SBIR Phase I: Cost-Effective Manufacture of High-Power Li-Ion Batteries for NGV

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This Small Business Innovative Research (SBIR) Phase I project proposes a unique rolled-ribbon cell for a Lithium-ion battery that has inherent cost advantages for a NGV FreedomCar compact pulse-power application. It can meet the cost requirements and deliver thousands of pulses and recharges. The battery is formed by stacking large capacity (5-10Ah), sealed, 125mm diameter, button cells to optimize power capability. The battery design projects power at 2-4kW/kg and power density at 7.5kW/liter similar to a ultracapacitor, with 20 times greater specific energy at 70-90Wh/kg . Of particular importance to high-power battery, the rolled-ribbon design overcomes safety concerns by its unique internal heat dissipation. Perpendicularly oriented electrode foils remove heat from the electrode interface to the disc-cell hardware without crossing Celgard separator. The high temperature stability of Lithium ion will be enhanced with a flame retardant electrolyte additive. The NGV FreedomCar can anticipate a viable safe, high power Li-ion battery using the rolled-ribbon cell design, that is more compact and cost-effective than ultracapacitors or other high-power batteries. Improved performance and temperature stability for Li-ion battery can enhance prospects for the civilian hybrid vehicle market. Gasoline savings will reduce air pollution and oil imports.