Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and...

IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary

Midsize Lithium Ion Battery PackPatrick Montalbano

© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium

Introduction

Design, Construction, and Applications of a Midsize Lithium Ion Battery Pack

Patrick Montalbano, KC2SAE

Rochester Institute of Technology, 2012College of Applied Science and Technology

Mechanical Engineering Technology



Battery Technologies

Lead Acid (Pb)•Very low cost, mass produced, highly scalable•Worst energy density: very heavy

Nickel Cadmium (NiCd)•Low cost, mass produced•Poor energy density, limited scale

Nickel Metal Hydride (NiMH)•Good energy density, good shelf life•Limited current

Lithium Ion (Li+)• High Energy density: lightweight• High cost, additional safety considerations

Energy Density




Form Factor

Rectangular Cells• Customized Shape• IC Protection

Cylindrical Cells• Standardized• Flexible Platform• Highly Scalable• Hardware Protection• Limited in Size

Model 18650• Highly Commercialized• Commodity Pricing

• Require additional voltage/circuit protection •Constant current/constant voltage charging

IntroductionBattery Technology

Form FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary

Nissan Leaf Battery



Lithium Applications

Integrated into personal electronics

Lithium is well suited for portable electronics:• Size Limitations• High power demand• Lightweight• Rechargeable

All-electric EV’s




Battery Backpack

Battery On-Frame Backpack

To be used for extended use of Amateur (ham) radio on hikes-Easily adaptable in military or commercial applications

Battery




Flat Midsize Pack

•Easy to Carry• 5.5 lbs

•Common voltage (14.4v)•High Capacity• 354 Wh

•Highly configurable

An innovative solution for midsize powered devices

• Carbon Fiber Composite• Load bearing

• Sealed against water/dust

•1.75” Overall Thickness

IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery Backpack

Midsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary



“Level 1” Assembly

Level 1: Parallel assemble providing cell level over-current protection

Level 2: Series elements producing operating voltageLevel 3: Power Control Board to load




Mold Making

1. Plug constructed from wood is 1:1 representation of

finished part

2. Fiberglass mold cavity is inverted for carbon fiber layup

IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” Assembly

Mold MakingLayupPrototypeSummary



Layup

3. Carbon reinforced epoxy laminate is compacted using vacuum

4. Part is removed and finished

IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold Making

LayupPrototypeSummary



Final Prototype

•(2) Anderson Power Pole terminals

•State of Charge ‘fuel’ LED gage

•Developer pass-through DB-9 (voltage and 1-wire

temperature)

Shown with UHF/VHF transceiver

IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayup

PrototypeSummary



Project Summary

Special thanks to battery cell sponsor, Tesla Motors.

IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototype

Summary

•Packs can be built using rejected automotive cells

Development Expenditures

14.4v, 22Ah @ 30A354 Wh13 x 9 x 1.75 inches5.5 lbs

Battery Specs.

Composites & tooling; $300Electrical connectivity & PCB; $80

Cells; $150 - $240Housing & hardware; $130

Commercialization Estimate

January 5th, 2012

Jaunary 6th, 2012

January 12, 2012

January 20th, 2012

February 1st, 2012

February 2nd, 2012

February 3rd, 2012

February 4th, 2012

February 10th, 2012

February 11th, 2012

February 17th, 2012

February 23rd, 2012

Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and...

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