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Ultracapacitors • Microelectronics • High Voltage Capacitors

IQPC3rd International Congress Advanced Battery TechnologyJune 22nd - June 25th

Ultracapacitor – a Dynamic and Efficient Power StorageDevice for Automotive

2

§ Introduction§ Storage Devices

§ Ultracapacitor§ Ultracap History

§ Technology & Design

§ Ultracapacitors in Automotive§ Applications

§ Micro & Mild Hybrid System

§ Combination of Ultracapacitors and Batteries

§ Back-Up

Content

3

Dynamic Ultracap Compared to Other Storages

4

Lead Acid BatteryLow cost, low lifetime

NiMH-BatteryOverall goodperformance

Li-Ion-BatteryHigh performanceHigh cost

UltracapacitorCycle life, high efficiency

Energy Density Power Density

Efficiency

Lifetime

Costs

Safety 01

23

45

Reference: Prof.Dr. Haag, Hochschule Esslingen, Germany

Storage Technologies

5

Ultracapacitor Technology

• Basic material: Carbon

– Carbon is one cost driver of Ultracaps

– Raw material: Coconut shells (among many others…)Activated carbon powderActivated carbon powder

BOOSTCAP® Electrode

Electrode

fabrication

Coating

Rolling/Kneading/

Pasting

Grind

Activation

6

The Pacific Connection

From here ..From here ..From here ..From here .. ………… to thereto thereto thereto there

The Coconut Connection

7

Mature Product?

20 years of Product Innovation

Ultracapacitors >650F

8

The 4 year long road …

9

Major Milestone

1,000,000th

large Cell *

December 2009

* large = >650F

10

Technology comparison (LFP)

Capacity Fade upon Cycling

0

20

40

60

80

100

120

1 10 100 1000 10000

Number of cycles

Capacity (%

vs. nom

inal)

Lithium Iron Phosphate Chemistry

4.2Ah nominal

10C in discharge (240A)

3.6C in charge (15.6A)

Temperature +25°C

Capacity Fade upon Cycling

0

20

40

60

80

100

120

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Number of cycles

Capacity (%

vs. nom

inal)

Lithium Iron Phosphate Chemistry

4.2Ah nominal

10C in discharge (240A)

3.6C in charge (15.6A)

Temperature +25°C

11

Technology comparison (EDLC)

Capacitance Fade upon Cycling

0

20

40

60

80

100

120

1 10 100 1000 10000 100000 1000000 10000000

Number of cycles

Cap

acit

an

ce (

% v

s.

no

min

al)

BCAP650

650F/2.7V nominal

100A in discharge

100A in charge

Temperature +25°C

Capacitance Fade upon Cycling

0

20

40

60

80

100

120

0 200000 400000 600000 800000 1000000 1200000 1400000 1600000

Number of cycles

Cap

acit

an

ce (

% v

s.

no

min

al)

BCAP650

650F/2.7V nominal

100A in discharge

100A in charge

Temperature +25°C

12

Technology comparison

Capacity/Capacitance Fade upon Cycling

0

20

40

60

80

100

120

1 10 100 1000 10000 100000 1000000 10000000

Number of cycles

Ca

pa

cit

y (

% v

s.

no

min

al)

Lithium Iron Phosphate Chemistry

4.2Ah nominal

10C in discharge

3.6C in charge

Temperature +25°C

BCAP650

650F/2.7V nominal

100A in discharge

100A in charge

Temperature +25°C

13

Energy Throughput Evolution for LFP Battery and BCAP650(based on constant nominal values)

0

100

200

300

400

500

600

700

800

1 10 100 1000 10000 100000 1000000 10000000

Number of Cycles

Cu

mu

lati

ve

En

erg

y (

kW

h)

Lithium Iron Phosphate Chemistry

4.2Ah nominal

10C in discharge

3.6C in charge

Temperature +25°C

BCAP650

650F/2.7V nominal

100A in discharge

100A in charge

Temperature +25°C

Technology comparison (LFP vs EDLC)

X 13

14

Mature Application

12,000 turbines in the field

Up to 5 years in operation

From cold climate condition to warm weather locations

Operating up to 8,500 hrs/year (life of car= 6,000hrs)

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Mature Application

1,500 + buses in the field

Up to 10 years in operation

Various climates

Hybrid, trolley, all electric variants

Fare generating!!!

Variety of modules

• Large 125V

• Medium 48V

• Smaller 16V

• Custom modules

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Mature Application

Global application

24/7/365 type of operation

Various climates

High cycling

Dramatic emission & noise reduction

Variety of modules

• Large 125V

• Medium 48V

• Smaller 16V

• Custom modules

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Mature Application

Global application

High reliability Back-up power

Instant bridge power (1 – 60 sec)

Voltage sag compensation

Buffering large momentary in-rush

or power surges

Variety of modules

•Medium 48V

• Smaller 16V

• Custom modules

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Service

ExoticIndustrial

Auto

New markets

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Consequence of Continuous Improvement – K2-Cell

MC-Cell K2-Cell

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Automotive

21

1

UC

1000

UC in combination with Batteries / Fuel-cells, etc.

Electric Power in kW

10 100

10

100

1000

10.000

100.000

Ele

ctr

ic E

ne

rgy p

er

cyc

le i

n W

h

10sec20sec

2 min

120 min

Mild Hybrid + Comfort Features

20 min

Mild Hybrid

StrongHybrid

Full Hybrid

bus

Electric vehicle

Plug In Hybrid

Micro Hybrid

Micro Hybrid:

• <2kW

• 310F – 2000F cells

Mild Hybrid

• <1kWh; 10àààà 15kW

• 7% to 12% FE

• 2000F-3000F cells

Full Hybrid Cars

• 2...20kWh

• 80kW àààà 200kW

• >20PCs of >=3000F cells

Hybrid Markets and Trends

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Use of UC in Automotive Systems

Micro Hybrid Systems

2nd generation Stop/Start :

• Engine starting

• Start-Stop

• Recuperation

• Passive Boost

Boardnet Stabilisation:

• Electric Water Pump

• Electrical Fan

• Electric A/C

• Electro-Mech.Valve Actuation

• Electric Supercharger

• Electric Roll Stabilization

• Electric Heating

• Electric Defrost

• Entertainment Systems

• Retractable Roof

Decentralized Power Supply:

• Electric Brakes

• Electrical Steering (4 Wheel)

• Electric Active Suspension

• Door Close/Lock

Mild Hybrid Sstem:

• Limited Electric Drive

• Engine starting

• Start-Stop

• Recuperation

• Active Boost

2010 2012 2014

<14V 14V >20V

Cell Size:310-2000FE>5Wh/kg

Cell Size:310-1200FE~5Wh/kg

Cell Size:1200-5000FE>15Wh/kg

P=<0.8kW

P=<2kW

P= 10-15kW

P= <2kW

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Potential through Reduction of Parallel Branches

40Wh:At EOL20: N_40_20%_3000F/2.7V=192/157.9=1.2 => 2 stringsAt EOL20: N_40_20%_3000F/3.0V=192/176.4=1.1 => 2 strings At EOL20: N_40_20%_5000F/3.0V=192/294.1=0.6 => 1 stringAt EOL20: N_40_20%_1250F/4.2V=192/104.1=1.8 => 2 strings

60Wh:At EOL20: N_60_20%_3000F/2.7V=288/157.9=1.8 => 2 stringsAt EOL20: N_60_20%_3000F/3.0V=288/176.4=1.6 => 2 stringsAt EOL20: N_60_20%_5000F/3.0V=288/294.1=1.0 => 1 stringAt EOL20: N_60_20%_1250F/4.2V=288/104.1=2.7 => 3 strings

80Wh:At EOL20: N_80_20%_3000F/2.7V=384/157.9=2.4 => 3 stringsAt EOL20: N_80_20%_3000F/3.0V=384/176.4=2.2 => 3 stringsAt EOL20: N_80_20%_5000F/3.0V=384/294.1=1.3 => 2 stringsAt EOL20: N_80_20%_1250F/4.2V=384/104.1=3.7 => 4 strings

50%!

33%!

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Ultracapacitor Lifetime Influences

Key Influencers of Reported Cycle Lifetime

• Cycle chosen• Maximum Voltage

• Minimum Voltage

• Duty Cycle and time at maximum voltage

• Environmental Conditions of the lifetime characterization

• Temperature and time at temperature

• Humidity

• Current • Reported in both charge and discharge

• Time dependent effects

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End Of Life = Service Life

We must talk about service lifetime of ultracapacitors –

not failure lifetime!

– Definition – service life is the period of useful lifetime before a predetermined end point is reached (interpreted from the ASTM definition of durability and serviceability).

– Failure lifetime implies parts have run to failure which is not generally achievable due to the long expected life.

– Must use accelerated lifetime models to predict service life.

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Outlook

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Conclusions

- Mature markets are expanding

- New markets are popping up

- Product line-up is evolving to meet wave of demand

- Auto applications are real

Ultracapacitor Technology is well proven

- not just by Maxwell

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Thank you very much for your attention!

Contact Info: Benoît Soucaze-Guillous

E-mail: bguillous@maxwell.com