Beth Lowery. GM Vice President Environment and Energy

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2 Beth Lowery GM Vice President Environment and Energy

3 Global Energy Consumption 35% of global energy needs are met by petroleum Energy demand will grow 2% annually from % more energy will be needed in 2030 Over 800 million vehicles in the world today In 15 years there will be 1.1 billion vehicles

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5 Advanced Propulsion Technology Strategy Improved Vehicle Fuel Economy and Emissions Energy Diversity Displace Petroleum IC Engine and Transmission Improvements Hybrid Electric Vehicles (incl. Plug-In HEV) Hydrogen Fuel Cell Vehicles Battery Electric Vehicles Near-Term Mid-Term Long-Term Petroleum (Conventional & Alternative Sources) Bio Fuels (Ethanol E85, Bio-diesel) Electricity (Conventional & Alternative Sources) ) Hydrogen

6 GM s 30 MPG or Over Club

7 The GM U.S. FlexFuel Club 16 models for 2007 MY! Over 2 Million on the Road Chevrolet Silverado Chevrolet Impala GMC Sierra Chevrolet Monte Carlo GMC Yukon & Yukon XL Chevrolet Uplander GMC Savana Chevrolet Avalanche, Suburban & Tahoe

8 GM s Hybrid Portfolio Two-Mode Hybrid Light Hybrid GM/Allison Hybrid Bus Chevrolet Silverado/GMC Sierra Saturn VUE GM Hybrid System Saturn Aura Chevrolet Malibu Tahoe/Yukon Two-Mode Hybrid Escalade Silverado/ Sierra Saturn VUE Green Line

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11 Support for Energy Diversity

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13 Denise Gray Director Hybrid Energy Storage Systems

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15 Recent Battery Applications at GM

16 GM s Energy Storage Systems Team Harnessing Resources and Experience 2006 consolidated battery testing and development groups Total of 30 chemists, engineers and scientists Battery development activities integrated Mainz Kastel Indianapolis Milford Proving Ground Warren Technical Center 2007 expansion of capabilities External hiring of battery experts Continued investment in battery testing Leveraging USABC funding

17 Critical Success Factors of Battery Systems

18 Johnson Controls - Saft Leveraging the capabilities of Johnson Controls, global leader in automotive batteries and seating & interior systems and Saft, world specialist in hightechnology batteries Extensive advanced battery portfolio including nickel and lithium systems Global research & development capabilities via 5 state-of-the-art centers Access to extensive manufacturing locations of both organizations Presenter: Mary Ann Wright

19 A123Systems A Leading Manufacturer of Li-ion Cells 250 employees in five countries Eight state of the art facilities 2 nd largest producer of high power lithium-ion cells in the world Over 5 million Li-ion cells in 2006 for use in re-chargeable power tools Quadrupling cell capacity in 2007 Presenter: Ed Bednarcik

20 Cobasys Systems Integrations Over 700 US and foreign patents and filings in the area of NiMH battery technology Automated production of: Battery modules Transportation systems Stationary systems Systems integration expertise Presenter: Scott Lindholm

21 Joe LoGrasso Engineering Group Manager Hybrid Energy Storage Systems

22 Building on GM s experience New Technology New Opportunities PHEV/E-Flex battery requirements A primer battery energy storage Why lithium-ion? From cells to packs to vehicles Where will it come from?

23 Traction Battery Needs

24 Battery for HEV/PHEV/E-Flex What s new??? Need Power + Energy Two-Mode Hybrid EV Range: Recharge: Power: Life: Two-Mode Plug-In Hybrid EV Range: Recharge: Power: Life: E-Flex Range-Extended EV Energy: Recharge: Power: Life: Only at low speeds and loads Only while driving EV driving in low speed city only 10 years/150k miles life 10+ miles all-electric driving at city While driving and with plug-in EV driving in city 10 years/150k miles life 40+ miles all-electric in city driving While driving and with plug-in EV driving full vehicle performance 10 years/150k miles life

25 Requirements for PHEV/E-Flex Need High Power AND High Energy Discharge Power Usable Energy Two-Mode Chevy Tahoe Two-Mode Saturn Vue Plug-In E-Flex Chevy Volt Two-Mode Chevy Tahoe Two-Mode Saturn Vue Plug-In E-Flex Chevy Volt

26 Battery usage varies greatly Typical HEV Drive Cycle All Electric Mode PHEV Cycle Electric Only Battery State of charge Plug-in Hybrid Mode Plug-in Hybrid Cycle Time ->

27 From HEV Batteries Plug-In HEV EVs HEV Batteries High power / low energy Ultra thin electrodes Thicker current collectors Short pulse power PHEV / E-Flex Batteries High power and high energy Thicker electrodes Thinner current collectors Longer power excursions Cell x 80 x 80 x 80 x 2-3 or x 80 Pack Two-Mode Two-Mode PHEV E-Flex Volt Charge Sustaining HEVs Greater Electrification Charge Depleting

28 Traction Battery Energy Storage Evolution Lead acid Decades of use as starting/lighting/ignition (SLI) batteries Implemented in mild hybrids (eg: GM Parallel Hybrid Truck) Nickel metal hydride (NiMH) Implemented in most hybrid vehicles available today Nearing maturity in cost and performance Lithium-ion (Li-ion) Very high energy and power density. Necessary for future hybrid performance and critical for PHEV & E-Flex architectures. New materials continually being developed (e.g., lithium titanate anodes, lithium iron phosphate cathodes) to improve performance Supercapacitors Very high power density and potentially low cost May be well matched for mild HEVs Active area of research and development

29 Current State of Battery Technology (Power & Energy) Range EV Energy Lithium-ion E-Flex/Chevy Volt Energy (Watt-hr / kg) Maximum stored energy per unit of battery mass Power Lithium-ion NiMH Lead Acid Today s HEVs Acceleration Supercap Two-Mode Hybrid w/ Li-ion Power (Watt / kg) Maximum power per unit of battery mass

30 Why Lithium-ion? Advantages Superior specific discharge power & energy ~40% less mass than NiMH ~20% less volume than NiMH Excellent cycle life Long term cost potential Relatively low self-discharge Easier to control (determine SOC & power available) Challenges Robustness & abuse tolerance Calendar life (>10 yrs) More sophisticated electronics to maintain cells Cold temperature performance Transportation regulations Initial cost as volumes ramp

31 Lithium-ion for Hybrid Vehicles Solutions that balance the 3 legged stool Lithium-ion HEV/PHEV Battery Robustness Life Cost

32 Bringing Products to Market Multi-phase process to develop new battery solutions CellËPackËVehicle Cell/Module Test Pack Development & Test In-Car Integration & Test Production Program Engineering & Validation Challenge: Expeditious yet rigorous engineering and program launches

33 Lithium-ion Supply Where will it come from? Large installed base of consumer lithium-ion batteries exist today Emergence of large format lithium-ion battery manufacturing Initially limited by investment needed Domestic capability growth Scale up high quality automotive lithium-ion battery manufacturing will be extremely important to enable wide-spread electrification of the automobile

34 Mary Ann Wright CEO Johnson Controls - Saft

35 Why Lithium-ion? Lithium is preferred to today s nickel technology More power Space and weight savings translates to Performance Fuel efficiency Cost benefits

36 A lithium-ion s battery components and electrochemistry are not dissimilar to traditional lead acid Positive electrode Negative electrode Separator material Electrolyte

37 Gasket Insulator Lithium Cell Structure Cathode cover Cathode lead Safety vent PTC Separator Cathode Positive electrode Anode Negative electrode Separator Electrolyte Can and terminals Insulator Center pin Anode container Cathode Anode lead Anode Safety vents

38 Gasket Insulator Lithium Cell Structure Cathode cover Cathode lead Safety vent PTC Separator Cathode Positive electrode Lithium chemistry Adjust dimensions to favor energy or power Insulator Center pin Anode container Cathode Anode Anode lead Anode Negative electrode Graphite material Copper foil conductor

39 Gasket Insulator Lithium Cell Structure Cathode cover Cathode lead Safety vent PTC Separator Separator Semi-permeable membrane Prevents contact between positive and negative charge Insulator Center pin Anode container Cathode Anode lead Anode Electrolyte Organic solution with added lithium salt Tune for life and cold weather performance

40 Gasket Insulator Lithium Cell Structure Cathode cover Cathode lead Safety vent PTC Separator Cans & Terminals Sealed metal cans - hermetic packaging Provide connection of foil electrodes Insulator Center pin Anode container Cathode Anode lead Anode Safety Vents Opens if needed to allow excess pressure out

41 Critical Success Factors Useful life and reliability Automotive compliant performance Automotive compliant quality

42 Ed Bednarcik VP and General Manager A123Systems

43 Critical Success Factors for HEV and PHEV battery manufacturing

44 High Power Lithium-ion Is A New Technology Being Rapidly Adopted By Several Non-Passenger Markets These sectors combined will consume more high power batteries over the next five years than passenger HEV and PHEV. As a result, market share in these sectors will dictate economies of scale and price performance in HEV and PHEV.

45 There Are Six Major Processes In Manufacturing Lithium-ion Cells, But There Are Important Differences Unique To High Power Unique To High Power Lithium-ion

46 Cell Manufacturing Processes (Mixing)

47 Cell Manufacturing Processes (Coating)

48 Cell Manufacturing Processes (Electrode Processing)

49 Cell Manufacturing Processes (Assembly)

50 Cell Manufacturing Processes (Formation and Testing)

51 Scott Lindholm Vice President Systems Engineering

52 What Does Systems Integration Mean? PROJECT MANAGEMENT TECHNICAL SUPPORT MODULAR SYSTEM DESIGN INTEGRATION MANUFACTURE ASSEMBLY SAFETY CONTROL ALGORITHMS ELECTRONIC MANAGEMENT BATTERY MANAGEMENT ENGINEERING PROTOTYPES THERMAL MANAGEMENT DEVELOPMENT TESTING

53 Mechanical Packaging

54 System Components

55 System Components Electronics Bay Thermal Management System Battery Cassette Bay

56 Thermal Management

57 Testing Salt-Mist Vibration Thermal Shock Mechanical Shock

58 Communications Continual Monitoring of: Voltage Current Temperature Safety Aspects State of Charge State of Health Power Energy

59 Customer Perspective No Exposure to High Voltage Safety

60 Safety System Service Disconnect Manufacturing Perspective Service Disconnect Receptacle Service Disconnect High Voltage Interlock First Responder / Dealer Service Perspective Low Voltage Connection High Voltage Interlock Cover Control Unit High Voltage Connections

61 What Does Systems Integration Mean? PROJECT MANAGEMENT TECHNICAL SUPPORT MODULAR SYSTEM DESIGN INTEGRATION MANUFACTURE ASSEMBLY SAFETY CONTROL ALGORITHMS ELECTRONIC MANAGEMENT BATTERY MANAGEMENT ENGINEERING PROTOTYPES THERMAL MANAGEMENT DEVELOPMENT TESTING

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63 Summary

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65 Battery development testing: cell pack vehicle Pack level verification tests running 24/7 Cycling equipment and temperature chambers represent multi million dollar investment critical to development efforts Examples of in-vehicle battery integration Visual progression of pack development Cell Structure System Requirements Cell Manufacturing Process Controls Testing Cell Chemistry Integration Safety

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