Proprietary Information, March,2006

Transcription

1

2 Ready for Global Shipment (LEV/EV) - High Volume Li-Ion Batteries! Tim Schäfer fer Company Secretary GAIA Akkumulatorenwerke GmbH, Nordhausen,, Germany Lithium Technology Corporation, Plymouth Meeting, PA, USA March 2006

3 Overview Company Overview Technology Manufacturing Process Product Portfolio Markets Li-Ion Batteries UN 3090 (Regulations) LIB Shipping and Testing Players & Solutions Developments/Projects GAIA-LTC Summary

4 Company Overview GAIA - a LTC Company Tim Schäfer Company Secretary Company Overview

5 History April 1996 Founding of GAIA 1997 Proprietary extrusion process 1998 Arch Hill, a Dutch venture capital company, acquires majority share of GAIA 1999 Installation of three pilot extrusion lines 2000 Refinement of battery production facilities 2002 Merger of GAIA and LTC 2003 Market entry with large format Lithium ion cells (special permission by LBA!) 2005 Market entry with Lithium ion batteries (special permission by LBA!)

6 Corporate Structure Lithium Technology Corporation is a Public US Corporation traded on the OTC Bulletin Board (LTHU.OB) LTC and GAIA were merged in 2002 combining two synergistic technologies Lithium Technology Corporation Plymouth Meeting Pennsylvania (USA) (US Operations) Plymouth Meeting Pennsylvania (USA) GAIA Akkumulatorenwerke, GmbH Nordhausen Thuringia (Germany)

7 Facilities US Operations (LTC - Plymouth Meeting) Corporate Headquarters US Government/Military Development Contracts R & D and cooperative programs with US raw material suppliers US Sales Battery design and assembly using GAIA cells Limited contract production of specialty flat cells European Operations (GAIA - Nordhausen) European Development Contracts R & D and cooperative programs with EU raw material suppliers European Sales Commercial Production of cylindrical cells Battery design and assembly

8 Current Operations Small Production/Large Pilot Scale Operation 57 Employees (17 in US, 40 in Germany) FACILITIES 176,000 ft 2 facility in Nordhausen, Germany 13,000 ft 2 facility in Plymouth Meeting, PA, USA PRODUCTS: Custom engineered batteries Development contracts Cylindrical and prismatic Lithium-Ion cells - from 5 Ah to 120 Ah

9 Company Overview GAIA a LTC Company Tim Schäfer Company Secretary Products & Technology

10 Process - Extrusion graphit, polymers and carbon black mixing and drying of anode materials y g g y p y dry blend anode electrolyte polymer anode on carrier foil LiCoO2, polymers and carbon black mixing and drying of cathode materials dry blend cathode electrolyte polymer cathode on carrier foil No emission of solvents Safe and environmental No ex-proof installation Cost-effective Co-extrusion of polymer blends

11 GAIA Product Portfolio Present cylindrical cells range in capacity from 5 Ah to 60 Ah GAIA offers two basic types of products taylored to different applications The HE product series is optimized towards high energy content with moderate rate capability (continuous discharge up to 2C) The HP and UHP series are designed to deliver maximum power (continuous discharge up to 10C) GAIA has developed battery packs of up to 600V to customer specifications

12 Large, High Power Engineered Lithium Ion Is LTC s Core Expertise GAIA cells offer the highest power of any commercial lithium ion cell in the western hemisphere* (most amperes or watts per kilogram) GAIA UHP product achieves 2400 W/kg (pulse) GAIA cells are the largest lithium ion cells produced in the western hemisphere (most energy capacity - watt-hours or amp hours) GAIA HE has 60 Ah or 216 Wh corresponding to 150 Wh/kg 120 Ah cell is in development LTC specializes in working with the customer to engineer solutions using standardized cells in customized configurations Custom engineered battery packs including electronic battery management systems * US and EU companies have an advantage selling the western hemisphere being domestic suppliers and it is unrealistic for US and EU companies to sell into Asia.

13 Company Overview GAIA a LTC Company Tim Schäfer Company Secretary GAIA Market

14 Markets with Projected Growth in Advanced Batteries Military/National Security Transportation Stationary Power Applications require flexibility in design, wide ranges of power output, broad operating temperatures, low weight and thousands of recharge cycles. Performance is more important than price. Market need is growing quickly. Development funding is available. Applications require rapid charging rates and long life in safe, durable high power storage for HEV, EV and fuel cell powered vehicles. Military, heavy duty and niche vehicle OEMs are early adopters. Immediate niches exist. Growing dependence on electrical power worldwide drives the demand for high quality high-reliability power for telecommunications, computers, mission critical applications, remote mobile and renewable power applications. Very large potential market.

15 Rechargeable Battery Market Size for National Security, Transportation, and Stationary Power Conventional Advanced Total Conventional Advanced Total Transportation $ 8,000 $ 50 $ 8,050 $ 7,400 $ 1,400 $ 8,800 National Security $ 2,000 $ 200 $ 2,200 $ 2,200 $ 500 $ 2,700 Stationary Power $ 5,000 $ 50 $ 5,050 $ 6,500 $ 250 $ 6,750 Total $ 15,000 $ 300 $ 15,300 $ 16,100 $ 2,150 $ 18,250 Conventional: Lead-Acid Advanced: Li-Ion, NiCd, NiMH Continuous growth of the advanced market over 700% in 8 years Within the advanced market, lithium ion will grow faster than competing chemistries Sources: Frost & Sullivan, LTC investigations

16 Safety Tests on Cell Level Electrical Tests Short Circuit at RT temperature rise Short Circuit at 60 C* Abnormal Charge Abnormal Discharge Mechanical Tests Crush small deformation Impact small dent Shock* de-contacting Vibration Fall small dents Environmental Tests Temperature Cycling Heating* Altitude Simulation ** According to UL1642 and ADR Summary of tests on 7.5 and 60Ah cells *small variation to the standard ** not a requirement on the cell level

17 Ready for Global Shipment- High Volume Li-Ion Batteries as Dg's! Tim Schäfer Battery Management System

18 Justification for the Battery Management System The recommended battery charging method is IUcharging (const. current, const. voltage) But: In a serial string the charger can not control individual cell voltages. Li-Ion cells do not tolerate overcharging with elevated voltages for balancing the cells (e.g. float or boost charging ) Abuse or operation out of range could result in safety issues by thermal runaway Li-Ion Batteries require a battery management system (BMS) or an electronic protection circuit

19 Block Diagram of BMS SOC SOH Energy management Comm. unit CAN Safety management Data acquisition U I T R Thermal management Fan, etc.. Contactor Battery Load & Charger

20 Example of 10S BMS Hardware Current sensor Master Slave (10S) to cells MUX µp Sensors & main switch µp 130 cm 2 CAN interface RS232 for flashing Master Optically decoupled RS485 bus 40 cm 2 Current / A Voltage / mv Temp. / C Range Resol. 4.8 ma 1 mv 0.1 C

21 Ready for Global Shipment- High Volume Li-Ion Batteries as Dg's! Tim Schäfer 288V Hybrid EV Battery with 80S HP Cell

22 288V HEV Battery with 2kWh Weight of cell Number of cells Packaging Weight today 0.32 kg % 42 kg Weight 33 kg Length Width Height 700 mm 292 mm 195 mm Volume Power (18s) 40 L 25 kw

23 Ready for Global Shipment (LEV/EV) - High Volume Li-Ion! Tim Schäfer Company Secretary Engineered Solutions

24 Engineered Batteries 36V/60Ah Battery for Silent Watch 86V 27Ah for a solar vehicle application. 97V/480Ah Battery Manned Underwater Vehicle Prototype for the navy of a friendly foreign nation 8 paralleled 27S modules of the C60 cell 8x[97V/60Ah] => 46kWh 36V/7.5Ah HEV prototype module

25 Battery design from specification through design and testing Nominal 360 V high power battery capable of 250A-300A pulses. Consisting of 100S UHP DD cells. Aluminum housing (6061 or 7075) Cylinder End plate BMS support plate ¼ G-10 Soft insulation ¼ silicone Upper header ¾ Delrin Cells 100 DD UHP Lower header ¾ Delrin Insulation Plate ¼ HDPE Aluminum End plate Mounting base for cell assembly Lithium Technology Corporation BATTERY EXPLODED ASSEMBLY DRAWING *wires and tie rods not shown PART/FILE/DRAWING AJM05112.DOC Ref AJM05112.PRT, AJM05085.PRT View 7, Levels 1,4,5,8,9,10,11,12,201 AJM 08/25/05

26 72V/60Ah Battery NASA-JSC Spider Robot project.

27 Tim Schäfer GAIA Akkumulatorenwerke GmbH Ready for Global Shipment- High Volume Li-Ion Batteries as Dg's!

28 Lithiumbatteries UN 3090 (Regulations)

29 International Regulations The international transportation regulations require battery and cell manufacturers or companies that ship equipment packed with or containing these cells and batteries to meet: UN testing, marking, packaging, Labelling, and shipping paper specifications. These regulations are incorporated into the ICAO Technical Instructions, IATA Dangerous Goods Regulations, and IMDG Code.

30 UN/ICAO /IATA /ADR/IMO/DOT. UN ICAO- IATA United Nations Model Regulations International Civil Aviation Organization International Air Transport Association ADR- Accord Europeen sur le transport des merchandises par route IMO- International Maritime Organization DOT- US Department of Transportation

31 What does Class 9 mean? Class 9 is one of nine hazardous materials shipping classifications defined by the UN HMR and other transportation regulations. Class 9 defines the specification packaging, markings, labelling, and shipping paper requirements for miscellaneous hazardous materials, which include lithium and lithium ion cells and batteries, among other materials.

32 dg- sticker : UN 3090 DG Lithiumbatteries - Sticker: CLASS 9 class 9

33 Transport Regulations for Lithium- Ion & Polymer Cells & Batteries International dangerous goods transportation regulations pertaining to lithium ion (and polymer) cells and batteries have undergone significant changes over the past years, These regulations are based on the UN Recommendations on the Transport of Dangerous Goods Model Regulations and the UN Manual of Tests and Criteria. If you are involved in buying, selling or shipping lithium ion or lithium polymer cells and batteries (Lithium Batteries) you need to understand the international regulations that apply to shipments of these batteries.

34 Which Types of Li-Ion are covered by regulations? Please note: All lithium, lithium-ion and lithiumpolymer batteries regardless of size will be covered by the regulations

35 All Li-Ion Cells and Batteries must be tested For instance : All cells and batteries must be tested in accordance with the requirements of the UN T- Tests (T1 - T8) found in the UN Manual of Tests and Criteria, The following cells and batteries-for instance (which are concerned in business) must pass the new UN Tests and be shipped as a Class 9 hazardous material: a Lithium Ion Cell with an equivalent lithium content of more than 1.5 grams (5Ah Li-Ion); a Lithium Ion Battery with an aggregate equivalent lithium content of more than 8 grams(26 Ah Li-Ion).

36 Definition ELC: Equivalent Lithium Content ELC, the Equivalent Lithium Content is calculated in grams on a per cell basis to be 0.3 times the rated capacity in ampere hours. Thus, the equivalent lithium content for a battery/battery pack is the rated capacity in ampere hours for a single cell multiplied by 0.3 and then multiplied by the number of cells in the battery/battery pack.

37 On the way : Globally Harmonized System (GHS) Dangerous Goods are regulated under forwarding view of transport risk. different carrier: - Railway, - Ground, Air, - Waterway, -Ocean Route, - Aero Space. National and International legal requirements, Interface function in a company in providing hot spot DGs is Shipping Department

38 UN 3090/UN3091 Lithium batteries/ Equipment UN 3090 UN 3091 Vorschrift Verpackungsvorschrift Sondervorschriften Verpackungsvorschrift Sondervorschriften ADR P , 230, 310, 636 P , 230, 636 IMDG-Code P , 230, 310 P , 230 PAX-A/C CAO-A/C ICAO-TI / IATA-DGR A45, A88, A A45, A48 Orange Book max. 5 kg br. max. 35 kg br. P , 230, 310 P , 230

39 Globally Harmonized System (GHS) -UN EcoSoc Committee: 1. Transport of Dangerous Goods 2. Global Harmonized System, (GHS)

40 Globally Harmonized System (GHS) The regulations that govern the transport of lithium ion cells and batteries include the International Civil Aviation Organization (ICAO) Technical Instructions and corresponding International Air Transport Association (IATA) Dangerous Goods Regulations, and the International Maritime Dangerous Goods (IMDG) Code.

41 Globally Harmonized System (GHS) UN (Orange Book), e.g. Inter-model Worldwide: UN Recommendations on the Transport of Dangerous Goods (DG) Manual of Test and Criteria (38.3 UN) (for Lithium Batteries- very detailed) ICAO-TI / IATA-DGR (Aircraft Worldwide) ADR (Ground Europe and Eastern Europe)/ EU RL 28 IMO (Ocean Worldwide) / SOLAS DOT (inside the US) / RID China other

42 In the US? In accordance with Part 49 of the Code of Federal Regulations, (49 CFR Sections ) of the US Hazardous Materials Regulations (HMR). Section provides specifications on exceptions and packaging for shipping based on details of weights, tests and classifications. The hazardous materials table in Section also provides related shipping information. DOT has the authority to issue fines up to 27,500 USD per infraction! Easily the fine per package could pass 150,000 USD per shipment

43 US Department of Transportation (DOT) The Office of Hazardous Materials Safety, which is within the US Department of Transportation's (DOT) Research and Special Programs Administration (RSPA), is responsible for coordinating the transportation of hazardous materials (also known as dangerous goods) by air, rail, highway and water and drafting the regulations that govern such materials.

44

45 Your Partner in Germany: Federal Ministry for Traffic, Building & Urban Development

46 On the Way : Globally Harmonized System ( GHS) TRANSPORT INFORMATION Road Transport Description: Lithium batteries UN-N : 3090 Classification: 9 (class 9) Packaging Class: II Packaging Order: P903 Special Provision: 310 (Chapter 3.3 ADR)

47

48 On the Way : Globally Harmonized System ( GHS) TRANSPORT INFORMATION Air Transport Description: Lithium batteries UN-N : 3090 Classification: 9 Packaging Class: II Packaging Order: 903 Special Provision: A88 (ICAO TI/IATA DGR) Special Authorization: U6/439.06/03 (LBA/Germany) valid to (GAIA-LTC for samples)

49

50 On the Way : Globally Harmonized System ( GHS) TRANSPORT INFORMATION /Sea Transport Description: Lithium batteries UN-N : 3090 Classification: 9 Packaging Class: II Packaging Order: P903 Special Provision: 310 (Chapter 3.3 IMDG Code)

51 On the Way : Globally Harmonized System ( GHS) REGULATORY INFORMATION The transport is based on the following rules: Germany: GGVSE; GGVSea Europe: ADR / RID International: ICAO TI/IATA DGR; IMDG Code USA: 49 CFR Ch Special Authorization: B63/439.11/05 (LBA/Germany) USA: in accordance with the Code of Federal Regulations (49 CFR Ch )

52 Testing Requirements (Summary of UN Manual of Tests and Criteria, Part III, Subsection 38.3) Test 1: Altitude Simulation - This test simulates air transport under low-pressure conditions. Store at pressure of 11.6 kpa or less for at least six hours at 20 ±5 C. Test 2: Thermal Test - This test assesses cell and battery seal integrity and internal electrical connections. The test is conducted using rapid and extreme temperature changes. Perform 10 cycles between 75 ±2 C and -40 ±2 C, six hours per cycle with no more than 30 minutes between cycles, and then observe for 24 hours at 20 ±5 C.

53 Testing Requirements (Summary of UN Manual of Tests and Criteria, Part III, Subsection 38.3) Test 3: Vibration - This test simulates vibration during transport. Perform sinusoidal waveform with a logarithmic sweep between 7 Hz and 200 Hz and back to 7 Hz traversed in 15 minutes. This cycle shall be repeated 12 times for a total of three hours for each of three mutually perpendicular mounting positions of the cell or battery. One of the directions of vibration must be perpendicular to the terminal face.

54 Testing Requirements (Summary of UN Manual of Tests and Criteria, Part III, Subsection 38.3) Test 4: Shock - This test simulates possible impacts during transport. Half-sine shock of peak acceleration of 150 gn and pulse duration of six milliseconds (large cells and batteries: 50 gn / 11 milliseconds). Each cell or battery shall be subjected to three shocks in the positive direction and three shocks in the negative direction of three mutually perpendicular mounting positions of the cell or battery for a total of 18 shocks.

55 Testing Requirements (Summary of UN Manual of Tests and Criteria, Part III, Subsection 38.3) Test 5: External Short Circuit - This test simulates an external short circuit. Simulates an external short circuit. After stabilizing at 55 ±2 C, apply an external resistance of less than 0.1 ohm for one hour and then observe for six hours. Test 6: Impact - This test simulates an impact. Place a 15.8 mm diameter bar across the center of the sample and then drop a 9.1 kg mass from a height of 61 ±2.5 cm on to the bar, and then observe for six hours.

56 Testing Requirements (Summary of UN Manual of Tests and Criteria, Part III, Subsection 38.3) Test 7: Overcharge - This test evaluates the ability of a rechargeable battery to withstand an overcharge condition. Charge at twice the manufacturer's recommended maximum continuous charge current for 24 hours at ambient temperature, and then observe for seven days. Test 8: Forced Discharge - This test evaluates the ability of a primary or a rechargeable cell to withstand a forced discharge condition. Force discharge at ambient temperature at an initial current equal to the maximum discharge current specified by the manufacturer, and then observe for seven days.

57 Quantities for Testing (Cylindrical Cell Type GAIA) For T1 - T 7 you need 20 cells and 16 batteries, for T6 10 cylindrical or 20 prismatic Cells, for T7 8 batteries ( 4 at 1 cycle-fully charged,4 after 50 cycles ending in fully charged states). In Summary : 50 or 60 cells and 24 Batteries. In detail for T1 trough T5 tests you need: 4batteries at 1 cycle and fully discharged status, 4batteries at 1 cycle and fully charged states, 4batteries after 50 cycles ending in fully charged states, 4batteries after 50 cycles ending in fully discharged states.

58

59 Ready for Global Shipment?

60 What's about Packaging?

61 Example: UN 4D Box

62 UN 3090 UN 4G Box : LIB- GAIA a LTC Company 15at2951.jpg

63 Collipost-system Box with UN - Certificate

64 GAIA: Qualified Partners & Solutions

65 Battery Warehouse Nordhausen with GAIA Li-Ion

66 DG Qualified Logistic Team Nordhausen

67 GAIA-LTC Qualified DG Handling & Monitoring Work- and Info Flow, Document Management, Special Permission by LBA of Germany, Supervision, Documentation,

68 GAIA Qualified DG Handling & Monitoring II Instructions, Reports, Authority Contacts, Service, Incidents,

69 GAIA-LTC Qualified DG Handling & Monitoring III Analysis, Statistic, Training.

70 Special Service: Packaging of High Volume Li-Ion

71 Parts, Chargers, Connectors & Others

72 Incoterms 2000/I

73 Incoterms 2000 /II

74 Training requirements for employees? Yes! In the US and also in Germany employees involved in the packaging or shipment of Class 9 Lithium or Lithium Ion cells and Batteries must complete a "49 CFR", ADR certified hazardous materials training course. Employees must renew their certification training every two years. It is strongly recommended that employees also complete an "IATA training" course.

75 Mark A45 und 188 (e) (i) UN 3090 Lithiumbatteries CAUTION! Lithium Batteries inside Handle with care Flammable if damaged If the package is damaged, it must be quarantined, inspected and repacked. Please contact: GAIA Akkumlatorenwerke Germany Fax:

76 Entry accordingly SV A45 und 188 (e) (ii) UN 3090 Lithium batteries Lithiumbatterien. Vorsichtig behandeln. Falls das Packstück beschädigt ist, müssen die Batterien separiert, überprüft und neu verpackt werden. Lithium batteries. Handle with care. If package is damaged, batteries must be quarantined, inspected and repacked.

77 UN 3091: Mark A45 und 188 (e) (i) UN 3090 CAUTION! Lithium Batteries packed with Equipment inside Handle with care Flammable if damaged This package contains fibreboard-boxes with: 1 battery packed in a fibreboard-box packed together with 1 equipment If the package is damaged, it must be quarantined, inspected and repacked. Please contact then: GAIA Akkumulatorenwerke GmbH IF DAMAGED

78 FedEx Solutions Use FedEx Supply Chain Services to develop Inbound Storage Outbound.

79 Kühne & Nagel

80 DB Logistics Schenker

81 Qualified DG Handling & Against Terrorism! ADR 2005 Increase of Regulations and Safety Issue's, More Qualification & Document Handling, Minimizing Risks

82 Many Thanks for Your Attention, - Thank You for Invitation! akku.com TimS@gaia-akku.com akku.com See You in Germany: FIFA WORLD CUP 2006 Germany for Champion!

83