The Handbook of Lithium-Ion Battery Pack Design

The Handbook of Lithium-Ion Battery Pack Design

Chemistry, Components, Types and Terminology

1st Edition - May 23, 2015

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  • Author: John Warner
  • eBook ISBN: 9780128016688
  • Hardcover ISBN: 9780128014561

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The Handbook of Lithium-Ion Battery Pack Design: Chemistry, Components, Types and Terminology offers to the reader a clear and concise explanation of how Li-ion batteries are designed from the perspective of a manager, sales person, product manager or entry level engineer who is not already an expert in Li-ion battery design. It will offer a layman’s explanation of the history of vehicle electrification, what the various terminology means, and how to do some simple calculations that can be used in determining basic battery sizing, capacity, voltage and energy. By the end of this book the reader has a solid understanding of all of the terminology around Li-ion batteries and is able to do some simple battery calculations. The book is immensely useful to beginning and experienced engineer alike who are moving into the battery field. Li-ion batteries are one of the most unique systems in automobiles today in that they combine multiple engineering disciplines, yet most engineering programs focus on only a single engineering field. This book provides you with a reference to the history, terminology and design criteria needed to understand the Li-ion battery and to successfully lay out a new battery concept. Whether you are an electrical engineer, a mechanical engineer or a chemist this book helps you better appreciate the inter-relationships between the various battery engineering fields that are required to understand the battery as an Energy Storage System.

Key Features

  • Offers an easy explanation of battery terminology and enables better understanding of batteries, their components and the market place.
  • Demonstrates simple battery scaling calculations in an easy to understand description of the formulas
  • Describes clearly the various components of a Li-ion battery and their importance
  • Explains the differences between various Li-ion cell types and chemistries and enables the determination which chemistry and cell type is appropriate for which application
  • Outlines the differences between battery types, e.g., power vs energy battery
  • Presents graphically different vehicle configurations: BEV, PHEV, HEV
  • Includes brief history of vehicle electrification and its future


Engineering designers, manufacturing managers, engineering technicians, chemical and mechanical engineers, thermal engineers, battery chemists, and anyone working in the Li-ion battery industry who is not an engineer by training

Table of Contents

    • Figure Captions
    • Preface
    • Acknowledgments
    • Acronyms List
    • Chapter 1. Introduction
      • Factors Influencing Consumer Adoption of Electric Vehicles
      • Evolving Vehicle Technology Needs
      • Purpose of the Book
      • Chapter Outline
    • Chapter 2. History of Vehicle Electrification
      • The History of the Modern Storage Battery
      • An Electrical Industry Emerges
      • Early Electric Vehicle Development
      • Modern Vehicle Electrification
    • Chapter 3. Basic Terminology
      • Vehicle and Industry Terms
      • Stationary and Grid Terminology
      • Battery Terms
    • Chapter 4. Battery Pack Design Criteria and Selection
      • Ohm’s Law and Basic Battery Calculations
      • Converting Customer Requirements into Pack Designs
      • Power to Energy Ratios
      • Large Stationary and Grid Systems
      • Quick Formula Summary
    • Chapter 5. Design for Reliability/Design for Service
      • Design for Reliability/Design for Service
      • Quality and Reliability
      • Failure Modes Effects Analysis
      • Design for Service
      • Chapter Summary
    • Chapter 6. Computer-Aided Design and Analysis
      • Organizations and Analysis Products
      • Analysis Tools
      • Battery Sizing Tools
    • Chapter 7. Lithium-Ion and Other Cell Chemistries
      • Lead Acid
      • Nickel Metal-Based Chemistries
      • Sodium-Based Chemistries
      • Lithium-Ion Cells
      • Cathode Chemistries
      • Anode Materials
      • Separators
      • Electrolytes
      • Safety Features
      • Lithium-Ion Cell Types and Sizes
      • Lithium-Ion Cell Manufacturers
    • Chapter 8. Battery Management System Controls
      • BMS Typologies
      • BMS Hardware
      • Balancing
      • Active versus Passive Balancing
      • Additional BMS Functionality
      • Software and Controls
    • Chapter 9. System Control Electronics
      • Contactors/Relays
      • High-Voltage Interlock Loop
      • Fuses
      • Battery Disconnect Unit
      • Connectors
      • Charging
    • Chapter 10. Thermal Management
      • Why Cooling?
      • Why Heating?
      • Active Thermal Management Systems
      • Passive Thermal Management Systems
      • Temperature—Protection and Insulation
      • Thermocouples and Measurement
    • Chapter 11. Mechanical Packaging and Material Selection
      • Module Designs
      • Use of Metals in Battery Design
      • Use of Plastics and Composites in Battery Design
      • Sealed Enclosures
    • Chapter 12. Battery Abuse Tolerance
      • Failure Modes of Lithium-Ion Batteries
      • Characterization and Performance Testing
      • Safety and Abuse Testing
      • Certification Testing
    • Chapter 13. Industrial Standards and Organizations
      • Voluntary Standards
      • Research and Development and Trade Groups
      • Mandatory Standards Organizations
      • Chinese Standards and Industry Organizations
      • European Standards and Industry Organizations
    • Chapter 14. Second Life and Recycling of Lithium-Ion Batteries
      • Repairing and Remanufacturing
      • Refurbishing, Repurposing, and Second Life
      • Second Life Partnerships
      • Recycling
    • Chapter 15. Lithium-Ion Battery Applications
      • Personal Transportation Applications
      • Automotive Applications
      • Bus and Public Transportation
      • HD Truck Applications
      • Industrial Applications
      • Robotics and Autonomous Applications
      • Marine and Maritime Applications
      • Grid and Stationary Applications
      • Aerospace Applications
    • Chapter 16. The Future of Lithium-Ion Batteries and Electrification
      • Major Trends
      • Technological Trends
      • Future Trends in Battery Technology
      • Conclusion
    • References
    • Appendix A. USABC 12-V Stop/Start Battery Pack Goals
    • Appendix B. USABC 48-V Battery Pack Goals
    • Appendix C. USABC HEV Battery Pack Goals
    • Appendix D. USABC PHEV Battery Pack Goals
    • Appendix E. USABC EV Battery Pack Goals
    • Index

Product details

  • No. of pages: 262
  • Language: English
  • Copyright: © Elsevier Science 2015
  • Published: May 23, 2015
  • Imprint: Elsevier Science
  • eBook ISBN: 9780128016688
  • Hardcover ISBN: 9780128014561

About the Author

John Warner

Dr John Warner is a sought-after and recognized battery industry expert and an experienced sales, business development, strategic marketing, and product management executive with nearly 30 years in the automotive and battery industries. Currently, Dr Warner serves as the founder and president at Warner Energy Consulting LLC and has led the sales and marketing functions for several major battery manufacturers and start-ups. Prior to his work in the battery industry Dr Warner worked with General Motors in a wide variety of leadership roles in program management, portfolio planning, strategy, and powertrain as well as another six years as an automotive product mechanical designer. Dr Warner also serves as the president for the global industry trade group NAATBatt International and he also serves as the Chair for the Society of Automotive Engineers (SAE) Battery Size Standardization Committee, Co-Chair for the SAE Bus Battery Safety committee, and Co-Chair for the SAE Advanced Battery Concepts Committee. He received his Doctor of Management, Organizational Leadership degree from the University of Phoenix, and his MBA, International Business and Leadership Studies and BA in Industrial Management from Baker College.

Affiliations and Expertise

Grand Blanc, MI, USA

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