Axeon Technologies

2. Lithium Ion Batteries :
Going the Distance
Axeon Technologies Ltd, Dr Allan Paterson 17th Feb 2011

3. Plan
Introduction to Axeon
Products - Automotive
Lithium Ion Cell Chemistry
Currently Available Technology
3
Future Developments?
Role of Nano-technology
R&D Projects / Collaborations
Case Study

4. Axeon : The Company

5. About Axeon
Axeon designs and manufactures advanced
lithium-ion battery systems for a variety of end
market applications:
Automotive (electric and hybrid vehicles)
Energy storage
Cordless power tools
Axeon Confidential 5
Mobile products
Europe’s largest privately-owned independent
lithium-ion battery systems supplier,
processing over 70 million cells a year

6. Axeon Locations
150 professional and 300 production staff
Axeon Confidential 6
Current locations:
UK, Dundee – HQ, Engineering, automotive production
UK, Birmingham – Sales and engineering office
Poland – volume production, planned automotive production
Germany – European business development, strategic purchasing
Switzerland – Small pack engineering
Italy – Sales office
US, Detroit – Sales Office
Asia - strategic purchasing

7. Axeon’s automotive experience
Electric urban delivery
vehicle: producing in
volume for British
manufacturer
Over a million vehicle
miles driven since 2007 =
Axeon is developing
smaller lighter batteries
using innovative battery
technology
Designing and developing
PHEV packs for JLR
Axeon Confidential 7
20MW of batteries shipped
Volume production; conversion
of Peugeot vehicles for the
leading British vehicle
converter. Range includes cars,
people carriers and vans
HEV sports car: developing
leading-edge technology for
premium European
manufacturer

8. Product Areas
Energy Storage
Micro-generation (~10-15KWh)
Community energy storage (25-100KWh)
Utility level (MW)
Niche solutions (e.g. hybrid ferries)
Power Tool
Axeon Confidential 8
High volume, low cost manufacture
A-rated supplier to Bosch
Mobile Power
Solutions for applications that require advanced
electronics
Bespoke solutions

9. Complete solution
Axeon Confidential 9
Cell sub
component
production
and test
Cell
Electroactive
“Ingredients”
e.g. Coatings
Cell Raw
Materials/process
e.g. Lithium
Carbonate
Cell
Assembly
and test
Battery
Assembly
and test
Battery pre
conditioning
Battery Supply Value Chain
Axeon Value Proposition
Responsible
Support
Inform

10. Partnership Strategy
Technology
Academic research
Cell suppliers (see next
Axeon Confidential 10
slide)
Governments
Participation with
relevant industry
bodies

11. Our cell partnerships are key
Axeon, which is cell-agnostic, has
relationships with all major suppliers of high
capacity Lithium cells
Local staff & agents assigned to cell audit
All suppliers subject to on-site quality audits
All cells subject to in-house qualification
Axeon Confidential 11
Verification of supplier specifications
Environmental testing
Cycle testing
Abuse testing

12. Lithium Ion Cell Chemistry

13. “Rocking chair” Lithium Ion Battery
Negative Electrode Electrolyte Positive Electrode
Axeon Confidential 13
Graphite Li+ ions
& Separator
LiCoO2
Issues : Expensive, Toxicity, Cycle life, Power
Research concentrated on replacing LiCoO2
LiMn2O4
LiFePO4 [LFP] / LiNi1/3Mn1/3Co1/3O2 [NCM] / Other?

14. Cell Chemistry - The Challenges
Future Development Requires…..
Reduce cost – materials (raw and synthesis)
Improve safety – short circuits, thermal runaway.
Cycle life – 1000s for EV, cycle life 10,000s for HEVs
Calendar life - 10 years (transport)
Axeon Confidential 14
Power Density – HEV, PHEV
Energy Density – PHEV, EV, load leveling
Materials Chemistry Challenges

15. Main contender cell chemistries
Cell level
Energy
density /
Wh/kg
Cell level
Energy
density /
Wh/l
Durability
Cycle life
(100 %
DoD)
Price
$/Wh
(Estimate)
Power
C-rate
Safety
Thermal
Runaway onset
LiCoO2 170-185 450-490 500 0.31-0.46 1C 170oC
LiFePO4
EV/PHEV
90-125 130-300 2000 0.3-0.6 5C cont.
10C pulse
270oC
LiFePO4
HEV
80-108 200-240 1000 0.8-1.2 30C cont.
50C pulse
270oC
Axeon Confidential 15
NCM HEV 150 270-290 1500 0.5-0.58 20C cont
40C pulse
215oC
NCM EV/PHEV 155-190 330-365 1500 0.5-0.58 1C cont
5C pulse
215oC
Titanate vs
NCM / LMO
65-100 118-200 12000 1-1.7 10C cont.
20C pulse
Not susceptible
NCA 95-120190 280 1000 0.45-0.6 4C cont
10C pulse
200oC
Manganese
Spinel EV/PHEV
90-110160 280 1000 0.45-0.55 3-5C cont 255oC

16. Example - Lithium Iron Phosphate
LiFePO4 remains attractive for Automotive
Electrochemical Performance
Cycle Life / Power capability
Enabled by new Nano-materials
Nano-particulate agglomerates – Fast diffusion
Doped / Carbon coated to make better conductor
Axeon Confidential 16
Safety
No oxygen release
Avoid thermal runaway
Issues
Cost / cycle life for Ultrahigh Power application

17. Cell Chemistry - Future Developments
Materials Chemistry Challenge New Advanced Battery Materials
High Power Density HEV – Future? “Nano-Materials”
High surface area – Internal = Meso-porous materials
External = Nano-tubes/wires
Nano-rods/
wires
TiO (B) C-Coated
Mesoporous LiMn2O4
Next generation nano-phosphates – Li-[Transition Metal]-Phosphates {Mn/Co/V}
Axeon Confidential 17
Hurdles– cost, energy density
Advanced Surface coatings SiO2 , RuO2, etc
20nm
2LiMnPO4

18. Alternative Battery Chemistries
High Energy Density EV – Future ?
Lithium Transition Metal Oxide Cathodes
E.g. Layered xLi2MnO3• (1-x)LiMO2
An electrochemically inactive (Li2M'O3) component is integrated with an
electrochemically active (LiMO2)component to provide improved structural and
electrochemical stability.
High energy density, High cell voltage, Long cycle life.
Alloys of Li with Silicon (Si) or Tin (Sn)
Nexilion, Sony Corporation (C/Sn/Co))
Amorphous Alloy - Very high energy density / capacity
However very large volume expansions that need to be accommodated
Limited size/capacity cells produced commercially so far
Axeon Confidential 18
New Improved Electrolyte - Higher operating voltages
The use of high V cathodes limited by the solvent oxidation 4.4 V vs. Li/Li+.
Requires new electrolytes Ionic liquids show most promise.
Poor conductivity limits rate capability.

19. Lithium-Air Batteries – High Energy Density?
Potentially 10 x Energy Density compared to current Li-ion tech
Use of porous cathode, small % catalyst allows rechargeability
Hurdles – cycle life, rate capability.
“Battery 500” project : IBM, UC Berkeley and five US National Labs
Electric vehicle battery that gives up to 500 miles per charge
IBM believes its nano-scale semiconductor fabrication techniques can
Axeon Confidential 19
increase the surface area of
the lithium-air battery's
electrodes by 100 times.
achieve range goal
2 year feasibility study

20. Lithium-Air Schematic
Dispense with intercalation cathode use O2 from air!
Li2O2
Dis-charge
20
Li anode Electrolyte Composite porous cathode
O2
charge
Li+

21. Lithium-Air Schematic
Dispense with intercalation cathode use O2 from air!
Li2O2
Charge
21
Li+
O2
Li anode Electrolyte Composite porous cathode

22. Li-Air – The Challenges...
Many Issues Remain :
Cyclability
Oxygen Selective Membrane , Suitable Electrolyte,
Recharge Potential / Hysteresis
Rate Capability
Axeon Confidential 22
Electrolyte stability
How long to commercialisation....10years?

23. Cell Chemistry – Commercial Availability?
Conversion rxn, e.g Li/Fe3F3
Secondary Zn-Air
(M=Co,V etc)
Li / Sulphur
LiFe-Sulphides/Silicates
Aerogel Li Vanadates
Li - Nano-silicon / Tin Alloy + high V TMO
Li4Ti5O12 Anode + Mn based Nano-titanate anode + Adv 5V Mn based
LiMnPO4 and LiFexMnyPO4 Na/Li3[M](PO4)2F3
Secondary Li-Air
Ionic liquid
Electrolyte
Relative Capability
2015-
2020+?
23
Q4
2013
LiNi1/3Mn1/3Co1/3O2 LiwMnxNiyCozO2
LiMn1/2Ni1/2O2
LiMn2O4
Q1
2011
Q1
2012
Q2
2012
Q3
2012
Q4
2012
Q1
2013
Q2
2013
Q3
2013
Q2
2011
Q3
2011
Q4
2011
LiFePO4
LiCoO2
LiFePO4(Doped or Coated with RuO2/TiO2. etc)
LiNixCoyAlZO2
Li2MnO3•LiMn1/2Ni1/2O2 Doped Co,Al,Ti etc
Mn Based Nano+Mesoporous
Li2MnO3•LiMn1/2Ni1/2O2
Axeon 2010 Confidential

24. Possible current/future cell options
Short Term Medium Term Long Term
City / EV LFP / LiMn2O4
Pouch
NCM / TMO
Pouch/Can Silicon/Tin-alloy
Rechargeable
metal air
systems
Urban Delivery
EV
LFP/NCM NCM / TMO
Pouch/Can
PHEV LFP/NCM
Pouch
NCM / TMO
Pouch/Can
24
Performance
HEV
Small Format
LFP
Small Format
LFP
Advanced Nano-
Material
electrodes
Axeon 2010 Confidential

25. RD Programs

26. Relative theoretical energy densities
Dynamite = 1375 Wh/kg
Wood = 4000 Wh/kg
Petrol = 12000 Wh/kg – highly energy inefficient
Axeon Confidential 26

27. Example Axeon Development Projects
OR
Future Project (C)
Axeon Confidential 27
TSB Project (A)
TSB Project (B)
Cells (D)
Development roadmap programmes Consortia Status
TSB (A) - Pouch cell NCM/BMS Axeon, Allied Ricardo Awarded
TSB (B) - TMO/Si Alloy Axeon, St Andrews University, Nexeon, Ricardo Awarded
Future project (C) - Li-Sulphur battery Oxis Energy, Axeon others TBD Planned
Cells (D) Testing sample cells now Envia Systems Ongoing

28. Technology Strategy Board RD Project (A)
“Advanced High Energy Density Battery and Next Generation BMS”
+ +
+
Next Generation, Increased
Functionality, Smaller, Lighter,
Cheaper, BMS
For a 30kWh EV battery, cells alone :
NCM
Chemistry
Pouch Cells
Small City Car +
Weight reduced by ~28%compared to LiFePO4
Volume reduced by ~ 47%
Axeon Confidential 28
cells alone
Weight / Volume reduction
NCM pouch cells, up to 340Wh/l and 170Wh/kg. Combined with a smaller/lighter Ricardo BMS should
prove to be a highly efficient technical solution.
Increased performance
High efficiency, via adaptive BMS capable of dynamic active and passive balancing.

29. Project Plan
Work Package Q4 Q5 Q6 Q7 Q8
Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun
Bench Top
Software
“A” Design
“A” Vehicle
“A” Build / Test
NOW
Axeon Confidential 29
“B” Design
“B” Vehicle
“B” Build / Test
“B” Vehicle Test
“A” Certification

30. TSB (B): Li-M-Si-O / Si Alloy battery for PHEV
The University of St Andrews
Si based alloy based next generation of negative electrodes
High volumetric and specific energy
Problem – particle fracture due to large volume expansion
Fix – Accommodate stress strain of volume expansion via nanostructure
Coupled with Li-TM-Silicate positive electrode
Axeon Confidential 30
Overall = High energy density 250 to 300 Wh/kg, low cost.
PHEV Battery Pack construction
Cell Chemistry characterisation
BMS calibration
Pack Engineering and Construction
Further Battery Management System Development
Smaller, Lighter, Cheaper BMS

31. Project Plan
Q2
10
Q3 10 Q41 10 Q1 11 Q2 11 Q3 11 Q4 11 Q1 12 Q2 12 Q2 12
Cathode
Development
Anode
Development
Scale Up
Cell Fabrication
Axeon Confidential 31
BMS
Development
Initial BMS
Testing
Pack
Engineering
Chemistry
Characterisation
Testing /
Validation Where We Are Now.
= = = =

32. St Andrews - Technology
Positive electrodes based on Fe highly attractive (cost and safety).
LiFePO4 operates at 3.4V vs. lithium now used in commercial cells.
Electrochemical activity in Li2FeSiO4 reported. (3V vs Li)
Cheaper raw raw materials.
Difficult to prepare single phase, and structural change on cycling
Poor e- conductivity (analogous to phosphates) and room temp performance
Mn highly attractive: higher potential than Fe-Silicate (~ 4V)
possibility of removing more than 1 Li (Mn4+ more stable than Fe4+) = High Capacity = High Energy
Axeon Confidential 32
Remains Inexpensive and safe
Structures related to LISICON
(LIthium SuperIonic CONductor)
materials with all cations tetrahedrally
coordinated by oxygen.

33. St Andrews - Technology
Alternative synthetic routes give single phase: (e.g. hydrothermal)
Best reported electrochemistry (50oC and low rate)
All require small particles and carbon coating to achieve satisfactory electrochemical performance
This structure type adopted by numerous other transition metals including Mn, Co
Mn highly attractive: higher potential than Li2FeSiO4 (~ 4V)
Remains Inexpensive and safe
possibility of removing more than 1 Li (Mn Mn4+ more stable than Fe )
Fe4+)
33
20 30 40 50 60 70 80 90
350
300
250
200
150
100
50
0
Intensity
2q / degrees (FeKa1
)
0 2 4 6 8 10 12 14 16 18 20
140
120
100
80
60
40
20
0
Capacity / mAhg-1
Cycle number
LISICON framework is very flexible – contains interstitial cation sites
Offers a wide range of possible substitutions e.g. Li2+2xM1-xSiO4
Axeon Holdings plc 2009 Confidential

34. Nexeon - Technology
Up to 9x Gravimetric, 3 x Volumetric Energy Density
Silicon Fibres robust to volume change
Axeon Confidential 34
Form pillars on particles without harvesting
Pillared Particles Hedgehog particles
Lower cost than graphite

35. Performance
Tune Capacity (mAh/g) by varying pillar : core ratio
Axeon Confidential 35
Optimised Electrochemical Performance
Step change energy storage 300Wh/kg

36. Conclusions

37. Summay
Axeon has extensive real world experience of EV and HEV
batteries including a range of cell chemistries and Battery
Management Systems.
Axeon is “Cell Agnostic” but well connected to cell vendors and
participating in joint research and development programs.
Main chemistries and improved derivatives will be around for
37
some time, but new advanced cell chemistries are rapidly
emerging making a step change in energy storage a possibility.
Nano-Technology - Enabler and playing increasing role.
Axeon has a future view of these rapidly developing
technologies backed up by real research and development
programs and real end customer development projects.
Axeon 2010 Confidential

38. Axeon
Nobel Court, Tel: +44 (0)1382 400040
Wester Gourdie, Fax: +44 (0)1382 400044
Dundee, DD2 4UH,
Scotland, UK www.axeon.com