International Battery is developing innovative manufacturing processes for large format lithium ion batteries using water-based slurries. They are implementing lean manufacturing and process validation to achieve efficiency. Their goal is to engage customers in product development and provide robust metrics to determine battery life cycle. International Battery aims to be the first US manufacturer of large lithium ion batteries using chemistry-agnostic and scalable manufacturing processes.

1. CHARGED 2020
The Global Energy Storage Forum 2010
30 June-1 July, San Diego-USA
Driving sustainable innovation along the energy storage and
smart-grid value chain
International Battery
World Class, American Made
Antonio Reis

2. International Battery
World Class. American Made.
Antonio Reis
June 2010

3. Value proposition in the production of Energy
Storage Systems:
Implementing a lean manufacturing system for large format lithium ion batteries.
– Implementing process validation to manufacturing processes to achieve
efficiency, consistency and control.
– Developing innovative manufacturing processes that provide robust key
indicators to determine life cycle of energy storage systems .
– Engaging customers in the product development from product
requirements document through manufacturing.
June 2010
2

4. The Company
• Company Overview
– International Battery is the first manufacturer of large-format
lithium-ion battery cells in the United States.
– International Battery is the first United States lithium ion
developers to used water based slurries in the manufacturing
process.
June 2010
3

5. The Company
• Company Overview
– Chemistry agnostic manufacturing processes.
– Proven, rapidly scalable U.S. manufacturing platform providing
speed to market.
– Validated manufacturing processes.
– Lower CAPEX
– Lower OPEX
– Diminished waste stream.
June 2010
4

6. The Company
Markets: When Energy Matters
 Stationary
 Distributed Energy Storage (DESS/CES)
 Bulk Energy Storage (BESS)
 UPS and Telecom
 Military / Defense
 Tactical Vehicle APU, Silent Watch
 Transportation / Propulsion / Mobile
 Hybrid Electric/Electric Vehicles
 Utility & Specialty Platforms
 Auxiliary Power Units (APU)
June 2010

7. Our Approach to Manufacturing Development
• Formulations
• Manufacturing/Product Development
• Quality
• Battery System Solutions
June 2010

8. Our Approach to Manufacturing Development
• Formulations
– Formulation optimization leveraging use of water based
slurries.
• Presently two validated chemistries: LFP and NCM
• Several chemistries evaluated.
– Development of chemistry agnostic processes.
June 2010

9. Our Approach to Manufacturing Development
• Manufacturing/Product Development
– Validation of designs that satisfy “applications specific”
requirements from the customer point of view.
– Identification and characterization of critical process
parameters.
– Define and achieve narrow process limits.
– Create manufacturing processes that can be deployed
anywhere in the world.
June 2010

10. Our Approach to Manufacturing Development
Quality
• Baseline
– ISO 9001 certification
– UN certification of the large format cell products
• Beyond ISO
– Definition and resolution of product and mfg process critical issues.
– Develop validated design control from product development to single
process validation.
– Economically feasible visibility of all business processes from
material sourcing to invoice processing thru a robust “Quality
Management System”.
June 2010

11. Our Value
• Water Based Electrode Slurries
– Low cost Capital Equipment.
– Lower manufacturing operating costs.
– Lowest environmental impact.
• Easier permitting.
June 2010

12. Our Value
Scalability
June 2010

13. Our Value
• Chemistry Agnostic
– Comprehensive alternative of PVDF/NMP systems.
– Optimum manufacturing solution for a large array of
energy storage applications.
– Baseline for future chemistry development.
– Best case for vertical integrated lithium ion systems
manufacturing.
June 2010

14. Our Value
June 2010

15. IB Development Approach
• Product engineering
– Requirement
– Feasibility
• FMEA, DFM, DFY
• Commercial Feasibility.
– Design verification
– Product validation
• Manufacturing engineering
– Mfg development
• Methods development
• Tooling
– Product optimization for Mfg
– Mfg throughput optimization
– Mfg quality systems verification
– Mfg systems validation
June 2010

16. QMS Robust Approach
Systems are made from cells with
identical characteristics to provide
optimum efficiency.
Focus on complete validation of the
manufacturing process.
International Battery IB-B-FHE-160 Discharge Capacity @ Room Temperature
4.0000
3.0000
Cell Voltage (Volts)
2.0000
Focus on complete
1.0000
validation of the
manufacturing process.
0
0 50.0000 100.0000 150.0000 200.0000
Discharge Capacity (Ah)
09114-02 09113-30 9114-06 09113-21
June 2010

17. Mfg Process Capability
June 2010

18. Our Value
• Large Format Prismatic Cells
– Least complex systems assembly.
– Robust electrical connections.
– Safety pressure release protection.
– 100% cell characterization.
– Optimum cell Resistance & Impedance.
– Up to 200 Ah cells.
– Enables individual cell monitoring and control
June 2010

19. Cell Performance
Life Cycle Characterization LFP Baseline 50 ºC
130.0
97.5
Capacity (%)
65.0
32.5
0
0 125 250 375 500
Cycle #
09141-19 R@50%DOD R@80%DOD
June 2010

20. Value thru Testing
• Abuse Testing
– Induced Destructive Overcharge
– Induced Destructive Discharge
– Altitude
– Vibration
– Induced Short Circuit
– Extreme Temperature
– Crush Test
– Nail Penetration
– ALCT
June 2010

21. Battery System Solutions Our Value
June 2010

22. Managing customer expectations
• Understanding the application requirements
– Common goal of all efforts - Customer Satisfaction.
• Understand customer expectations.
• Understand customer suffering.
• Understand “product features” value in the application.
• Comprehensive Product Requirements Document
• Failure mitigation (failure impact to the customer?).
• Ranking of requirements (A stakeholder perspective of “must have”,
“should have” and “nice-to-have”).
• Requirements correlations.
June 2010

23. Joint Requirements Development
• Define the system design
– Upfront evaluation to reduce risk.
• Load profiles. (Cell size)
• Meaningful ALCT feasibility.
• Systems Control feasibility.
– Thermal management perspective.
• Termination design.
• Cell packaging.
• Module packaging.
June 2010

24. Evolutionary product development
• Application specific systems
– Short development cycles.
– Planned upgrades without full validation requirements.
– Continuous customer evaluation and feedback.
June 2010

25. Questions?
Thank You!
Antonio Reis
June 2010