Selected System: NCA-G NCA-G NMC441-G LFP-G LMO-LTO LMO-G

Positive Electrode

Active material capacity, mAh/g: 160 160 175 150 108 100

Weight %

Active material 89 89 89 89 89 89

Carbon 6 6 6 6 6 6

Binder 5 5 5 5 5 5

Binder solvent NMP NMP NMP NMP NMP NMP

Void, Vol% % 32 32 32 50 32 32

Density, g/cm3

Active material 4.78 4.78 4.65 3.45 4.23 4.23

Carbon 1.825 1.825 1.825 1.825 1.825 1.825

Binder 1.77 1.77 1.77 1.77 1.77 1.77

Negative Electrode

N/P capacity ratio after formation 1.25 1.25 1.25 1.2 1.10 1.2

Active material capacity, mAh/g: 330 330 330 330 170 330

Weight %

Active material 95 95 95 95 89 95

Carbon 0 0 0 0 6 0

Binder 5 5 5 5 5 5

Binder solvent Water Water Water Water Water Water

Void, Vol% % 34 34 34 34 40 34

Density, g/cm3

Active material 2.24 2.24 2.24 2.24 3.40 2.24

Carbon 1.95 1.95 1.95 1.95 1.95 1.95

Binder 1.1 1.10 1.10 1.10 1.10 1.10

Positive Foil

Material Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum

Thickness, m 20 20 20 20 20 20

Negative Foil

Material Copper Copper Copper Copper Aluminum Copper

Thickness, m 12 12 12 12 20 12

Separator

Thickness, m 20 20 20 20 20 20

Void, Vol% % 50 50 50 50 50 50

Density, g/cm3

0.46 0.46 0.46 0.46 0.46 0.46

Electrolyte density, g/cm3

1.2 1.20 1.20 1.20 1.20 1.20

Cell Voltage and Resistance Parameters

OCV at full power (at SOC for power rating), V 3.551 3.551 3.663 3.300 2.408 3.819

Open circuit voltage at 50% SOC, V 3.68 3.680 3.750 3.350 2.514 3.954

Solid state diffusion limiting C-rate (10-s), A/Ah 27 27 27 120 200 120

Negative electrode cm2/cm3

74000 74000 74000 74000 500000 74000

Positive electrode cm2/cm3

8900 8900 8900 420000 49200 49200

Electrode system ASI for power, ohm-cm2

 Selected ASI value 30

 At 50% SOC, 2-sec burst 18 18 21 20 6 16

 At 50% SOC, 10-sec burst 23.6 23.6 26.6 25 8 20

 At bottom of SOC range, 10-sec burst 30 30 33 32 10 25

ASI correction factor, % 3 3 3 1.5 1.5 2

Electrode system ASI for energy, ohm-cm2

51.92 51.9 58.5 55.0 13.3 44.0

Maximum electrode coating thickness, m 100 100 100 100 100 100

Available battery energy, % of total

 Selected % energy 70

 microHEV and HEV-HP 25 25 25 25 25 25

 PHEV 70 70 70 70 75 70

 EV 80 80 80 80 85 80

Default Values

Cell Chemistry

 1 0900006480f75800.xls11/29/2011
Cell Materials Costs NCA-G NMC441-G LFP-G LMO-LTO LMO-G

Positive Electrode, $/kg p

 Active material 37.00 0.95 37.00 29.00 20.00 10.00 10.00

 Carbon 6.80 1.00 6.80 6.80 6.80 6.80 6.80

 Binder PVDF 10.00 1.00 10.00 10.00 10.00 10.00 10.00

 Binder Solvent (NMP) 3.20 1.00 3.20 3.20 3.20 3.20 3.20

Negative electrode material, $/kg

 Active Material 19.00 0.95 19.00 19.00 19.00 12.00 19.00

 Carbon Black 6.80 1.00 6.80 6.80 6.80 6.80 6.80

 Binder PVDF 10.00 1.00 10.00 10.00 10.00 10.00 10.00

 Binder Solvent 0.00 1.00 0.00 0.00 0.00 0.00 0.00

Positive current collector foil, $/m2

0.80 1.00 0.80 0.80 0.80 0.80 0.80

Negative current collector foil, $/m2

1.80 1.00 1.80 1.80 1.80 0.80 1.80

Separators, $/m2

2.00 1.00 2.00 2.00 2.00 2.00 2.00

Electrolyte, $/L 21.60 1.00 21.60 21.60 21.60 21.60 21.60

 2 0900006480f75800.xls11/29/2011
Other

 3 0900006480f75800.xls11/29/2011
 4 0900006480f75800.xls11/29/2011
System Chemistry Input

Finished Cell Materials Battery 1 Battery 2 Battery 3 Battery 4 Battery 5

Positive Electrode, g Weight % Density

Active material 89 4.78 192.95 192.39 191.80 191.40 191.10

Carbon 6 1.825 13.01 12.97 12.93 12.90 12.88

Binder 5 1.77 10.84 10.81 10.78 10.75 10.74

Void Vol. % 32 - - - - -

Total 100 2.749 216.80 216.17 215.51 215.05 214.72

Negative Electrode, g Weight % Density

Active material 95 2.24 119.86 119.47 119.03 118.71 118.46

Carbon 0 1.95 - - - - -

Binder 5 1.10 6.31 6.29 6.26 6.25 6.23

Void Vol. % 34 - - - - -

Total 100 1.406 126.17 125.75 125.30 124.96 124.70

Balance of Cell Thick., m Density

Positive foil, m2

Al 20 2.70 0.476 0.571 0.726 0.893 1.077

Negative foil, m2 Cu 12 8.92 0.517 0.615 0.774 0.946 1.135

Separator, m2

20 0.46 0.929 1.116 1.419 1.747 2.108

Electrolyte , L 1.20 0.0693 0.0711 0.0742 0.0775 0.0813

Positive terminal assembly, g 9.5 9.6 9.8 10.1 10.4

Negative terminal assembly, g 31.2 31.7 32.5 33.4 34.3

Thickness of cell container aluminum layer, μm 100 100 100 100 100

Thickness of cell container (PET-Al-PP), μm 150 150 150 150 150

Density of cell container, g/cm3 2.2 2.2 2.2 2.2 2.2

Cell container (PET-Al-PP), g 23.0 23.6 24.6 25.7 26.9

Cell mass, g 579 599 632 668 708

Length-to-width ratio for positive electrode 1.30 1.30 1.30 1.30 1.30

Cell thickness, mm 8.0 8.0 8.0 8.0 8.0

Thickness of cell edge from positive electrode to outside of fold, mm 1.0 1.0 1.0 1.0 1.0

Thickness of terminal material, mm 1.00 1.00 1.00 1.00 1.00

Top of positive electrode to top of terminal, mm 15 15 15 15 15

Cell Capacity Parameters

Positive active material capacity, mAh/g: 160 160 160 160 160

Positive electrode capacity, Ah/cm3

0.392 0.392 0.392 0.392 0.392

Negative active material capacity, mAh/g: 330 330 330 330 330

Negative electrode capacity, Ah/cm3

0.441 0.441 0.441 0.441 0.441

Negative-to-positive capacity ratio after formation 1.25 1.25 1.25 1.25 1.25

Cell Voltage and Resistance Parameters

OCV at full power, V 3.551 3.551 3.551 3.551 3.551

Open circuit voltage average for discharge, V 3.680 3.680 3.680 3.680 3.680

Electrode system ASI for energy, ohm-cm2

51.9 51.9 51.9 51.9 51.9

Excess negative area, % 2.50 2.46 2.40 2.34 2.28

Maximum allowable electrode coating thickness, m 100 100 100 100 100

Cell terminal contact voltage loss, % of cell OCV 0.01 0.01 0.01 0.01 0.01

Rate of terminal temperature rise at full power, oC/sec 0.05 0.05 0.05 0.05 0.05

Target % OCV at full power 80 80 80 80 80

% OCV at full power adjusted for thickness limit 82.5 80.0 80.0 80.0 80.0

Battery Input Parameters

Vehicle type (microHEV, HEV-HP, PHEV, EV) PHEV PHEV PHEV PHEV PHEV

Duration of power burst (10 or 2), s 10 10 10 10 10

Battery power, kW 50 65 80 95 110

Number of cells per module 16 16 16 16 16

Number of cells in parallel 1 1 1 1 1

Number of modules in row 3 3 3 3 3

Number of rows of modules 2 2 2 2 2

Number of modules per battery 6 6 6 6 6

Cells per battery 96 96 96 96 96

Voltage drop for bus bar for packs with one row of modules, V 0.03 0.03 0.03 0.03 0.03

Battery pack insulation thickness, mm 10 10 10 10 10

Battery jacket total thickness, mm 13 13 13 13 13

Number of batteries manufactured per year 100,000 100,000 100,000 100,000 100,000

Cell Chemistry Input

Battery Performance and Design Input

Program for Calculating Performance and Materials Requirements

LiNi0.80Co0.15Al0.05O2-Graphite

 1 11/29/2011
Battery 1 Battery 2 Battery 3 Battery 4 Battery 5

Calculated Cell Parameters

Capacity, Ah

Cell group capacity 30.9 30.8 30.7 30.6 30.6

Cell capacity 30.9 30.8 30.7 30.6 30.6

ASI Calculation

Limiting current density, mA/cm2

85 85 85 85 85

Limiting C-rate, A/Ah 27 27 27 27 27

Electrode system ASI for power, ohm-cm2

29.8 30.4 31.5 32.7 34.0

Current collector resistance parameter, ohms 0.005409 0.005409 0.005409 0.005409 0.005409

Current collector ASI, ohms-cm2

0.781 0.802 0.836 0.875 0.917

Total cell terminal ASI, ohms-cm2

0.073 0.086 0.107 0.128 0.151

Cell and battery terminal connections, ohms 0.000372 0.000278 0.000226 0.000190 0.000164

Total cell hardware and battery resistance, ohm-cm2

0.887 0.918 0.975 1.036 1.102

Total cell ASI for power, ohm-cm2

30.6 31.4 32.4 33.7 35.1

Total cell ASI for energy (C/3 rate), ohm-cm2

55.2 55.7 56.6 57.5 58.5

Electrode Coating Thickness Calculation

Positive electrode thickness parameter, m 99.7 74.7 58.5 47.3 39.1

Negative electrode thickness parameter, m 110.7 83.0 65.0 52.6 43.5

Positive electrode thickness at adjusted % OCV, m 90.0 74.7 58.5 47.3 39.1

Negative electrode thickness at adjusted % OCV, m 100.0 83.0 65.0 52.6 43.5

Cell Area Calculation

Area determined at target % OCV 7,911 10,524 13,401 16,523 19,961

Area limited by max. allowed electrode thickness, 8,758 8,732 8,705 8,687 8,674

Cell area based on total ASI for power, cm2

 8,758 10,524 13,401 16,523 19,961

Cell Dimensions

Number of bicell layers (97% packing density) 17 19 23 28 32

Width of positive electrode, mm 143 145 148 152 156

Length of positive electrode, mm 185 188 193 198 203

Length of current collector tabs, mm 16 16 16 16 16

Width of terminals, mm 135 137 140 144 148

Length of terminal material, mm 26 26 26 26 26

Width of cell, mm 145 147 150 154 158

Length of cell, mm 215 218 223 228 233

Volume of cell, cm3

249 256 268 280 294

Module Parameters

Weight of each cell group interconnect (copper), g 0.0 0.0 0.0 0.0 0.0

Module state-of-charge regulator assembly, g 128 128 128 128 128

Terminal heating factor, W/g 0.019 0.019 0.019 0.019 0.019

Terminal resistance factor, A-ohms/cm 0.00054 0.00054 0.00054 0.00054 0.00054

Module terminals, if more than one module (each 2.0-cm long), g 24 32 39 46 54

Module terminal resistance both terminals, ohms 0.0000120 0.0000090 0.0000073 0.0000061 0.0000053

Module wall thickness (aluminum), mm 0.5 0.5 0.5 0.5 0.5

Length of aluminum conductor, mm 185 188 193 198 203

Thickness of aluminum conductors, mm 0.40 0.40 0.40 0.40 0.40

Total weight of aluminum conductors, g 547 562 588 616 648

Balance of module materials, g 227 232 239 246 255

Module length, mm 217 220 225 230 235

Module width, mm 144 144 144 144 144

Module height, mm 146 149 152 156 160

Module volume, L 4.58 4.70 4.91 5.14 5.40

Module weight, kg 10.20 10.54 11.10 11.72 12.41

Program for Calculating Performance and Materials Requirements

LiNi0.80Co0.15Al0.05O2-Graphite

 2 11/29/2011
Calculated Battery Parameters

Total battery energy storage, kWh 10.71 10.71 10.71 10.71 10.71

Useable battery energy storage, kWh 7.50 7.50 7.50 7.50 7.50

OCV at full power, V 340.9 340.9 340.9 340.9 340.9

Nominal battery voltage (OCV at 50% SOC) 353.3 353.3 353.3 353.3 353.3

Battery power at target % OCV and SOC, kW 55.4 65.0 80.0 95.0 110.0

Maximum current at full power, A 178 238 293 348 403

Maximum current density at full power, mA/cm2

20.31 22.65 21.89 21.08 20.21

C-rate at full power, A/Ah 5.8 7.7 9.6 11.4 13.2

Coolant space above and below modules and at end of jacket, mm 0.6 0.5 0.5 0.4 0.4

Thickness of module compression plates (steel), mm 1.5 1.5 1.5 1.5 1.5

Battery pack length, mm 461 461 461 461 461

Battery pack width, mm 471 476 485 495 506

Battery pack height, mm 174 176 179 183 187

Battery volume, L 37.7 38.6 40.0 41.7 43.5

Weight of each module inter-connect (5-cm long), g 30 40 49 58 67

Weight of both battery terminals (each 5.0-cm long), g 74 99 122 145 168

Weight of module compression plates and steel straps, g 1537 1577 1645 1719 1803

Weight of bus bar for packs with one row of modules, g 0 0 0 0 0

Resistance of module interconnects if more than one module, ohms 0.0000903 0.0000674 0.0000547 0.0000461 0.0000398

Resistance of battery terminals 0.0000181 0.0000135 0.0000109 0.0000092 0.0000080

Power of battery heaters, kW 2.0 2.0 2.0 2.0 2.0

Weight of battery pack heaters (0.1 kg/kW), kW 0.2 0.2 0.2 0.2 0.2

Battery jacket weight parameter, g/cm2

0.84 0.84 0.84 0.84 0.84

Battery coolant weight within jacket, kg 2.76 2.58 2.39 2.26 2.16

Battery jacket weight, kg 10.5 10.3 10.3 10.5 10.7

Battery weight, kg 71.7 73.5 77.0 80.8 85.1

Pack integration (BMS & disconnects), kg 4.0 4.0 4.0 4.0 4.0

Pack integration (BMS & disconnects), L 4.0 4.0 4.0 4.0 4.0

Battery Cooling System

Heat generation rate for pack, W 3871 3062 2303 1829 1501

Cooling System Refrig 4 Refrig 4 Refrig 4 Refrig 3 Refrig 3

Weight and Volume of Cooling System Exterior to Battery

 Weight, kg 7.0 7.0 7.0 5.0 5.0

 Volume, L 2.8 2.8 2.8 2.0 2.0

Vehicle Electric Range

Energy requirement, Wh/mile 300 300 300 300 300

Available battery energy, % of total 70 70 70 70 70

Vehicle range, miles 25.00 25.00 25.00 25.00 25.00

Cell Capacity Calculation

Select capacity, battery energy, or vehicle range, but only one.

 Capacity (Ah)

 Battery energy (kWh)

 Vehicle range (miles) 25.0 25.0 25.0 25.0 25.0

Capacity at C/3, Ah 30.872 30.782 30.688 30.624 30.576

Capacity holding 30.872 30.782 30.688 30.624 30.576

Positive electrode thickness 90.0 74.7 58.5 47.3 39.1

Positive electrode thickness holding 90.0 74.7 58.5 47.3 39.1

Convergence parameter 0.3 0.3 0.3 0.3 0.3

 3 11/29/2011
Battery 1 Battery 2 Battery 3 Battery 4 Battery 5

Calculated Battery Parameters

Battery energy storage, kWh 10.7 10.7 10.7 10.7 10.7

Battery power at target % OCV, kW 55.4 65.0 80.0 95.0 110.0

Required battery power, kW 50.0 65.0 80.0 95.0 110.0

Capacity, Ah 31 31 31 31 31

Number of cells 96 96 96 96 96

Battery weight, kg 71.7 73.5 77.0 80.8 85.1

Battery volume, L 37.7 38.6 40.0 41.7 43.5

Weight and Volume of Components Exterior to Battery

 Weight, kg 11.0 11.0 11.0 9.0 9.0

 Volume, L 5.6 5.6 5.6 4.0 4.0

Cooling system power requirement, W 1,551 1,226 923 733 601

Vehicle electric range, miles 25.0 25.0 25.0 25.0 25.0

Investment Costs

Capital equipment cost including installation, mil$ 162 166 172 178 184

Building, Land and Utilities

 Area, m2

 18,948 19,433 20,177 20,934 21,722

 Cost, $/m2

 3,000 3,000 3,000 3,000 3,000

 Building investment, mil$ 56.8 58.3 60.5 62.8 65.2

Launch Costs

 Rate: 5% of direct annual materials + 10% of other annual costs

 Total, million$ 12.91 13.32 13.99 14.72 15.52

Working capital (30% of annual variable costs), mil$ 34.97 36.13 38.00 40.06 42.33

Total investment, mil$ 266.47 273.36 284.13 295.40 307.38

Unit Cost of Battery Pack, $

Variable Cost

Materials and Purchased Items 

 Cell materials 1,551 1,619 1,732 1,855 1,991

 Cell purchased Items 87 87 88 89 90

Summary of Results

LiNi0.80Co0.15Al0.05O2-Graphite

 1 11/29/2011

 Cell purchased Items 87 87 88 89 90

 Module 306 306 307 308 309

 Battery pack 138 140 142 147 152

 Total 2,081 2,153 2,269 2,398 2,541

Direct Labor

 Electrode processing 37 40 44 48 53

 Cell assembly 34 34 34 34 34

 Formation cycling, testing and sealing 22 22 22 22 22

 Module and battery assembly 20 20 20 20 20

 Cell and materials rejection and recycling 9 9 9 9 9

 Receiving and shipping 9 9 9 9 9

 Control laboratory 6 6 6 6 6

 Total 136 139 143 148 152

Variable Overhead 114 117 121 125 129

Total Variable Cost 2,332 2,409 2,533 2,671 2,822

Fixed Expenses

General, Sales, Administration 137 140 145 150 155

Research and Development 119 122 127 131 136

Depreciation 298 305 316 328 340

Total Fixed Expenses 554 567 588 609 631

Profits after taxes 133 137 142 148 154

Total unit cost per battery not including warranty, $ 3,019 3,113 3,263 3,427 3,607

Summary of Unit Costs, $

Materials 1,551 1,619 1,732 1,855 1,991

Purchased Items not including cooling system 530 534 537 544 551

Direct Labor 136 139 143 148 152

Variable Overhead 114 117 121 125 129

General, Sales, Administration 137 140 145 150 155

Research and Development 119 122 127 131 136

Depreciation 298 305 316 328 340

Profit 133 137 142 148 154

Warranty (includes battery pack only) 169 174 183 192 202

Price to OEM for battery pack, $ 3,188 3,287 3,446 3,619 3,809

Pack integration (BMS & Disconnects), $ 435 435 435 435 435

Estimated cost to OEM for thermal management, $ 320 320 280 240 240

Total cost to OEM for complete battery system, $ 3,943 4,042 4,161 4,294 4,484

Price to OEM for modules for one pack, $ 3,014 3,111 3,267 3,436 3,620 1 11/29/2011
Battery 1 Battery 2 Battery 3 Battery 4 Battery 5

Annual Processing Rates

Number of batteries manufactured per year 100,000 100,000 100,000 100,000 100,000

Energy, kWh per year 1,071,429 1,071,429 1,071,429 1,071,429 1,071,429

Number of accepted cells per year 9,600,000 9,600,000 9,600,000 9,600,000 9,600,000

Number of cells adjusted for yield 10,105,263 10,105,263 10,105,263 10,105,263 10,105,263

Electrode area, m2 per year 8,849,807 10,635,012 13,542,347 16,696,902 20,171,351

Positive active material, kg per year 2,114,763 2,108,617 2,102,158 2,097,740 2,094,497

Negative active material, kg per year 1,313,655 1,309,372 1,304,627 1,301,131 1,298,344

Binder solvent, kg per year 2,851,366 2,843,080 2,834,371 2,828,414 2,824,041

Dry room operating area, m2

4,050 4,087 4,142 4,196 4,251

Direct Materials Costs

Total Cell Materials per Accepted Cell Yield, %

Positive Electrode Materials (dry), g 92.2

 Active Material 220.3 219.6 219.0 218.5 218.2

 Carbon 14.9 14.8 14.8 14.7 14.7

 Binder PVDF 12.4 12.3 12.3 12.3 12.3

 Binder Solvent (NMP) 297.0 296.2 295.2 294.6 294.2

 Total (dry) 247.5 246.8 246.0 245.5 245.1

Negative Electrode Materials (dry), g 92.2

 Active Material 136.8 136.4 135.9 135.5 135.2

 Carbon Black 0.0 0.0 0.0 0.0 0.0

 Binder 7.2 7.2 7.2 7.1 7.1

 Binder Solvent (water) 172.8 172.3 171.7 171.2 170.8

Manufacturing Cost Calculations

LiNi0.80Co0.15Al0.05O2-Graphite

 1 11/29/2011

 Binder Solvent (water) 172.8 172.3 171.7 171.2 170.8

 Total (dry) 144.0 143.6 143.1 142.7 142.4

Positive current collector (aluminum foil), m2

90.2 0.555 0.666 0.847 1.042 1.257

Negative current collector (copper foil), m2

90.2 0.603 0.717 0.903 1.105 1.325

Separators, m2

98.0 0.998 1.199 1.524 1.877 2.264

Electrolyte, L 94.0 0.078 0.080 0.083 0.087 0.091

Annual Cell Materials Rates

Positive Electrode

 Active Material, kg 2,114,763 2,108,617 2,102,158 2,097,740 2,094,497

 Carbon, kg 142,568 142,154 141,719 141,421 141,202

 Binder PVDF, kg 118,807 118,462 118,099 117,851 117,668

 Binder Solvent (NMP) makeup, kg 14,257 14,215 14,172 14,142 14,120

Negative Electrode Material, kg

 Active Material (graphite), kg 1,313,655 1,309,372 1,304,627 1,301,131 1,298,344

 Carbon Black, kg 0 0 0 0 0

 Binder PVDF, kg 69,140 68,914 68,665 68,481 68,334

Positive current collector (aluminum foil), m2

5,328,846 6,396,410 8,130,140 10,005,110 12,063,572

Negative current collector (copper foil), m2

5,786,976 6,887,360 8,673,422 10,603,519 12,720,785

Separators, m2

9,583,913 11,507,405 14,633,493 18,017,217 21,735,290

Electrolyte, L 744,771 764,317 797,160 833,501 873,939

Positive terminal assemblies 10,105,263 10,105,263 10,105,263 10,105,263 10,105,263

Negative terminal assemblies 10,105,263 10,105,263 10,105,263 10,105,263 10,105,263

Cell Containers 10,105,263 10,105,263 10,105,263 10,105,263 10,105,263

Aluminum thermal conductor 9,600,000 9,600,000 9,600,000 9,600,000 9,600,000

Positive binder solvent evaporated, kg 2,851,366 2,843,080 2,834,371 2,828,414 2,824,041

Negative binder solvent evaporated, kg 1,659,354 1,653,944 1,647,949 1,643,534 1,640,013

 1 11/29/2011
Unit Cell Materials Costs Baseline p

Positive Electrode, $/kg

 Active Material 37.00 0.95 36.61 36.62 36.62 36.63 36.63

 Carbon 6.80 1.00 6.80 6.80 6.80 6.80 6.80

 Binder PVDF 10.00 1.00 10.00 10.00 10.00 10.00 10.00

 Binder Solvent (NMP) 3.20 1.00 3.20 3.20 3.20 3.20 3.20

Negative electrode material, $/kg

 Active Material 19.00 0.95 18.92 18.92 18.93 18.93 18.93

 Carbon Black 6.80 1.00 6.80 6.80 6.80 6.80 6.80

 Binder 10.00 1.00 10.00 10.00 10.00 10.00 10.00

Positive current collector, $/m2

0.80 1.00 0.80 0.80 0.80 0.80 0.80

Negative current collector, $/m2

1.80 1.00 1.80 1.80 1.80 1.80 1.80

Separators, $/m2

2.00 1.00 2.00 2.00 2.00 2.00 2.00

Electrolyte, $/L 21.60 1.00 21.60 21.60 21.60 21.60 21.60

Hardware Costs, $/unit

 Positive terminal assembly 0.29 0.29 0.29 0.29 0.29

 Negative terminal assembly 0.44 0.44 0.45 0.45 0.46

 Cell container 0.27 0.27 0.27 0.28 0.28

Cell Materials Cost, $

Positive Electrode (dry)

 Active Material 8.07 8.04 8.02 8.00 7.99

 Carbon 0.10 0.10 0.10 0.10 0.10

 Binder PVDF 0.12 0.12 0.12 0.12 0.12

 Binder Solvent (NMP) 0.00 0.00 0.00 0.00 0.00

Negative electrode material (dry)

 Active Material 2.59 2.58 2.57 2.57 2.56

 Carbon Black - - - - -

 2 11/29/2011

 Carbon Black - - - - -

 Binder 0.07 0.07 0.07 0.07 0.07

Positive current collector 0.44 0.53 0.68 0.83 1.01

Negative current collector 1.09 1.29 1.63 1.99 2.39

Separators 2.00 2.40 3.05 3.75 4.53

Electrolyte 1.68 1.72 1.79 1.88 1.97

Positive terminal assembly, $/unit 0.80 0.26 0.26 0.26 0.26 0.27

Negative terminal assembly, $/unit 0.80 0.40 0.40 0.41 0.41 0.42

Cell container, $/unit 0.80 0.24 0.25 0.25 0.25 0.26

Total cost of cell winding materials, $ 16.16 16.87 18.04 19.32 20.74

Total cost of cell materials, $ 17.06 17.78 18.96 20.25 21.67

Cost of Module Materials and Purchased Items, $

Aluminum thermal conductors (each) 0.80 0.22 0.22 0.22 0.23 0.24

Aluminum thermal conductors/module 3.45 3.50 3.60 3.70 3.82

Cell group interconnects (copper) - - - - -

Module state-of-charge regulator 44.94 44.93 44.91 44.90 44.89

Module terminals 0.87 0.91 0.95 0.98 1.02

Balance of module materials 1.68 1.69 1.72 1.74 1.76

Total cost per module 50.94 51.03 51.17 51.32 51.49

Cost of Battery Pack Materials and Purchased Items, $

Module Inter-connectors and signal wiring 12.19 13.95 15.55 17.16 18.76

Module compression plates and steel straps 3.07 3.15 3.29 3.44 3.61

Battery terminals 19.00 21.00 21.00 23.00 25.00

Bus bar for batteries with one row of modules - - - - -

Battery jacket 103.42 102.05 102.41 103.31 104.61

Total cost per battery 137.68 140.15 142.25 146.90 151.98

Total cost of materials for cells and battery, $ 2,081.28 2,152.82 2,268.94 2,398.38 2,541.38

Cost of Pack Integration (BMS & Disconnects)

Battery current and voltage sensing, $ 100.00 100.00 100.00 100.00 100.00

Module controls 120.00 120.00 120.00 120.00 120.00

Automatic battery disconnect, $ 200.00 200.00 200.00 200.00 200.00

 2 11/29/2011
Manual disconnect, $ 15.00 15.00 15.00 15.00 15.00

Total cost of battery management system 435.00 435.00 435.00 435.00 435.00

Cost to OEM for Materials and Purchased Items for Thermal Management System, $

Baseline thermal system 120.00 120.00 120.00 120.00 120.00

Additions to AC system 160.00 160.00 120.00 80.00 80.00

Heating system 40.00 40.00 40.00 40.00 40.00

Total cost to OEM for thermal management system 320.00 320.00 280.00 240.00 240.00

 3 11/29/2011
Battery Assembly Costs

Baseline

Operation (Pertinent rate) Plant p

Receiving (Energy/yr)

 Volume ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232

 Direct Labor, hours/year 14,400 0.40 15,655 15,655 15,655 15,655 15,655

 Capital Equipment, million$ 3.6 0.60 4.1 4.1 4.1 4.1 4.1

 Plant Area, square meters 900 0.50 999 999 999 999 999

Electrode Processing

Materials preparation

 Positive materials (positive mass/yr)

 Volume ratio (volume/baseline volume) 1.235 1.231 1.228 1.225 1.223

 Direct Labor, hours/year 14,400 0.50 16,002 15,979 15,954 15,937 15,925

 Capital Equipment, million$ 2.0 0.70 2.3 2.3 2.3 2.3 2.3

 Plant Area, square meters 600 0.60 681 680 679 678 677

 Negative materials (negative mass/yr)

 Volume ratio (volume/baseline volume) 1.089 1.086 1.082 1.079 1.077

 Direct Labor, hours/year 14,400 0.50 15,030 15,005 14,978 14,958 14,942

 Capital Equipment, million$ 2.0 0.70 2.1 2.1 2.1 2.1 2.1

 Plant Area, square meters 600 0.60 632 630 629 628 627

Electrode coating

 Positive materials (area/yr)

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Solvent evaporated, kg 2,309,021 0.2 2,851,366 2,843,080 2,834,371 2,828,414 2,824,041

 Direct Labor, hours/year 28,800 0.50 29,903 32,780 36,991 41,074 45,145

 Capital Equipment, million$ 8.0 0.80 8.9 10.3 12.4 14.7 17.1

 4 11/29/2011

 Capital Equipment, million$ 8.0 0.80 8.9 10.3 12.4 14.7 17.1

 Plant Area, square meters 750 0.80 796 923 1,119 1,324 1,540

 Negative materials area/yr)

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Solvent evaporated, kg 1,527,105 0.2 1,659,354 1,653,944 1,647,949 1,643,534 1,640,013

 Direct Labor, hours/year 28,800 0.50 29,903 32,780 36,991 41,074 45,145

 Capital Equipment, million$ 8.0 0.80 8.6 10.0 12.1 14.3 16.7

 Plant Area, square meters 750 0.80 796 923 1,119 1,324 1,540

Binder solvent (NMP) recovery (kg/yr)

 Volume ratio (volume/baseline volume) 1.235 1.231 1.228 1.225 1.223

 Direct Labor, hours/year 14,400 0.40 15,668 15,650 15,631 15,617 15,608

 Capital Equipment, million$ 3 0.60 3.4 3.4 3.4 3.4 3.4

 Plant Area, square meters 225 0.60 255 255 254 254 254

 4 11/29/2011
Calendering

 Positive materials (area/yr)

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Direct Labor, hours/year 14,400 0.50 14,951 16,390 18,495 20,537 22,573

 Capital Equipment, million$ 1.0 0.70 1.1 1.2 1.4 1.6 1.9

 Plant Area, square meters 225 0.60 235 263 304 344 386

 Negative materials area/yr)

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Direct Labor, hours/year 7,200 0.50 7,476 8,195 9,248 10,268 11,286

 Capital Equipment, million$ 1.0 0.70 1.1 1.2 1.4 1.6 1.9

 Plant Area, square meters 225 0.60 235 263 304 344 386

Inter-process materials handling (area/yr)

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Direct Labor, hours/year 28,800 0.7 30,356 34,523 40,886 47,341 54,038

 Capital Equipment, million$ 1.5 0.7 1.6 1.8 2.1 2.5 2.8

 Plant Area, square meters 900 0.6 942 1,051 1,215 1,378 1,544

Electrode Slitting (area/yr)

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Direct Labor, hours/year 28,800 0.5 29,903 32,780 36,991 41,074 45,145

 Capital Equipment, million$ 2.0 0.7 2.1 2.4 2.8 3.3 3.8

 Plant Area, square meters 300 0.6 314 350 405 459 515

Vacuum Drying of Electrodes

 Volume ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457

 Direct Labor, hours/year 14,400 0.5 14,951 16,390 18,495 20,537 22,573

 Capital Equipment, million$ 1.6 0.7 1.7 1.9 2.3 2.6 3.0

 Plant Area, square meters 300 0.6 314 350 405 459 515

Control Laboratory

 Volume ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232

 5 11/29/2011

Control Laboratory

 Volume ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232

 Direct Labor, hours/year 28,800 0.5 31,971 31,971 31,971 31,971 31,971

 Capital Equipment, million$ 1.5 0.7 1.7 1.7 1.7 1.7 1.7

 Plant Area, square meters 300 0.6 340 340 340 340 340

Cell Assembly in Dry Room

Cell stacking (number of cells)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Cell Capacity, Ah 40 0.3 30.87 30.78 30.69 30.62 30.58

 Direct Labor, hours/year 36,000 0.7 50,025 50,025 50,025 50,025 50,025

 Capital Equipment, million$ 4.0 0.8 5.4 5.4 5.4 5.4 5.4

 Plant Area, square meters 600 0.8 874 874 874 874 874

Current collector welding (number of cells/yr)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 36,000 0.7 50,025 50,025 50,025 50,025 50,025

 Capital Equipment, million$ 4.0 0.8 5.8 5.8 5.8 5.8 5.8

 Plant Area, square meters 600 0.8 874 874 874 874 874

Inserting cell in container (number of cell/yr)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 21,600 0.5 27,322 27,322 27,322 27,322 27,322

 Capital Equipment, million$ 3.0 0.7 4.2 4.2 4.2 4.2 4.2

 Plant Area, square meters 600 0.6 795 795 795 795 795

 5 11/29/2011
Electrolyte filling, and cell sealing (number of cells/yr)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 36,000 0.5 45,537 45,537 45,537 45,537 45,537

 Capital Equipment, million$ 5.0 0.7 6.9 6.9 6.9 6.9 6.9

 Plant Area, square meters 900 0.6 1,193 1,193 1,193 1,193 1,193

Dry Room Control (operating area, sq. meters)

 Volume ratio (volume/baseline volume) 1.350 1.362 1.381 1.399 1.417

 Direct Labor, hours/year 14,400 0.4 16,237 16,296 16,382 16,468 16,554

 Capital Equipment, million$ 20 0.6 23.9 24.1 24.3 24.5 24.7

 Plant Area, square meters 100 0.4 113 113 114 114 115

Formation Cycling (number of cells/yr)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Cell Capacity, Ah 40 0.3 30.9 30.8 30.7 30.6 30.6

 Direct Labor, hours/year 57,600 0.7 80,040 80,040 80,040 80,040 80,040

 Capital Equipment, million$ 30 0.8 40.4 40.4 40.4 40.3 40.3

 Plant Area, square meters 2,200 0.8 2,964.6 2,962.0 2,959.3 2,957.4 2,956.1

Final Cell Sealing

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 14,400 0.5 18,215 18,215 18,215 18,215 18,215

 Capital Equipment, million$ 2.0 0.7 2.8 2.8 2.8 2.8 2.8

 Plant Area, square meters 450 0.6 597 597 597 597 597

Charge Retention Testing

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 21,600 0.4 26,068 26,068 26,068 26,068 26,068

 Capital Equipment, million$ 4.75 0.7 6.60 6.60 6.60 6.60 6.60

 Plant Area, square meters 900 0.6 1,193 1,193 1,193 1,193 1,193

Module Assembly (number of cells/yr)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 6 11/29/2011

Module Assembly (number of cells/yr)

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 43,200 0.5 54,644 54,644 54,644 54,644 54,644

 Capital Equipment, million$ 6.0 0.7 8.3 8.3 8.3 8.3 8.3

 Plant Area, square meters 600 0.6 795 795 795 795 795

Battery Pack Assembly and Testing, 100,000 Battery Packs per year

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Number of modules per Pack 4 0.3 6 6 6 6 6

 Direct Labor, hours/year 43,200 0.5 54,644 54,644 54,644 54,644 54,644

 Capital Equipment, million$ 6.0 0.7 9.4 9.4 9.4 9.4 9.4

 Plant Area, square meters 900 0.6 1,193 1,193 1,193 1,193 1,193

Rejected Cell and Scrap Recycle (number of cells/yr) 

 Volume ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

 Direct Labor, hours/year 36,000 0.7 50,025 50,025 50,025 50,025 50,025

 Capital Equipment, million$ 2.5 0.7 3.5 3.5 3.5 3.5 3.5

 Plant Area, square meters 600 0.6 795 795 795 795 795

Shipping (energy/yr)

 Volume ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232

 Direct Labor, hours/year 28,800 0.5 31,971 31,971 31,971 31,971 31,971

 Capital Equipment, million$ 5.0 0.7 5.8 5.8 5.8 5.8 5.8

 Plant Area, square meters 900 0.6 1,020 1,020 1,020 1,020 1,020

Summary for Battery Pack

 Direct Labor, hours/year 756,522 772,911 797,184 821,026 845,077

 Capital Equipment, million$ 161.75 165.61 171.62 177.82 184.36

 Plant Area, square meters 18,948 19,433 20,177 20,934 21,722

Summary for Cost of Modules Only

 Direct Labor, hours/year 720,092 736,481 760,754 784,597 808,648

 Capital Equipment, million$ 157.0 160.9 166.9 173.1 179.7

 Plant Area, square meters 18,351 18,836 19,580 20,337 21,126

 6 11/29/2011
Number of cells/pack 96 96 96 96 96

Number of modules/pack 6 6 6 6 6

Positive Active Material 774.25 772.11 769.87 768.33 767.20

Negative Active Material 248.53 247.76 246.91 246.28 245.78

Carbon and Binders 28.95 28.86 28.77 28.70 28.65

Positive Current Collector 42.63 51.17 65.04 80.04 96.51

Negative Current Collector 104.17 123.97 156.12 190.86 228.97

Separators 191.68 230.15 292.67 360.34 434.71

Electrolyte 160.87 165.09 172.19 180.04 188.77

Cell Hardware 86.89 87.36 88.12 88.95 89.87

Module Hardware 305.63 306.20 307.01 307.93 308.94

Battery Jacket 137.68 140.15 142.25 146.90 151.98

Battery Pack Total 2,081.28 2,152.82 2,268.94 2,398.38 2,541.38

Battery Management System 435.00 435.00 435.00 435.00 435.00

Thermal Management System 320.00 320.00 280.00 240.00 240.00

Direct Labor Summary, hours/year

Electrode processing 204,143 220,473 244,659 268,417 292,381

Cell assembly 189,146 189,204 189,291 189,377 189,463

Formation cycling, testing and sealing 124,322 124,322 124,322 124,322 124,322

Module and battery assembly 109,288 109,288 109,288 109,288 109,288

Cell and materials rejection and recycling 50,025 50,025 50,025 50,025 50,025

Receiving and shipping 47,626 47,626 47,626 47,626 47,626

Control laboratory 31,971 31,971 31,971 31,971 31,971

Total 756,522 772,911 797,184 821,026 845,077

Materials and Purchased Items Summary

 7 11/29/2011

30%

10%

9% 1%

17%

7%

4%

12%

6%

Positive Active Material

Negative Active Material

Carbon and Binders

Positive Current Collector

Negative Current Collector

Separators

Electrolyte

 7 11/29/2011
1%

4%

9% Cell Hardware

Module Hardware

Battery Jacket

 8 11/29/2011
Baseline Manufacturing Rates Material Yields

Number of batteries manufactured per year 100,000 Cell yield, % 95

Effective full days of operation per year 300 Materials yield per accepted cell, %

Number of 8-hr shifts per day 3 Positive electrode material (dry) 92.2

Number of annual 8-h shifts 900 Negative electrode material (dry) 92.2

Energy, kWh per year 869,416 Positive current collector (aluminum foil) 90.2

Number of accepted cells per year 6,000,000 Negative current collector (copper foil) 90.2

Number of cells adjusted for yield 6,315,789 Separators 98.0

Electrode area, m2 per year 8,209,039 Electrolyte 94.0

Positive active material, kg per year 1,712,524 Binder solvent recovery, % 99.5

Negative active material, kg per year 1,205,892 Module Purchased Materials Cost

Positive binder solvent evaporated, kg per year 2,309,021 State-of-charge regulator and safety monitors

Negative binder solvent evaporated, kg per year 1,527,105 Cost per cell, $ 2.50

Dry room, enclosed operating area, m2 3,000 Plus cost per Capacity, $/Ah 0.010

Unit Cell Materials Cost Module terminals

Positive Electrode, $/kg p Cost per Mass, $/kg 5.00

 Active Material 37.00 0.95 Plus cost per module, $ 0.75

 Carbon 6.80 1.00 Balance of module materials

 Cost per Mass, $/kg 3.00

 Binder PVDF 10.00 1.00 Plus cost per module, $ 1.00

 Binder Solvent (NMP) 3.20 1.00 Battery Purchased Materials Cost

Negative electrode material, $/kg Module Inter-connectors and signal wiring

 Active Material 19.00 0.95 Cost per Mass, $/kg 5.00

 Carbon Black 6.80 1.00 Plus cost per interconnect, $ 1.00

 Binder PVDF 10.00 1.00 Module compression plates and steel straps, $,kg 2.00

 Binder Solvent 0.00 1.00 Battery terminals

Positive current collector foil, $/m2

0.80 1.00 Cost per battery, $ 15.00

Negative current collector foil, $/m2

1.80 1.00 Plus cost per capacity, $/A (rounded up) 0.02

Separators, $/m2

2.00 1.00 Bus bar for packs with one row of modules, $ 20.00

Electrolyte, $/L 21.60 1.00 Battery Jacket

Unit Cell Hardware Costs Cost per battery jacket weight, $/kg 7.00

 Plus cost per battery, $ 30.00

Cost per Plus Cost Battery Management System

Mass, $/kg per Cell, $ p PHEV

Positive terminal 4.00 0.25 0.80 MicroHEV HEV-HP and EV

Negative terminal 6.00 0.25 0.80 Current and voltage sensing, $ 40 70 100

Cell Container 3.00 0.20 0.80 Module controls, $/module 10 10 20

Alum. heat conductor 4.00 0.10 0.80 Auto. battery disconnect, $ 50 70 200

Manual disconnect, $ 15 15 15

Thermal Controls

PHEV

MicroHEV HEV-HP and EV

Cost inputs that vary with cell chemistry Baseline thermal system,$ 30 80 120

Cost inputs that are do not vary with chemistry Additions to AC system, $/kW 40 40 40

Heating system, $/kW 20 20 20

Cost Input

Baseline

 1 11/29/2011
Cost Rates for Manufacturing

Investment Costs

Cost of building (including land and utilities), $/m2

3000

Launch Cost rates

 Percent of direct annual materials cost, % 5

 Percent of direct labor plus variable overhead, % 10

Working capital, percent of annual variable cost, % 15

Unit Cost of Battery Pack

Variable Cost

Direct labor rate, $/hr 18

Variable overhead rate

 % of direct labor 40

 % of depreciation 20

Fixed Expenses

General, Sales, Administration rates

 Percent of direct labor plus variable overhead, % 25

 Percent of depreciation, % 25

Research and Development rate, % of depreciation 40

Depreciation rates

 Percent of capital equipment investment (6-year rate), % 16.7

 Percent of building investment (20-year rate), % 5

Profits After Taxes, % of investment 5

 2 11/29/2011
Warranty Cost, % added to price 5.6

Battery Assembly Costs

Baseline Baseline

Operation Plant p Operation Plant p

Receiving Cell Assembly in Dry Room

 Pertinent volume: energy/year Cell stacking

 Direct Labor, hours/year 14,400 0.40 Pertinent volume: number of cells/year

 Capital Equipment, million$ 3.6 0.60 Baseline Cell Capacity, Ah 40 0.30

 Plant Area, square meters 900 0.50 Direct Labor, hours/year 36,000 0.70

Electrode Processing Capital Equipment, million$ 4.0 0.80

Materials preparation and delivery to coating Plant Area, square meters 600 0.80

 Positive materials Current collector welding

 Pertinent volume: positive active mass/year Pertinent volume: number of cells/year

 Direct Labor, hours/year 14,400 0.50 Direct Labor, hours/year 36,000 0.70

 Capital Equipment, million$ 2.0 0.70 Capital Equipment, million$ 4.0 0.80

 Plant Area, square meters 600 0.60 Plant Area, square meters 600 0.80

 Negative materials Inserting cell in container

 Pertinent volume: negative active mass/year Pertinent volume: number of cells/year

 Direct Labor, hours/year 14,400 0.50 Direct Labor, hours/year 21,600 0.50

 Capital Equipment, million$ 2.0 0.70 Capital Equipment, million$ 3.0 0.70

 Plant Area, square meters 600 0.60 Plant Area, square meters 600 0.60

Electrode coating Electrolyte filling, and cell sealing

 Positive materials Pertinent volume: number of cells/year

 Pertinent volume: cell area/year Direct Labor, hours/year 36,000 0.50

 Baseline solvent evaporated, kg 2,309,021 0.20 Capital Equipment, million$ 5.0 0.70

 Direct Labor, hours/year 28,800 0.50 Plant Area, square meters 900 0.60

 Capital Equipment, million$ 8.0 0.80 Dry room airlocks and management

 Plant Area, square meters 750 0.80 Pertinent volume: dry room operating area, sq. meters

 Negative materials Direct Labor, hours/year 14,400 0.40

 Pertinent volume: cell area/year Capital Equipment, million$ 20.0 0.60

 Baseline solvent evaporated, kg 1,527,105 0.20 Plant Area, square meters 100 0.40

 Direct Labor, hours/year 28,800 0.50 Formation Cycling

 Capital Equipment, million$ 8.0 0.80 Pertinent volume: number of cells/year

 Plant Area, square meters 750 0.80 Baseline Cell Capacity, Ah 40 0.30

Solvent recovery Direct Labor, hours/year 57,600 0.70

 Pertinent volume: NMP mass/year Capital Equipment, million$ 30.0 0.80

 Direct Labor, hours/year 14,400 0.40 Plant Area, square meters 2,200 0.80

 Capital Equipment, million$ 3.0 0.60 Final Cell sealing

 Plant Area, square meters 225 0.60 Pertinent volume: number of cells/year

Calendering Direct Labor, hours/year 14,400 0.50

 Positive materials Capital Equipment, million$ 2.0 0.70

 Pertinent volume: cell area/year Plant Area, square meters 450 0.60

 Direct Labor, hours/year 14,400 0.50 Charge-Retention Testing

 Capital Equipment, million$ 1.0 0.70 Pertinent volume: number of cells/year

 Plant Area, square meters 225 0.60 Direct Labor, hours/year 21,600 0.40

 Negative materials Capital Equipment, million$ 4.75 0.70

 Pertinent volume: cell area/year Plant Area, square meters 900 0.60

 Direct Labor, hours/year 7,200 0.50 Module Assembly

 Capital Equipment, million$ 1.0 0.70 Pertinent volume: number of cells/year

 Plant Area, square meters 225 0.60 Direct Labor, hours/year 43,200 0.50

Inter-process Materials Handling Capital Equipment, million$ 6.0 0.70

 Pertinent volume: cell area/year Plant Area, square meters 600 0.60

 Direct Labor, hours/year 28,800 0.70 Battery Pack Assembly and Testing

 Capital Equipment, million$ 1.5 0.70 Pertinent volume: number of cells/year

 Plant Area, square meters 900 0.60 Number of modules per pack 4 0.30

Electrode Slitting (positive and negative) Direct Labor, hours/year 43,200 0.50

 Pertinent volume: cell area/year Capital Equipment, million$ 6.0 0.70

 Direct Labor, hours/year 28,800 0.50 Plant Area, square meters 900 0.60

 Capital Equipment, million$ 2.0 0.70 Rejected Cell and Scrap Recycle

 Plant Area, square meters 300 0.60 Pertinent volume: number of cells/year

Vacuum Drying of Electrodes Direct Labor, hours/year 36,000 0.70

 Pertinent volume: cell area/year Capital Equipment, million$ 2.5 0.70

 Direct Labor, hours/year 14,400 0.50 Plant Area, square meters 600 0.60

 Capital Equipment, million$ 1.6 0.70 Shipping

 3 11/29/2011
Battery 1 Battery 2 Battery 3 Battery 4 Battery 5

Calculated Battery Parameters

Battery energy storage, kWh 10.7 10.7 10.7 10.7 10.7

Battery power at 80 % OCV, kW 55.4 65.0 80.0 95.0 110.0

Required battery power, kW 50.0 65.0 80.0 95.0 110.0

Capacity, Ah 30.9 30.8 30.7 30.6 30.6

Number of cells 96.0 96.0 96.0 96.0 96.0

Battery weight, kg 71.7 73.5 77.0 80.8 85.1

Battery volume, L 37.7 38.6 40.0 41.7 43.5

Vehicle electric range, miles 25.0 25.0 25.0 25.0 25.0

Investment Costs

Capital equipment cost including installation, mil$ 157 161 167 173 180

Building, Land and Utilities

 Area, m2

 18,351 18,836 19,580 20,337 21,126

 Cost, $/m2

 3,000 3,000 3,000 3,000 3,000

 Building investment, mil$ 55 57 59 61 63

Launch Costs

 Rate: 5% of direct annual materials + 10% of other annual costs

 Total, million$ 12 13 13 14 15

Working capital (30% of annual variable costs), mil$ 33 34 36 38 40

Total investment, mil$ 257 264 275 286 298

Unit Cost of Modules for One Battery Pack, $

Variable Cost

Materials and Purchased Items 

 Cell materials 1,551 1,619 1,732 1,855 1,991

 Cell purchased Items 87 87 88 89 90

 Module 306 306 307 308 309

 Total 1,944 2,013 2,127 2,251 2,389

Direct Labor

 Electrode processing 37 40 44 48 53

 Cell assembly 34 34 34 34 34

 Formation cycling, testing and sealing 22 22 22 22 22

 Module assembly and testing 16 16 16 16 16

 Rejection and recycling 9 9 9 9 9

 Receiving and shipping 9 9 9 9 9

 Control laboratory 6 6 6 6 6

 Total 133 136 140 145 149

Variable Overhead 111 114 118 122 126

Total Variable Cost 2,188 2,262 2,385 2,518 2,664

Fixed Expenses

General, Sales, Administration 133 136 141 146 151

Research and Development 116 119 123 128 132

Depreciation 289 296 308 319 331

Total Fixed Expenses 538 551 572 593 615

Profits after taxes 129 132 137 143 149

Total unit cost per battery not including warranty, $ 2,854 2,946 3,094 3,253 3,428

Summary of Unit Costs, $

Materials 1,551 1,619 1,732 1,855 1,991

Purchased Items 393 394 395 397 399

Direct Labor 133 136 140 145 149

Variable Overhead 111 114 118 122 126

General, Sales, Administration 133 136 141 146 151

Research and Development 116 119 123 128 132

Depreciation 289 296 308 319 331

Profit 129 132 137 143 149

Warranty 160 165 173 182 192

Price, $ 3,014 3,111 3,267 3,436 3,620

Price for Modules Only
Thermal Data Input

Battery 1 Battery 2 Battery 3 Battery 4

Heat Generation Rates in Battery Pack During Driving

microHEV battery packs, default heat generation 100 100 100 100

HEV-HP Battery Packs

Estimated average power from battery pack, kW 6.0 6.0 6.0 6.0

Default heat generation, W 300 231 188 158

PHEV or EV Battery Packs

Calculation of Default Heat Generation

 Battery power, kW 50 65 80 95

 Maximum average long-term discharge rate, kW 23.4 23.4 23.4 23.4

 Cell ASI for energy at C/3 rate, ohm-cm2

55.2 55.7 56.6 57.5

 Average voltage on discharge, V 293 301 310 316

 Average current on discharge, I 80.0 77.6 75.4 74.0

 Heat generation, W or joules/sec 3871 3062 2303 1829

 Efficiency for discharge, % 83.5 86.9 90.2 92.2

Override heat generation, W

Selected heat generation rate, W 3871 3062 2303 1829

Thermal Conductivities

Layer Thicknesses, microns

Positive foil 20.0 20.0 20.0 20.0

Negative foil 12.0 12.0 12.0 12.0

Positive electrode 90.0 74.7 58.5 47.3

Negative electrode 100.0 83.0 65.0 52.6

Separator 20.0 20.0 20.0 20.0

Total Bicell Layer 452.1 387.4 318.9 271.8

Thermal Conductivities, W/cm-K

Aluminum 2.0 2.0 2.0 2.0

Copper 3.8 3.8 3.8 3.8

Positive electrode 0.013 0.013 0.013 0.013

Negative electrode 0.013 0.013 0.013 0.013

Separator 0.0020 0.0020 0.0020 0.0020

Thermal conductivity through folded cell edge 0.01 0.01 0.01 0.01

Across layers 0.00918 0.00875 0.00818 0.00768

Parallel to layers 0.20046 0.23178 0.27874 0.32476

Ethylene glycol-50% water solution 0.0043 0.0043 0.0043 0.0043

Heating Under Adiabatic Conditions for Discharge of Available Energy for PHEV or EV Battery Packs

Estimated heat capacity of battery, J/g-oC 0.85 0.85 0.85 0.85

Mass of battery pack less 50% of jacket mass kg 66.4 68.4 71.8 75.6

Available energy, kWh 7.5 7.5 7.5 7.5

Temperature rise under adiabatic conditions for available energy, oC 79.1 60.8 43.5 32.9

Temperature Drop from Cell Center to Module Wall at Steady State

Heat rejection per cell, W 40.33 31.89 23.99 19.05

Length of aluminum conductor, cm 18.55 18.82 19.27 19.76

Override thickness of aluminum conductors, cm

Default thickness of aluminum conductors, cm 0.04 0.04 0.04 0.04

Total conduction thickness including pouch aluminum, cm 0.06 0.06 0.06 0.06

Thickness of cell, cm 0.80 0.80 0.80 0.80

Width of cell, cm 14.5 14.7 15.0 15.4

Thickness of cell edge, cm 0.10 0.10 0.10 0.10

Thermal conductivity of aluminum, W/cm-K 2.00 2.00 2.00 2.00

Thermal conductivity across cell layers, W/cm-K 0.00918 0.00875 0.00818 0.00768

Thermal conductivity parallel to cell layers, W/cm-K 0.20046 0.23178 0.27874 0.32476

Heat transfer through cell edges per unit temperature differential, W/

oC 0.71928 0.79263 0.89911 1.00056

Heat transfer through cell sides per unit temperature differential, W/

oC 3.01345 3.18884 3.41815 3.61357

Temperature drop from cell center to module wall, oC 10.80 8.01 5.56 4.13

Thermal Modeling
Cooling with Ethylene Glycol-50% Water at Steady State

Volume of ethylene glycol-50% water solution within battery, L 2.58 2.42 2.24 2.11

Mass of ethylene glycol-50% water solution within battery, kg 2.76 2.58 2.39 2.26

Total rise in fluid temperature, oC 1.0 1.0 1.0 1.0

Heat capacity of ethylene glycol-50% water solution, J/g-oC 3.26 3.26 3.26 3.26

Fluid density, g/mL 1.07 1.07 1.07 1.07

Required rate of fluid flow, mL/sec 1109 877 659 524

Fluid mass rate (G), g/sec-cm2

47.39 40.16 32.74 27.65

Flow passage thickness, cm 0.58 0.53 0.48 0.44

Hydraulic diameter, Dh 1.04 0.95 0.86 0.79

Fluid flow cross-section through battery pack jacket, cm2

25 23 22 20

Fluid flow velocity, cm/sec 44.3 37.5 30.6 25.8

Total flow distance, cm 101 101 101 102

Fluid viscosity (μ), poise (g/s-cm) 0.05 0.05 0.05 0.05

Reynolds number 982 767 565 439

Pressure drop, bars = 48*μ*GL/(RhoDh^2) 0.010 0.010 0.010 0.010

Target pressure drop, bars 0.010 0.010 0.010 0.010

Total efficiency of pump and motor, % 50 50 50 50

Power to compressor and pump, W 1551 1226 923 733

Temperature Drop From Module Wall to Bulk Fluid 

Graetz number, Gz 425 305 203 145

Mean Nusselt number, Nu 13.97 12.56 11.05 9.98

Conductivity of fluid, W/cm-oC 0.0043 0.0043 0.0043 0.0043

h = Nu*k/Dh, W/cm2-

oC 0.057989 0.056600 0.055064 0.053989

Effective area, cm2

3201 3248 3325 3409

Temperature difference at steady state, oC 20.86 16.66 12.58 9.94

Maximum rise of center of cells above coolant inlet 32.16 25.16 18.63 14.57

Heating and Cooling Required for Maintaining Pack Temperature

Cooling during hot ambient conditions

Effective ambient temperature, oC 50 50 50 50

Battery temperature target, oC 25 25 25 25

Insulation thickness, cm 1 1 1 1

Insulation area, cm2

7013 7116 7287 7473

Thermal conductivity of pack jacket insulation, W/cm-K 0.00027 0.00027 0.00027 0.00027

Cooling required at steady state, W 47 48 49 50

Heating during cold ambient conditions

Ambient temperature, oC -15 -15 -15 -15

Battery temperature target, oC 5 5 5 5

Heat Input required at steady state, W 38 38 39 40
Heat Required to Heat Battery During Cold Start

Battery temperature at startup, oC -15 -15 -15 -15

Battery temperature after heating, oC 5 5 5 5

Heat required, Wh 314 323 339 357

Power of heating elements, W 2000 2000 2000 2000

Time required for heat up, min 9.4 9.7 10.2 10.7

Cooling System Parameters for Use of Vehicle Air Conditioner

Cooling Added Added Performance

System Capacity, W Weight, kg Volume, L Coefficient

Refrig 1 500 2.0 0.8 2.5

Refrig 2 1000 3.0 1.2 2.5

Refrig 3 3000 5.0 2.0 2.5

Refrig 4 6000 7.0 2.8 2.5

Adjustable parameters

Constant parameters
Battery 5

100

6.0

136

110

23.4

58.5

320

73.0

1501

93.6

1501

20.0

12.0

39.1

43.5

20.0

237.2

2.0

3.8

0.013

0.013

0.0020

0.01

0.00725

0.37034

0.0043

ery Packs

0.85

79.8

7.5

25.5

15.63

20.28

0.04

0.06

0.80

15.8

0.10

2.00

0.00725

0.37034

1.09922

3.78621

3.20
2.01

2.16

1.0

3.26

1.07

430

23.84

0.41

0.74

19

22.3

102

0.05

353

0.010

0.010

50

601

107

9.15

0.0043

0.053237

3500

8.06

11.76

50

25

1

7678

0.00027

52

-15

5

41
-15

5

377

2000

11.3
Baseline Lithium-Ion Battery Manufacturing Plant Schematic Diagram

100,000 battery NCA-Gr packs per year, 50-kW battery power, 40-Ah capacity, 60 cells per battery

Operating year: 300 days with three 8-hr shifts per day (two shifts for receiving and shipping)

Shipping

Receiving

Control 

Laboratory

Battery Pack 

Assembly and 

Testing

Module 

Cell Stacking

Solvent 

Evaporation

Positive

Negative

Electrode 

Coating

Positive

Negative

Electrode 

Slitting

Vacuum 

Drying

Electrode Materials 

Preparation

Positive

Negative Calendering

Solvent 

Recovery

Air 

Locks

Baseline Lithium-Ion Battery Manufacturing Plant Schematic Diagram

100,000 battery NCA-Gr packs per year, 50-kW battery power, 40-Ah capacity, 60 cells per battery

Operating year: 300 days with three 8-hr shifts per day (two shifts for receiving and shipping)

The areas in this diagram for each processing step are approximately proportional to the 

estimated plant areas in the baseline plant.

Shipping

Cell and 

Scrap 

Recycling

Receiving

Control 

Laboratory

Assembly Route

Battery Pack 

Assembly and 

Testing

Module 

Assembly

Formation 

Cycling

Current 

Collector

Welding

Enclosing 

Cell in 

Container

Electrolyte Filling

and Cell Closing

Cell Stacking

Solvent 

Evaporation

Positive

Negative

Electrode 

Coating

Positive

Negative

Electrode 

Slitting

Vacuum 

Drying

Electrode Materials 

Preparation

Positive

Negative Calendering

Solvent 

Recovery

Air 

Locks

ChargeRetention 

Testing 

Final 

Cell 

Sealing

Dry Room

Materials 

Handling

Outdoor dry-room air 

processing equipment
Polymer Seal of 

Cell Container 

to Terminal 

Ultrasonic Welds

of Terminal to 

Collector Foils

Cell Cross-Sections

After Edge Sealing

After Edge Shaping and 

Addition of Aluminum 

Conduction Channel

Cell with Stiff, MultiLayer Container

Terminal Seal

Polymer Seal of 

Cell Container 

to Terminal 

Ultrasonic Welds

of Terminal to 

Collector Foils

Cell Cross-Sections

After Edge Sealing

After Edge Shaping and 

Addition of Aluminum 

Conduction Channel

Aluminum 

Conduction 

Channel
Heat Transfer Surfaces

on Top and Bottom of 

Container in Contact

with Cell Conductors

Module 

Terminal 

Cell Terminal 

Connections

Heat Transfer Surfaces

on Top and Bottom of 

Container in Contact

with Cell Conductors

Module 

Terminal 

Cell Terminal 

Connections

Double-Seamed 

Module Closure
A

A

B

B

Pack Cover 

Attached to 

Module Tray

Compression Plate 

and Straps

Coolant 

Polymer Foam to 

Block Flow

A

A

Section A-A Section B-B

B

B

Pack Cover 

Attached to 

Module Tray

Compression Plate 

and Straps

Coolant 

Coolant 

Inlet

Polymer Foam to 

Block Flow

Pack with Two Rows of Modules

Pack with One Row of Modules

Section A-A Section B-B
Pack with One Row of Modules
NCA Graph NMC441 Graph

Negative to positive capacity ratio parameter 1.25 1.25

Negative to positive mass ratio 0.61 0.66

Actual negative to positive capacity ratio 1.24 1.24

Positive Negative Positive Negative

Half cell reversible capacity, mAh/g: 160 330 175 330

First cycle efficiency: 0.87 0.90 0.87 0.90

First cycle capacity, mAh/g: 184 367 201 367

Li captured in negative SEI, mAh/g: 22 24

Cyclable Li left in negative, mAh/g: 2 2

Delivered full cell capacity, mAh/g: 160 264 175 264

To enter into System Selection worksheet NCA Graph NMC441 Graph

Active material capacity, mAh/g: 160 330 175 330

N/P capacity ratio after formation 1.25 1.25

Input required

Output to model (manually entered)
LFP Graph LMO LTO LMO Graph

1.07 1.10 1.12

0.54 0.70 0.36

1.20 1.07 1.20

Positive Negative Positive Negative Positive Negative

167 330 108 170 108 330

0.99 0.90 0.95 0.99 0.95 0.90

169 367 114 172 114 367

20 1 13

0 5 0

149 275 108 155 100 275

LFP Graph LMO LTO LMO Graph

149 330 108 170 100 330

1.20 1.10 1.20
NMC333 Graph

1.25

0.57

1.24

Positive Negative

150 330

0.87 0.90

172 367

21

2

150 264

NMC333 Graph

150 330

1.25
BatPaC Model Version: β

This model was created by:

Paul Nelson, Kevin Gallagher, Ira Bloom and Dennis Dees

Chemical Science and Engineering Division

Argonne National Laboratory

9700 S. Cass Ave, Lemont, IL 60439

www.cse.anl.gov

July,17 2011