safety Features

Military Application

• Li-ion D cell in volume production:

− 5.6Ah (390Wh/l, 155Wh/kg)

− 1,100 cycles

− -400C operation

• Selected for major military application -

Bowman

BOWMAN

l To provide a communicationssystem until at least 2026

l 50,000 radios &25,000 computer terminals

l Deployment on:– 18,000 vehicles

– 160 ships & 300 aircraft

l Will be used by 60,000servicemen

BOWMAN Requirements

BOWMAN

Customer, prime & sub-contractor relationships

MoD (UK)

General Dynamics Ltd (UK)

Harris(HF radio)

ITT(VHF radio)

Litton(Data term)

Cogent(KVMS)

AEAT(Batteries

& chargers)

AGM(Li-ion cells)

l AGM cell is a keycomponent for HF &VHF radio batteriesthat require

– -40C operation

– -50C storage

– high cycle life

l Data terminals & KVMSuse small cells

BOWMAN secondary batteries - Requirements

BOWMAN

Military Drivers

• Even more energy

• More intelligence

• Cost & logistics benefits

• Environmentally friendly

Even More Energy

AEA TARGET

And beyond - fuel cellsSTAGE 3

Further improvement inperformance through betteranode materials

STAGE 2

STAGE 1 Improved performance throughbetter cathode materials

Military Drivers

• Even more energy

• More intelligence

• Cost & logistics benefits

• Environmentally friendly

More Intelligence

Today’s Electronics Technology

Ø Fuel Gauge

Ø Safety and BalancingCircuitry

Ø SMBus Interface

STANDARD

More Intelligence

l Capability:

Ø Lower power circuitry

Ø Ruggedised SMART data acquisition systems

l Benefits:

Ø Extended shelf life

Ø Increased operational life

Ø Battery usage profiling – improvedlogistics

Military Drivers

• Even more energy

• More intelligence

• Cost & logistics benefits

• Environmentally friendly

Costs & Logistics

• Significantly improved logistics

− Warehousing

− Maintenance

• Significant reductions in procurement &overhead costs

Military Drivers

• Even more energy

• More intelligence

• Cost & logistics benefits

• Environmentally friendly

Environmentally Friendly

Lithium-ion recycling

How could this impact on you?

Successful pursuit ofmore portable energy& associatedintelligence will be akey military strategicadvantage

In Pursuit of More Energy:

Equipping our Armed, Security and

Emergency Services

Tony JefferyTony Jeffery

July 2003July 2003