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Development of a Fast-Charging Li-Ion polimer Battery for StoreDot High-Speed Charging Battery Pack for Electric Vehicles (EVs)

BatteryThermalManagementEVBatteryFastChargingLiIonPolymer

Background and Customer Requirements

In April 2019, StoreDot introduced a revolutionary new type of Li-Ion polymer (pouch) cells capable of achieving incredibly high charge rates—10C charge current, which enables a full charge in just 5 minutes. The goal was to create a fully operational battery pack to demonstrate StoreDot's superior cell technology by powering an electric vehicle (EV).

Client Requirements:

  • A functional Li-Ion polymer battery pack for EV applications.
  • Proof of 10C charge rate capability.
  • Compatibility with a given mechanical casing.
  • Design and implementation of a charging system to support the high charge rate.

Key Challenges:

  1. Mechanical Constraints: The provided casing was not designed for this type of battery, making it too small to fit all the required cells.
  2. Wiring Challenges: The high current required heavy-duty conductors and wiring, with limited space within the casing.
  3. Heat Dissipation: Extremely high currents generated significant heat, requiring effective cooling solutions.
  4. Charging System: A charger capable of handling the 10C charge rate (130A) was needed.

Design Process:

Maximizing Space
  • A 3D-printed case extension was designed to fit the battery into the motorcycle seat, maximizing the available volume.
  • The cells were optimally arranged to minimize the need for busbars and wiring.
Heat Management
  • Two heat dissipation options were explored:
    • Option 1: Air cooling with wide spacing between cells and fans for better airflow.
    • Option 2: Conductive plates between cells to transfer heat to the casing.
  • After testing and simulations, Option 1 (air cooling) was selected for its superior effectiveness.
  • A custom internal matrix with slots for each cell was designed to maximize spacing, and a 500mm 3D-printed part was created to support this structure.
Wiring and Connectors
  • Custom-shaped copper conductors were designed to handle currents up to 150A.
  • Anderson 4×2 PP45-15 pins were used for the 150A charge connector, and a D-type connector was used for balancing.
 

Demonstrator and Testing

  • A smaller version of the battery module (6S4P) was assembled using the same matrix design.
  • Charge/discharge tests were performed, including heat dissipation tests, to validate the design.
  • High-precision venting strips were added to the casing, aligned with the spacing between the cells, to improve airflow and cooling.

Final Battery Assembly

  • The final battery pack (14S12P, 51.8V, 13.2Ah) was assembled, with the casing extended using 3D printing to maximize space between cells.
  • The battery was designed to handle a maximum voltage of 58.8V and a charging power of 7,650W (58.8V × 130A).

Production Process

  • The production process included cell testing and grouping, assembly of conductors, and integration of the cooling system.
  • High-precision venting strips were added to ensure proper heat dissipation during operation.

Final solution

  • The final product was a fully operational Li-Ion polymer battery pack, capable of 10C charging, designed to fit within the constraints of the given mechanical casing.
  • The battery successfully demonstrated StoreDot’s advanced cell technology in a real-world EV application.

Conclusion

AMICELL successfully delivered a custom-designed battery solution that not only met but exceeded StoreDot's requirements for high-speed charging and heat management. This case study highlights AMICELL’s expertise in developing innovative battery solutions for cutting-edge applications.

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