John R. Pierson

Innovative valve-regulated battery designs rekindle excitement inlead/acid battery technology

Abstract Recent innovative approaches to the extension of valve-regulated lead/acid (VRLA) technology have led to thedevelopment of several unique products that possess performance attributes not previously achieved in lead/acid technologies, namely: (i)starting, lighting, ignition (SLI) VRLA batteries; (ii) StackPack™ foil batteries, and (iii) spiral-wound Thin Metal Film (TMF ™) batteries.TheVRLA automotive product has been demonstrated to be capable of improving on the durability of conventional flooded designs in extreme high-temperature climate and extreme drive-cycle operating conditions. In uninterruptible power supply (UPS) applications, the StackPack™ battery, at a 15-min discharge rate has delivered 23.3 Wh kg−1 and 1090 Wh 1−1 as compared with 16.0 Wh kg−1 and 595 Wh 1−1 for traditional designs. TMF™ prototypes have exhibited power capability of an order of magnitude higher than conventional VRLA designs and have been utilized successfully in a vehicle for seven months and over 31 000 km (19 200 miles).

Development of automotive battery systems capable of surviving modern underhood environments

Abstract The starting, lighting, and ignition (SLI) battery in todays automobile typically finds itself in an engine compartment that is jammed with mechanical, electrical, and electronic devices. The spacing of these devices precludes air movement and, thus, heat transfer out of the compartment. Furthermore, many of the devices, in addition to the internal combustion engine, actually generate heat. The resulting underhood environment is extremely hostile to thermally-sensitive components, especially the battery. All indications point to a continuation of this trend towards higher engine-compartment temperatures as future vehicles evolve. The impact of ambient temperature on battery life is clearly demonstrated in the failure-mode analysis conducted by the Battery Council International in 1990. This study, when combined with additional failure-mode analyses, vehicle systems simulation, and elevated temperature life testing, provides insight into the potential for extension of life of batteries. Controlled fleet and field tests are used to document and quantify improvements in product design. Three approaches to battery life extension under adverse thermal conditions are assessed, namely: (i) battery design; (ii) thermal management, and (iii) alternative battery locations. The advantages and disadvantages of these approaches (both individually and in combination) for original equipment and aftermarket applications are explored.

Inspira : an enabling battery technology for high voltage automotive electrical systems

Abstract Vehicle manufacturers worldwide are recognizing the need to elevate the electrical system voltage on their product from the present standard of 12 V to a significantly higher, yet safe, voltage. One of the major challenges emerging from the move to higher voltages is the size, weight, volume, cost and complexity of the battery required to support such a system. Inspira™, a valve-regulated, lead–acid, spiral-wound Thin Metal Foil™ battery, provides a small, lightweight, flexible solution to the challenge.

Energy storage and management systems for 42 V architectures

Vehicle manufacturers worldwide have recognized the trend toward increased on-board power demands is causing a need to raise the electrical system voltage from the present standard of 12 V to a higher, yet safe, voltage. One of the major challenges emerging from the transition to higher voltages is the size, weight, volume, cost and complexity of the energy storage system required to support the vehicle system and its loads. This paper discusses these changes, their implications, and presents potential solutions to address the future needs of vehicle manufacturers.