1. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Introduction Design, Construction, and Applications of a Midsize Lithium Ion Battery Pack Patrick Montalbano, KC2SAE Rochester Institute of Technology, 2012 College of Applied Science and Technology Mechanical Engineering Technology

2. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Battery Technologies Lead Acid (Pb) Very low cost, mass produced, highly scalable Worst energy density: very heavy Nickel Cadmium (NiCd) Low cost, mass produced Poor energy density, limited scale Nickel Metal Hydride (NiMH) Good energy density, good shelf life Limited current Lithium Ion (Li+) High Energy density: lightweight High cost, additional safety considerations Energy Density

3. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Form Factor Rectangular Cells Customized Shape IC Protection Cylindrical Cells Standardized Flexible Platform Highly Scalable Hardware Protection Limited in Size Model 18650 Highly Commercialized Commodity Pricing Require additional voltage/circuit protection Constant current/constant voltage charging Nissan Leaf Battery

4. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Lithium Applications Integrated into personal electronics Lithium is well suited for portable electronics : Size Limitations High power demand Lightweight Rechargeable All-electric EVs

5. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Battery Backpack Battery On-Frame Backpack To be used for extended use of Amateur (ham) radio on hikes -Easily adaptable in military or commercial applications Battery

6. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Flat Midsize Pack Easy to Carry 5.5 lbs Common voltage (14.4v) High Capacity 354 Wh Highly configurable An innovative solution for midsize powered devices Carbon Fiber Composite Load bearing Sealed against water/dust 1.75 Overall Thickness

7. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Level 1 Assembly Level 1: Parallel assemble providing cell level over-current protection Level 2: Series elements producing operating voltage Level 3: Power Control Board to load

8. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Mold Making 1.Plug constructed from wood is 1:1 representation of finished part 2.Fiberglass mold cavity is inverted for carbon fiber layup

9. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Layup 3. Carbon reinforced epoxy laminate is compacted using vacuum 4. Part is removed and finished

10. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Final Prototype (2) Anderson Power Pole terminals State of Charge fuel LED gage Developer pass-through DB-9 (voltage and 1-wire temperature) Shown with UHF/VHF transceiver

11. Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and Innovation Symposium Project Summary Special thanks to battery cell sponsor, Tesla Motors. Packs can be built using rejected automotive cells Development Expenditures 14.4v, 22Ah @ 30A 354 Wh 13 x 9 x 1.75 inches 5.5 lbs Battery Specs. Composites & tooling; $300 Electrical connectivity & PCB; $80 Cells; $150 - $240 Housing & hardware; $130 Commercialization Estimate

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