HEATING SOLUTIONS FOR BATTERIES

HEATING SOLUTIONS FOR BATTERIES

LEAD-ACID NICKEL METAL HYDRIDE LITHIUM ION SODIUM ION ZEBRA WE MAKE IT HAPPEN Heating solutions Backer Calesco has the experience, knowledge and capabilities to help you develop and manufacture heating solutions for all type of applications. A thin flexible foil heater provides excellent heating efficiency in the area where you need it most. Our heating products together with our measurement and control devices offer our customers complete solutions. Our engineers will not only suggest solutions they can also take part and contribute to your product development by using our advanced technical tools and lab facilities. MEMBER OF BACKER-GROUP BACKER CALESCO is a part of Backer group, within NIBE Industrier. NIBE Industrier is an international heating technology company whose business operations are organised in three separate business areas: NIBE Energy Systems, NIBE Element and NIBE Stoves. The Group has more than 10,000 employees and operates in 20 countries in Europe, North America, Australia and Asia. The legal structure of the Group comprises a number of subsidiaries, who run their own operations via their own companies or branch offices. NIBE is listed on the NASDAQ OMX Stockholm Exchange, Large Cap list, with a secondary listing on the SIX Swiss Exchange. Our extensive experience and competence as well as our reliable quality and service guarantees your success. Our ambition is to not only be a supplier, but your preferred partner. QUALITY ASSURANCE Production locations Backer Calesco main office and production in SWEDEN Production facility in POLAND Production facility in CHINA Sales office/warehouse in the US Calesco is certified According to SS-EN ISO 14001:2004 and ISO 9001-2008 by INTERTEK Our facility in China & Poland is certified According to ISO 14001, ISO 9001 and ISO-TS 16949 Third part approvals VDE / ETL / S / UL / FDA /TüV

OUR SERVICES R&D Broad product portfolio Product validation test laboratory Watt density requirements selection Physical design and optimization Integration Heaters Temperature sensors Flex circuits Components Heat sinks Assembly and Production One stop shop Heater forming - performance & physical Small series to Mass production Full service TEMPERATURE CONTROL Control and engergy balance Flexible foil heaters provide excellent thermal transfer where you need it most. Heaters are used in thermal control design to protect components under cold-case environmental conditions or to make up for heat that is not dissipated. It is usually necessary to arrange some form of control to ensure that the desired temperature is maintained. Heaters are used with thermostats, PTC, PT100/PT1000 sensors, thermocouples, solid-state or digital controllers to provide exact temperature control of a particular component Integrated control/smart heater The demands for smart simple solutions creates new applications and we can offer solutions with integrated thermal controllers and sensors communicating through RS232, WiFi or Zigbee. Typical applications Lead-acid Nickel Metal Hydride Lithium Ion Sodium Ion Zebra

HEATING SOLUTIONS For batteries Our need of environmental friendly vehicles creates a demand for more efficient batteries both for Hybrid and Electrical cars. Since 2008, a renaissance in electric vehicle manufacturing has occurred due to advances in batteries and energy management, concerns about increasing oil prices, and the need to reduce greenhouse gas emissions. Rechargeable batteries have been used in automotive applications for many years, mainly lead acid batteries for engine starters or deep cycle batteries for forklifts and as auxiliary batteries for RV s. All batteries deliver their power via a chemical reaction inside the battery that releases electrons. When batteries are exposed to cold weather the temperature of the battery drops and the chemical reactions occur more slowly, so the battery cannot produce the same amount of current that it can at room temperature. In lead-acid batteries a temperature of 0 C can drop a its output by 50 percent or more. When decreasing below -20 C in some situations, the chemical reactions will happen so slowly and give so little power that the battery will appear to be dead when, in fact, if it is warmed up, it will go right back to normal output. This affect is more drastic in lead-acid batteries than lithium-ion. Also a batteries charging rate is affected by temperature. The optimal charging rate can vary based on the temperature of the battery. The charging current needs to be lower when it is cold, so it takes longer to charge up a battery. This is affected more by lithium-ion batteries than lead-acid. Capacity vs temperature Both lead acid and lithium-ion lose capacity in cold weather environments, but as shown in graph above lithium-ion loses significantly less capacity as the temperature drops into the -20 C range. The rate of discharge influences the lead acid performance, so two different rates have been shown for the lead acid battery. Available Capacity (% Rated) 120 100 80 60 40 20 0-20 0 20 40 Temperature ( C) Li-ion (2hr rate) Lead-acid (2hr rate) Lead-acid (10hr rate)

INTERNAL Dry surface heater Larger area Laminated to Aluminum plate to improve heat transfer PTC max temp +80 C PET max temp +100 C PEN max temp +150 C Kapton max temp +300 C Mica max temp +500 C 265 to 2500W HEAT PLATE Dry surface heater Larger area Laminated to Aluminum plate to improve heat transfer PET max temp +100 C PEN max temp +150 C Kapton max temp +300 C 50 to 550W

WRAP AROUND Dry surface heater Larger area Laminated to Aluminum plate to improve heat transfer PTC max temp +80 C PET max temp +100 C PEN max temp +150 C Kapton max temp +300 C 50 to 1350W HOUSE Dry surface heater Larger area Laminated to Aluminum plate to improve heat transfer PTC max temp +80 C PET max temp +100 C PEN max temp +150 C Kapton max temp +300 C Mica max temp +500 C 20 to 750W

FLUID Wet surface heater Free floating 265 to 750W PET max temp +100 C PEN max temp +150 C Silicone max temp +230 C Mesh Heater +150 C THRU FLOW Dry surface heater Larger area Laminated to Aluminum plate to improve heat transfer 25 to 550W PTC max temp +80 C PET max temp +100 C PEN max temp +150 C PRISMATIC CELL AND POUCH BATTERIES Dry surface heater Small or larger area Laminated to Aluminum pouch to improve heat transfer 5 to 550W PTC max temp +80 C

THE MARKET As of June 2015, the number of mass production highway-capable all-electric passenger cars and utility vans available in the market is limited to over 30 models, mainly in the United States, Japan, Western European countries and China. However, battery price is coming down rapidly and sales are increasing, by May 2015 over 500,000 light-duty electric vehicles have been sold worldwide. As of June 2015, the world s top selling highway-capable electric car is the Nissan Leaf, released in December 2010 and sold in 46 countries, with global sales of over 180,000 units, followed by the Tesla Model S with over 78,000 units sold since 2012. BATTERY CAR TYPES Battery electric vehicles (BEV), plug-in hybrid electric vehicles (PHEV), conventional hybrids and hydrogen fuel-cell powered. While each has its advantages and disadvantages, all save on fuel and emit fewer greenhouse gases. Battery Electric Vehicle (BEV) A battery electric vehicle (BEV) runs entirely on a battery and electric drive train, without a conventional internal combustion engine. These vehicles must be plugged into an external source of electricity to recharge their batteries. Like all electric vehicles, BEVs can also recharge their batteries through regenerative braking. In this process, the vehicle s electric motor assists in slowing the vehicle and recovers some of the energy normally converted to heat by the brakes. Plug-in Hybrid Electric Vehicles (PHEVs) Plug-in hybrid vehicles (PHEVs) run mostly on batteries that are recharged by plugging into the power grid. They are also equipped with an internal combustion engine that can recharge the battery and/or to replace the electric drive train when the battery is low and more power is required. Hybrid Electric Vehicles (HEVs) HEVs on the road today have two complementary drive systems: a gasoline engine and fuel tank and an electric motor, battery and controls. The engine and the motor can simultaneously turn the transmission, which powers the wheels. HEVs cannot be recharged from the power grid. Their energy comes entirely from gasoline and regenerative braking. Fuel-cell Electric Vehicles The fuel-cell is another type of electric vehicle expected to be widespread on the market in the next few years.

BASIC BATTERY TYPES Lead-acid Storage capacity of the current generation of common deep cycle lead acid batteries decreases with lower temperatures. Nickel Metal Hydride (NiMh) Low in energy density. The NiCd is used where long life, high discharge rate and economical price are important. NiCd will gradually lose its performance. The NiCd contains toxic metals and is environmentally unfriendly. Zebra (Molten Salt) Battery must be heated for use, cold weather doesn t strongly affect its operation except for in increasing heating costs. Zebras can last for a few thousand charge cycles and are non toxic. Sodium Ion Li-ion in ultra-slim geometry and simplified packaging. Main applications are mobile phones. Lithium Ion Li-ion in ultra-slim geometry and simplified packaging. Main applications are mobile phones. PROPERTIES OF DIFFERENT LI-SYSTEMS energy energy energy Cost power Cost power Cost power Life span Safety Life span Safety Life span Safety Performance Performance Performance LiCoO 2 (LCO) LiMnO 2 (LMO) LiFePO 4 (LFP) energy energy energy Cost power Cost power Cost power Life span Safety Life span Safety Life span Safety Performance Performance Performance LiNiMnCoO 2 (NMC) LiNiCoAlO 2 (NCA) Li 4 Ti 5 O 12 (LTO) ANODE

SECONDARY BATTERY SYSTEMS Lead- Acid Ni-Cd Ni-MeH Ni-Zn Li- Titanate Li-iron Phosfate Li-ion* Li-ion Polymer Wh/kg 30-45 45-55 60-100 68 65-73 95-150 150-270 150-233 Wh/lit 99 184 397 186 131 300 742 530 Nominal Voltage 2 1,25 1,25 1,65 2,4 3,2 3,5-3,8 3,6-3,75 Cycle-life (80%) init Cap.) 200-300 1500 300-500 250 6000-20000 1500-2000 300-1000 300-500 Self discharge 5-7 20 10-30 10 5 5 5 5 Source: Shmuel DE-Lion Energy Ltd PERFORMANCE OF DIFFERENT LI-ION SYSTEMS LiCoO 2 LiMnO 2 LiNiMnCoO 2 LiFePO 4 LiNiCoAlO 2 Li 4 Ti 5 O 12 Energy (Wh/kg) 150-200 100-150 150-220 90-120 200-250 70-80 Cycle Life 500-1000 500-1000 1000-2000 1500-2000 500 3000-7000 Power Capability Moderate High Moderate Very High Moderate Very High Discharge Temp. ( C) -20 to +60-20 to +60-20 to +60-20 to +60-20 to +60-30 to +60 Charge Temp. ( C) 0 to +45 0 to +45 0 to +45 0 to +45 0 to +45-20 +45 Source: Battery University (www.batteryuniversity.com)

TO BE CONSIDERED Application environment Under Hood Temperatures Vibration Levels of liquid Expected life time of heater Performance requirements Maximum voltage Min max temp / Regulation Time allowed to use Temperature Over-Temp Response (time/temp) Reaction time temp regulation Helping Charge / Discharge Temperate battery to operate Installation and mounting Connector Cable vs flex tail Fasteners vs. Integrated Space available Surrounding s Surrounding s TEMPERATURE CONTROL Temperature control Alternatives Resistance controlled max. power density 5W/sqcm² NTC Controlled max. power density 2W/sqcm² PTC Heater max. power density 0,25W/sqcm² Thermostat over heat protection max. power density 2W/sqcm² Resistance controlled The heater is the sensor, no added parts in the fluid or on the heater surface Robust and exact Quick and easy to regulate Cu, Brass or Al circuit Known technology Constant wattage long life NTC Surface mounted integrated in circuitry Exact measurement on spot or on surface if mounted right Known technology Constant wattage long life PTC heater (self regulating) Max. power density 0.25 W / sqcm² No added parts Aging over time, shorter lifetime MOUNTING OF HEATER Overmolded Encapsulated in tank, box or battery wall No air bubbles Long lifetime Robust No open parts exposed to fluid Supported (envelope) Heater encapsulated in metal to withstand fluid and stress from ice etc. No parts open to fluid Mechanically strong Heater in fluid Heats where it s needed Laminated by adhesive or glue to inside of wall Free floating in Fluid

Backer Calesco Rev.7 2017-07-05 Backer BHV AB / Div. Calesco Västra Åvägen 11 SE-734 51 Kolbäck Tel: +46 (0) 220 453 00 backercalesco.se EVERYDAY EVERYWHERE