### Selected Sy **stem: NCA-G**  **NCA-G NMC441-G**  **LFP-G LMO-LTO**  **LMO-G**

**Positiv e Electrode**  Active material capacity , mAh/g: 160 160 175 150 108 100

We ight %

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/cm 3

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 **Negativ e 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

We ight %

Active material 95 95 95 95 89 95

Carbon 0 0 0 0 6 0

Binder 5 5 5 5 5 5

Binder solvent Wa ter Wa ter Wa ter Wa ter Wa ter Wa ter Void, Vol% % 34 34 34 34 40 34 Density, g/cm 3

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

**Positiv e Foil** 

Material Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Thickness,  m 20 20 20 20 20 20 **Negativ e 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/cm 3 0.46 0.46 0.46 0.46 0.46 0.46 **Electroly**

**te density , g/cm**  **3** 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 cm 2 /cm 3 74000 74000 74000 74000 500000 74000

Positive electrode cm 2 /cm 3 8900 8900 8900 420000 49200 49200 Electrode system ASI for power, ohm-cm 2

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-cm 2 51.92 51.9 58.5 55.0 13.3 44.0 Maximum electrode coating thickness,  m 100 100 100 100 100 100

**Ava ilable 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, $/m 2 0.80 1.00 0.80 0.80 0.80 0.80 0.80 Negative current collector foil, $/m 2 1.80 1.00 1.80 1.80 1.80 0.80 1.80 Separators, $/m 2 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.xls11/29/20114 0900006480f75800.xls11/29/2011

### Sy **stem Chemistry Input** 

**Finished Cell Materials Battery 1**  **Battery 2 Battery 3**  **Battery 4 Battery 5**  Positive Electrode, g We ight % 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 We ight % 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, m 2 Al 20 2.70 0.476 0.571 0.726 0.893 1.077 Negative foil, m 2 Cu 12 8.92 0.517 0.615 0.774 0.946 1.135 Separator, m 2 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-w idth 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/cm 3 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/cm 3 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 pow er, 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-cm 2 51.9 51.9 51.9 51.9 51.9 Excess negative area, % 2.50 2.46 2.40 2.34 2.28
Maximum allow able 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 pow er, o C/sec 0.05 0.05 0.05 0.05 0.05 Target % OCV at full pow er 80 80 80 80 80 % OCV at full pow er 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 pow er burst (10 or 2), s 10 10 10 10 10 Battery pow er, 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 row s 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 w ith 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

**LiNi0.80Co0.15A l0.05O2-Graphite** 

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


### Calculated Cell Parameters
**Capacity , A**  **h** 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/cm 2 85 85 85 85 85 Limiting C-rate, A/Ah 27 27 27 27 27 Electrode system ASI for pow er, ohm-cm 2 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-cm 2 0.781 0.802 0.836 0.875 0.917
Total cell terminal ASI, ohms-cm 2 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 hardw are and battery resistance, ohm-cm 2 0.887 0.918 0.975 1.036 1.102 Total cell ASI for pow er, ohm-cm 2 30.6 31.4 32.4 33.7 35.1 Total cell ASI for energy (C/3 rate), ohm-cm 2 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 A rea Calculation**  Area determined at target % OCV 7,911 10,524 13,401 16,523 19,961 Area limited by max. allow ed electrode thickness, 8,758 8,732 8,705 8,687 8,674 Cell area based on total ASI for pow er, cm 2 8,758 10,524 13,401 16,523 19,961
**Cell Dimensions** Number of bicell layers (97% packing density) 17 19 23 28 32

Wi dth 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

Wi dth of terminals, mm 135 137 140 144 148 Length of terminal material, mm 26 26 26 26 26

Wi dth of cell, mm 145 147 150 154 158 Length of cell, mm 215 218 223 228 233
Volume of cell, cm 3 249 256 268 280 294


### Module Parameters

We ight 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 w all 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 w eight 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 w idth, 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 w eight, kg 10.20 10.54 11.10 11.72 12.41



### Program for Calculating Performance and Materials Requirements

**LiNi0.80Co0.15A l0.05O2-Graphite** 

2 11/29/2011

### Calculated Battery **Parameters**
Total battery energy storage, kW h 10.71 10.71 10.71 10.71 10.71 Useable battery energy storage, kW h 7.50 7.50 7.50 7.50 7.50 OCV at full pow er, 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 pow er at target % OCV and SOC, kW 55.4 65.0 80.0 95.0 110.0 Maximum current at full pow er, A 178 238 293 348 403 Maximum current density at full pow er, mA/cm 2 20.31 22.65 21.89 21.08 20.21 C-rate at full pow er, 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 w idth, 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

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

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

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

We ight of bus bar for packs w ith 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

Pow er of battery heaters, kW 2.0 2.0 2.0 2.0 2.0

We ight of battery pack heaters (0.1 kg/kW ), kW 0.2 0.2 0.2 0.2 0.2 Battery jacket w eight parameter, g/cm 2 0.84 0.84 0.84 0.84 0.84 Battery coolant w eight w ithin jacket, kg 2.76 2.58 2.39 2.26 2.16 Battery jacket w eight, kg 10.5 10.3 10.3 10.5 10.7 Battery w eight, 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 Sy**

**stem**
Heat generation rate for pack, W 3871 3062 2303 1829 1501 Cooling System Refrig 4 Refrig 4 Refrig 4 Refrig 3 Refrig 3

We ight and Volume of Cooling System Exterior to Battery

W eight, 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, W h/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 (A**  **h) 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, kW h 10.7 10.7 10.7 10.7 10.7 Battery pow er at target % OCV, kW 55.4 65.0 80.0 95.0 110.0 Required battery pow er, 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 w eight, kg 71.7 73.5 77.0 80.8 85.1 Battery volume, L 37.7 38.6 40.0 41.7 43.5

We ight and Volume of Components Exterior to Battery

W eight, 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 pow er 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, m 2 18,948 19,433 20,177 20,934 21,722 Cost, $/m 2 3,000 3,000 3,000 3,000 3,000 Building investment, mil$ 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

Wo rking 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**

**LiNi0.80Co0.15A l0.05O2-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 w arranty, $ 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

Wa rranty (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** 

**An nual Processing Rates**  Number of batteries manufactured per y ear 100,000 100,000 100,000 100,000 100,000 Energy , kW h per y ear 1,071,429 1,071,429 1,071,429 1,071,429 1,071,429 Number of accepted cells per y ear 9,600,000 9,600,000 9,600,000 9,600,000 9,600,000 Number of cells adjusted for y ield 10,105,263 10,105,263 10,105,263 10,105,263 10,105,263
Electrode area, m 2 

### per y ear 8,849,807 10,635,012 13,542,347 16,696,902 20,171,351

Positive active m aterial, kg per y ear 2,114,763 2,108,617 2,102,158 2,097,740 2,094,497 Negative active m aterial, kg per y ear 1,313,655 1,309,372 1,304,627 1,301,131 1,298,344 Binder solvent, kg per y ear 2,851,366 2,843,080 2,834,371 2,828,414 2,824,041 Dry room operating area, m 2 

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

## Direct Materials Costs
**Total Cell Materials per A ccepted 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

**LiNi0.80Co0.15A l0.05O2-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), m 2 

### 90.2 0.555 0.666 0.847 1.042 1.257 Negative current collector (copper foil), m 2 

### 90.2 0.603 0.717 0.903 1.105 1.325 Separators, m 2 

### 98.0 0.998 1.199 1.524 1.877 2.264 Electroly te, L 94.0 0.078 0.080 0.083 0.087 0.091

**An nual 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), m 2 

### 5,328,846 6,396,410 8,130,140 10,005,110 12,063,572 Negative current collector (copper foil), m 2 

### 5,786,976 6,887,360 8,673,422 10,603,519 12,720,785 Separators, m 2 

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

Alum inum 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, $/m 2 

### 0.80 1.00 0.80 0.80 0.80 0.80 0.80 Negative current collector, $/m 2 

### 1.80 1.00 1.80 1.80 1.80 1.80 1.80 Separators, $/m 2 

### 2.00 1.00 2.00 2.00 2.00 2.00 2.00 Electroly te, $/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 Electroly te 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, $**

Alum inum thermal conductors (each) 0.80 0.22 0.22 0.22 0.23 0.24

Alum inum 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

Autom atic 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 sy stem 435.00 435.00 435.00 435.00 435.00 **Cost to OEM for Materials and Purchased Items for Thermal Management System, $** Baseline thermal sy stem 120.00 120.00 120.00 120.00 120.00 Additions to AC sy stem 160.00 160.00 120.00 80.00 80.00 Heating sy stem 40.00 40.00 40.00 40.00 40.00 Total cost to OEM for thermal management sy stem 320.00 320.00 280.00 240.00 240.00

3 11/29/2011

## Battery

**A ssembly**  **Costs**

**Baseline Operation (Pertinent rate)**  **Plant p**  **Receiving (Energy/yr)**

Volum e ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232 Direct Labor, hours/y ear 14,400 0.40 15,655 15,655 15,655 15,655 15,655 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.235 1.231 1.228 1.225 1.223 Direct Labor, hours/y ear 14,400 0.50 16,002 15,979 15,954 15,937 15,925 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.089 1.086 1.082 1.079 1.077 Direct Labor, hours/y ear 14,400 0.50 15,030 15,005 14,978 14,958 14,942 Capital Equipm ent, 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/y r)

Volum e 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/y ear 28,800 0.50 29,903 32,780 36,991 41,074 45,145 Capital Equipm ent, million$ 8.0 0.80 8.9 10.3 12.4 14.7 17.1

4 11/29/2011 Capital Equipm ent, 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/y r)

Volum e 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/y ear 28,800 0.50 29,903 32,780 36,991 41,074 45,145 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.235 1.231 1.228 1.225 1.223 Direct Labor, hours/y ear 14,400 0.40 15,668 15,650 15,631 15,617 15,608 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457 Direct Labor, hours/y ear 14,400 0.50 14,951 16,390 18,495 20,537 22,573 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457 Direct Labor, hours/y ear 7,200 0.50 7,476 8,195 9,248 10,268 11,286 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457 Direct Labor, hours/y ear 28,800 0.7 30,356 34,523 40,886 47,341 54,038 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457 Direct Labor, hours/y ear 28,800 0.5 29,903 32,780 36,991 41,074 45,145 Capital Equipm ent, 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**

Volum e ratio (volume/baseline volume) 1.078 1.296 1.650 2.034 2.457 Direct Labor, hours/y ear 14,400 0.5 14,951 16,390 18,495 20,537 22,573 Capital Equipm ent, 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**

Volum e ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232

5 11/29/2011 **Control Laboratory**

Volum e ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232 Direct Labor, hours/y ear 28,800 0.5 31,971 31,971 31,971 31,971 31,971 Capital Equipm ent, 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 A ssembly in Dry Room**  Cell stacking (number of cells)

Volum e 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/y ear 36,000 0.7 50,025 50,025 50,025 50,025 50,025 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 36,000 0.7 50,025 50,025 50,025 50,025 50,025 Capital Equipm ent, 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/y r)

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 21,600 0.5 27,322 27,322 27,322 27,322 27,322 Capital Equipm ent, 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

### Electroly

te filling, and cell sealing (number of cells/y r)

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 36,000 0.5 45,537 45,537 45,537 45,537 45,537 Capital Equipm ent, 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)

Volum e ratio (volume/baseline volume) 1.350 1.362 1.381 1.399 1.417 Direct Labor, hours/y ear 14,400 0.4 16,237 16,296 16,382 16,468 16,554 Capital Equipm ent, 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)**

Volum e 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/y ear 57,600 0.7 80,040 80,040 80,040 80,040 80,040 Capital Equipm ent, 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**

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 14,400 0.5 18,215 18,215 18,215 18,215 18,215 Capital Equipm ent, 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**

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 21,600 0.4 26,068 26,068 26,068 26,068 26,068 Capital Equipm ent, 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 A**

**ssembly (number of cells/yr)**

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600

6 11/29/2011 **Module A**

**ssembly (number of cells/yr)**

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 43,200 0.5 54,644 54,644 54,644 54,644 54,644 Capital Equipm ent, 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 A**

**ssembly and Testing, 100,000 Battery Packs per year**

Volum e 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/y ear 43,200 0.5 54,644 54,644 54,644 54,644 54,644 Capital Equipm ent, 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)**

Volum e ratio (volume/baseline volume) 1.600 1.600 1.600 1.600 1.600 Direct Labor, hours/y ear 36,000 0.7 50,025 50,025 50,025 50,025 50,025 Capital Equipm ent, 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)**

Volum e ratio (volume/baseline volume) 1.232 1.232 1.232 1.232 1.232 Direct Labor, hours/y ear 28,800 0.5 31,971 31,971 31,971 31,971 31,971 Capital Equipm ent, 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/y ear 756,522 772,911 797,184 821,026 845,077 Capital Equipm ent, 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/y ear 720,092 736,481 760,754 784,597 808,648 Capital Equipm ent, 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 Electroly te 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 Sy stem 435.00 435.00 435.00 435.00 435.00 Thermal Management Sy stem 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 cy cling, 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 m aterials rejection and recy cling 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 **Ma terials and Purchased Items Summary** 

7 11/29/2011 

# 30%

10%

1% 9% 17% 7% 4% 12% 6% Positive Active Material

Negative Active Material

Carbon and Binders

Positive Current Collector

Negative Current Collector

Separators

Electroly te

7 11/29/2011

# 1% 4% 9% Cell Hardware

Module Hardware

Battery Jacket

8 11/29/2011

### Baseline Manufacturing Rates **Ma terial 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, kW h 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, m 2 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, m 2 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, $/m 2 0.80 1.00 Cost per battery, $ 15.00 Negative current collector foil, $/m 2 1.80 1.00 Plus cost per capacity, $/A (rounded up) 0.02 Separators, $/m 2 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), $/m 2 3000
Launch Cost rates Percent of direct annual materials cost, % 5 Percent of direct labor plus variable overhead, % 10

Wo rking 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 11/29/2011Wa rranty Cost, % added to price 5.6 

### Battery A

**ssembly 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, kW h 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, m 2 18,351 18,836 19,580 20,337 21,126 Cost, $/m 2 3,000 3,000 3,000 3,000 3,000 Building investment, mil$ 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

Wo rking 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

Wa rranty 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-cm 2 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- o C 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, kW h 7.5 7.5 7.5 7.5 Temperature rise under adiabatic conditions for available energy, o C 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

Wi dth 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 / o C 0.71928 0.79263 0.89911 1.00056 Heat transfer through cell sides per unit temperature differential, W / o C 3.01345 3.18884 3.41815 3.61357 Temperature drop from cell center to module wall, o C 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, o C 1.0 1.0 1.0 1.0 Heat capacity of ethylene glycol-50% water solution, J/g- o C 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-cm 2 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, cm 2 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- o C 0.0043 0.0043 0.0043 0.0043
h = Nu*k/Dh, W /cm 2

- o C 0.057989 0.056600 0.055064 0.053989
Effective area, cm 2 3201 3248 3325 3409 Temperature difference at steady state, o C 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, o C 50 50 50 50 Battery temperature target, o C 25 25 25 25 Insulation thickness, cm 1 1 1 1
Insulation area, cm 2 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, o C -15 -15 -15 -15 Battery temperature target, o C 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, o C -15 -15 -15 -15 Battery temperature after heating, o C 5 5 5 5 Heat required, W h 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 We ight, 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 

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

3.202.01

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 M**  **anufacturing Plant Schematic Diagram** 

**100,000 battery**

**N CA** 

**- Gr**  **packs per y ear,**  **50**

**- kW battery**  **p ow**  **er, 40** 

**- Ah**  **c apacity**  **, 60 cells per battery Operating**  **ye ar:**  **300 day s with**  **three 8**

**- hr**  **shifts per day**

**( tw**  **o shifts for receiving and shipping)**



# Shipping **Receiv ing** 

**Control Laboratory**  **Battery Pack** 
**As sembly** 

**a nd**  **Testing**



# Module **Cell Stacking**  **Solvent Evaporation** 
**Positive**

**Negative Electrode**  **Coating**
**Positive**

**Negative Electrode**  **Slitting**

**Vacuum Dry**  **ing Electrode Materials**  **Preparation**
**Positive**

**Negative Calendering**  **Solvent Recovery** 

**Ai r**  **Locks** 

# Baseline Lithium

**- Ion**  **Battery M**  **anufacturing Plant Schematic Diagram** 

**100,000 battery**

**N CA** 

**- Gr**  **packs per y ear,**  **50**

**- kW battery**  **p ow**  **er, 40** 

**- Ah**  **c apacity**  **, 60 cells per battery Operating**  **ye ar:**  **300 day s with**  **three 8**

**- hr**  **shifts per day**

**( tw**  **o 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 Recy**  **cling** 

# Receiv **ing**

**Control Laboratory** 



# As **sembly Route**  **Battery Pack** 
**As sembly** 

**a nd**  **Testing**



# Module

**As sembly**  **Formation**

**Cy cling**  **Current**
**Collector Welding**  **Enclosing**
**Cell in** 
**Container**

**Electroly te Filling**  **and Cell Closing Cell**  **Stacking Solvent**  **Evaporation**
**Positive**

**Negative Electrode**  **Coating**
**Positive**

**Negative Electrode**  **Slitting**

**Vacuum Dry**  **ing Electrode Materials**  **Preparation**
**Positive**

**Negative Calendering**  **Solvent Recovery** 

**Ai r**  **Locks**



# Charge

  ** Retention** **Testing Final** 

**Cell Sealing** 

**Dry**

**R oom**  **Materials**

**Handling**

**Outdoor dry**

**- room**  **air**

**processing equipment** 

## Poly **mer Seal of** 
**Cell Container**
**to Terminal**

**Ultrasonic Welds**
**of Terminal to**
**Collector Foils** 

# Cell Cross

**- Sections** 

**Af ter**  **Edge Sealing**

**Af ter**  **Edge Shaping and** 
**Ad dition of A**  **luminum**
**Conduction Channel** 



# Cell w **ith Stiff, Multi** 

**** **Lay er Container**  **Terminal Seal**

**Poly mer**  **Seal of**
**Cell Container**
**to Terminal**

**Ultrasonic Welds**
**of Terminal to**
**Collector Foils** 

# Cell Cross

**- Sections** 

**Af ter**  **Edge Sealing**

**Af ter**  **Edge Shaping and** 
**Ad dition of A**  **luminum**
**Conduction Channel** 

**Al uminum** 
**Conduction**
**Channel**

# Heat **Transfer Surfaces** 

**on Top and Bottom of**
**Container in Contact** 
**wi th Cell**  **Conductors**

**Module**
**Terminal Cell Terminal** 
**Connections Heat**  **Transfer Surfaces**  **on Top and Bottom of**
**Container in Contact** 
**wi th 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 m ass 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 cy cle efficiency : 0.87 0.90 0.87 0.90 First cy cle capacity , mAh/g: 184 367 201 367

Li captured in negative SEI, mAh/g: 22 24 Cy clable Li left in negative, mAh/g: 2 2 Delivered full cell capacity , mAh/g: 160 264 175 264

To enter into Sy stem Selection worksheet **NCA Graph**  **NMC441 Graph** 

Active m aterial 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