BatteryCellTeardownAnalysis PDF

2018MY Tesla Model 3
2018 Tesla Model 3
Battery Cell Teardown

Analysis
August 2018
CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 1

BATTERY CELL TEARDOWN

ANALYSIS REPORT
Disclaimer
Ricardo Inc. has taken all reasonable care in compiling the analyses provided
in this report. Information contained in this report is based on limited data
available to Ricardo believed correct on the date of publication. Ricardo does
not assume any liability, nor provide any warranty to activities based on the
contents of this report.
This report is restricted and may not be distributed, re-published, sold or

exchanged outside of the purchasing entity.


ANALYSIS REPORT
Specifications


ANALYSIS REPORT
Overview
Cell Parameters Capacities (Amp Hrs)
Cell manufacturer Panasonic Cell capacity (Ah) 4.78 [meas avg]

Cell format Cylindrical Pack capacity (Ah) 220 (calc)
Cell type 21700 Cooling medium Liquid cooled
Pack location Underbody

Winding process Spiral winding
Cell Dimensions
Cathode type (Lix)Ni0.90Co0.05Al0.05O1.57
Length (mm) 70 (meas)
Anode type Graphite
Width or DIA (mm) 21 (meas)
Separator PE (10um)
Height/ Thickness
Separator coating Al2O3 ceramic (10um) N/A
(mm)
Electrolyte salt LiPF6 Pack Dimensions
EC + DMC + EMC + Length (mm) 1470

Electrolyte solvent
MPC + LiFSI
Width (mm) 2155
Cell case Aluminum laminate
Height (mm) 340
Wh per cell (Wh) 17.5 [meas]
Pack Box Volume (m3) 1.08

Box Vol. Energy
Pack energy (kWh) 75 [spec] ~70 (calc)
Density (kWh/m3)
Pack configuration 96S46P Mass
1058 cells (2 modules) Per cell mass (kg) 0.069
# Cell/module
1150 cells (2 modules)
Pack mass (kg) w/
~460 (meas)
# Module/pack 4 fasteners (kg)
Energy density – Cell
Total # of cells 4416 ~255 (calc)
(Wh/kg)
Voltages Energy density – Pack
~163 (calc)
(Wh/kg)
Cell voltage
3.7
(~ nominal VDC)
Module voltage 85.1 (2 modules)
(~ nominal VDC) 92.5 (2 modules)
Pack voltage
355
(~ nominal VDC)


ANALYSIS REPORT
Summary
 Battery module 1 containing 1058 cells (23S46P) from Tesla Model 3 was
disassembled and cells were characterized using visual, electrical, physical and
chemical techniques.
 Each cell has a estimated capacity of 4.78 Ah with specific gravimetric energy density
of 254.8 Wh/kg and volumetric energy density 722.3 Wh/L.
 Energy density is on the high end for cylindrical cells of similar sizes . The cell is
optimized for high energy which is achieved through highly compacted electrodes with
low amount of additives and thin separator.
 Cells have low internal DC resistance of 25 mOhm at +30 oC to reduce power losses
 Cell is optimized for up to 5C discharge rate at temperatures higher than 0 oC. The cell
is operational at -20 oC without external temperature control only in case of low rate
discharge (C/5).
 Cell chemistry is NCA(90,5,5) – graphite/Si. NCM(90,5,5) and has a low Co content for
higher capacity and lower cost.
 Anode is graphite with silicon additive (~3.5 w.%). Silicon additive has a form of
crystalline particles (~3um size) uniformly dispersed inside anode layer with Si content
of ~50 w.% in the particles.
 Separator is single-layer dry-processed 10 um thick PE with polymer/ceramic coating

on cathode side. Ceramic coating consists of 1 micron ceramic particles containing Al
and oxygen (potentially alumina, boehmite) inside polymeric binder.
 Apart from usual LiPF6 in EC:DMC:EMC battery electrolyte contains methyl phenyl
carbonate (MPC) additive for improved performance.
 OCV, power capability, cell resistance were measured using HPPC. Usable energy of
the cell at 84W (maximum power assist FreedomCar goal) is 6.3 Wh determined using
HPPC test.


ANALYSIS REPORT
Module Teardown


ANALYSIS REPORT Pack
Overview
• Vehicle System: EV Traction

Battery
• Pack Energy: 75kWh (stated)
• Cell Arrangement:
• 2 modules – 23S46P
with 1058 cells each
• 2 modules – 25S46P
with 1150 cells each
• Total battery pack
contains 4416 cells
• Cell Mass: 0.069 kg

Module
• Cell Diameter: ~21mm (meas)
• Cell Height: ~70mm (meas)
Cell Module Pack

Cell Nominals:
85.1V and
3.7V 355V
92.5V
4.78 Ah 220 Ah 220 Ah
21mm
• Cell Supplier: Panasonic Cell
70mm

BATTERY CELL TEARDOWN Module Weight Repartition

ANALYSIS REPORT
Module Structural Analysis QTY/ Weig Weig

Components Modu ht ht
le (kg) %
• Small module
Terminal Protection 2 0.184 0.21%
structure
Terminals 2 0.396 0.46%
BMS PCB + Flex
1+2 0.157 0.18%
PCB
Cells 1058 73.002 84.38%
Top Enclosure 1 7.917 9.15%
Side Covers 1 0.695 0.80%
1
Cooling Channels 1 0.514 0.59%
1
2 Insulation sheets 1 0.078 0.09%
3
2 Cell Interconnects 3 0.631 0.73%
Bottom Enclosure 1 2.725 3.15%
4
Outer Bottom
1 0.221 0.26%
Enclosure
5
6 Total: 86.5 100%
10

BATTERY CELL TEARDOWN Module

ANALYSIS REPORT
Cell Connection to BMS
Module Structural Analysis
• All cells oriented in one direction

with cans bottom parts facing the
plastic sheet
• Cells are connected to the BMS

using polyimide flexible printed
circuit strips.
• Two strips per pack. 24

connections to cells on each strip.
• Strips are welded to the bottom of

the cell cans (anode).
Cell Cap Side
• On cell cap side the pack is

covered with potting compound
(foam). The foam covers the cell
interconnects
• All interconnects are on cell cap

side (aluminum plates with wire
bonding to cells)
Potting Compound
AI interconnects
(Potting compound removed)


ANALYSIS REPORT
Cell Interconnect
• Cells are interconnected using

wire bonding to aluminum plates.
• 2 plates connected to terminals

(positive and negative)
• 46 connections per plate;
• 22 plates make series connection

• 94 connections per plate
• (46 cell x 2 wires + 2 extra
wires for cells connected to
BMS);
• Total number of connections: 2160
• Total number of cells: 1058

(23S46P)
Two wires per cell (positive and negative)
• Wire diameter: 0.485 mm
• These wires act as fuses – they

would melt if high current is
applied to the cell and disconnect
the cell


ANALYSIS REPORT
Cells Connected to BMS
• 3 wire bonds for the cells that are

welded to the BMS lead strip on
the bottom:
• one wire for positive
connection;
• two wires for negative
connection.
• Two cells that are connected to

the monitoring board have usual 2
wires:
• one for positive and one for
negative


ANALYSIS REPORT
Cell Placement
• Aluminum interconnecting plates

were placed on patterned plastic
sheets to prevent cells shorting.
• The interconnect is attached to

the plastic using gray adhesive
(presumably thermally conducting)
Heat transferring strip(Aluminum)
• The cells are glued to each other,

to the pack plastic shell and to the
heat transferring strips using gray
adhesive
Grey adhesive(hard)


ANALYSIS REPORT
Heat Transfer Strips
• Heat transferring strips (7 per

module) go along the module and
are filled with liquid coolant (
Glycol)
• Material between cells presumably

for damping vibrations
• The strips have fine system of

channels inside with thin walls
(aluminum) to improve coolant
pressure flow and heat transfer
efficiency.


ANALYSIS REPORT
Cell Structural Analysis


ANALYSIS REPORT
Structural Analysis Summary
Item Sub-item Panasonic
Folding structure Spiral winding
Cathode thickness (um) 143
Anode thickness (um) 174
Separator thickness (um) 10
Structure
Cathode 41.54
Analysis
Anode 28.6
Weight
repartition Separator 1.84
(%)
Packaging 19.09
Electrolyte 8.94

BATTERY CELL TEARDOWN Cell External View

ANALYSIS REPORT Cap Side
• Cell weight: 0.069kg
Bottom Side
21mm
Foam
70mm

BATTERY CELL TEARDOWN Cell Internal View

ANALYSIS REPORT Cell Opened
Cell Structural Analysis Anode insulation
Electrolyte excess
Cathode tab
Jelly Roll Extracted
Cell can
Cathode tab tape
Positive insulation
Cap
Negative insulation
Anode tab Jelly roll Cathode tab

BATTERY CELL TEARDOWN Cell Internal View

ANALYSIS REPORT Jelly Roll
8.5mm
Tape length: 61mm
20.5mm
Jelly Roll Extracted
1mm
• Separator appears folded that may

help prevent particles entering the
roll during cap crimping process.
This also help damping vibrations
of jelly roll inside the can
20.5mm
• Jelly roll does not have a center
pin inside. Metal pin is used by
some manufactures inside jelly roll.

BATTERY CELL TEARDOWN Cell Insulation

ANALYSIS REPORT

Negative
• Negative:
• Outer diameter: 20mm
• Inner diameter: 5mm
• Thickness: 219um
Positive
• Positive:
• Outer diameter: 20mm
• Thickness: 329um
• Holes in the positive insulation to

let gas out to the vent in case of
internal cell gassing

BATTERY CELL TEARDOWN Cap

ANALYSIS REPORT

Inside CID bottom disk
• Thickness: 0.9mm
• Diameter: 21mm
• Can edges crimped around the

cap
• Cap appears to be a separate

assembly that is placed in the can
and crimped (not assembled inside
the can).
CID insulation
Insulation (sealant)
Outside Vent line
Weight
Component
mg
Insulation ring (sealant) 0.1528
CID insulation 0.0397
CID bottom disk 0.1318
CID capsule with PCT 0.5533
Total 0.8776

BATTERY CELL TEARDOWN Current Interrupt Device (CID)

ANALYSIS REPORT
• Current interrupt Device (CID) in
14.1mm
the cap: The metal membrane
collapses in case of high internal
cell pressure and disconnects
cathode tab from the cap leaving
the cell at open circuit
Weld spot to cathode tab
• CID insulator thickness: 345um
3mm
CID bottom disk CID insulator (plastic) CID membrane

BATTERY CELL TEARDOWN Positive Temperature Coefficient(PTC) Device

ANALYSIS REPORT
• CID capsule is bonded together

with positive temperature
coefficient material (PTC).
• Electrically connects CID
membrane to the outer positive cell
terminal.
PTC
• If the cell heats up, the PTC

resistance increases until it creates
an open circuit disconnecting the
cell internally.
• This transition is reversible and the
would cell reconnects if it cools
down.
• In some case, the effect may not
be 100% reversible and the PTC
may have higher resistance after
the event.

BATTERY CELL TEARDOWN Cell Schematics

ANALYSIS REPORT
Cap Schematic
Overlap of Jelly Roll Components
No pin inside
the roll
Outside Inside

BATTERY CELL TEARDOWN Anode Tabbing

ANALYSIS REPORT
Anode Tab
• Anode Tab
• Concave shape
• Tab weight: 175.6 mg
• Tab thickness: 111-115 um
• Tab dimension: 70mm x
3mm
• 5 weld spots: 3 mm x 3 mm
• Tape on one side covering tab

• Tape dimensions: 60mm x
11.5mm
• Overlaps with coated anode: 1-
2mm

BATTERY CELL TEARDOWN Cathode Tab

ANALYSIS REPORT
• Cathode tab is welded to 6mm

bare patch.
• One weld spot: 25mm x 3 mm
• Tab dimensions: 76 mm x 3.5mm x
165 um
• Tab weight: 110.8 mg
• Tab is slightly concave for jelly roll
curvature
• Tape around tab: 11 mm x 11 mm
• Tape on both sides of cathode:
(66.5 + 66.5)mm x 11 mm
• Tape overlaps with coated
cathode: 1 – 1.5 mm

BATTERY CELL TEARDOWN Separator

ANALYSIS REPORT
• Two separator sheets with the

same width but different length
Parameters Values
Width, mm 67
#1: 93.4
Length, cm
#2: 95.4
Thickness per sheet, um 10
Areal weight wet, mg/cm2 1.86
Areal weight dry, mg/cm2 1.00
Total weight wet*, g 2.35
Total weight dry*, g 1.26
* total weight calculated based on measured areal weight and measured dimensions

BATTERY CELL TEARDOWN Anode

ANALYSIS REPORT
Parameters Values
Coated width, mm 65
Total width, mm 65
Total Length, cm 96.3 6.5
tab
Double-sided length, cm 86.5 Inside
Single-sided length, cm 6.1

Double-sided
1.5
Uncoated length, cm 3.7

Double-sided thickness, um 174
Single-sided thickness, um 91
86.5
Uncoated thickness, um 8
94.7
Double-sided areal weight wet,
34.6
mg/cm2
Double-sided areal weight dry,
32.9
mg/cm2
6.1
Single-sided areal weight wet, Single-sided

20.7
mg/cm2
2.2
Single-sided areal weight dry, Uncoated

19.8
mg/cm2 outside
Uncoated areal weight, mg/cm2 6.77
Units: cm
Calculated total weight wet*, g 20.44
Calculated total weight dry*, g 19.45

BATTERY CELL TEARDOWN Cathode

ANALYSIS REPORT
Inside
Parameters Values
Coated width, mm 63
Total width, mm 63
Total length, cm 86.5
Coated length, cm 85.9
Uncoated length, cm 0.6
Coated thickness, um 143
Uncoated thickness, um 15
Coated areal weight wet, mg/cm2 50.0
Coated areal weight dry, mg/cm2 48.4
Uncoated areal weight, mg/cm2 4.1
Outside
Calculated total weight wet*, g 29.3
Calculated total weight dry*, g 28.4
Units: cm

BATTERY CELL TEARDOWN Cell Component Weight Summary

ANALYSIS REPORT
Component Weight, g % total cell weight

Packaging 13.10 19.09%
Can 12.01 17.50%
Cap 0.90 1.31%
Insulation 0.19 0.28%
Positive 0.14 0.20%
Negative 0.05 0.08%
Dry jelly roll 49.40 71.97%
Cathode 28.51 41.54%
Current collector 2.23 3.25%
Coating 26.17 38.13%
Tab 0.11 0.16%
Anode 19.63 28.60%
Current collector 4.24 6.18%
Coating 15.21 22.16%
Tab 0.18 0.26%
Separator 1.26 1.84%
Electrolyte 6.13 8.94%
In jelly roll* 5.57 8.12%
Excess electrolyte** 0.56 0.82%
TOTAL: 68.63 100.00%
* - calculated as a difference in weight between wet and dry jelly roll
components;
** - calculated as a difference between measured cell weight and

sum of components weight;


ANALYSIS REPORT
Cell Performance Analysis

Capacity (Ah) and Capacity Retention (%)

BATTERY CELL TEARDOWN vs. Charge and Discharge Rate
ANALYSIS REPORT
Cell Performance
Cell level characteristics:

• Weight: 68.6 g
• Volume: 0.0242 L
• Capacity: 4.78 Ah
• Energy: 17.48 Wh
• Specific Energy: 254.8 Wh/kg
• Energy Density: 722.3 Wh/L
• Gravimetric and volumetric

energy density is on the high end
of the range for typical cylindrical
cells.
Room temperature, Two Cycles
Item CC Ch. @1A CV Ch. @4.2V CC Dsch. @1A
Value 4.2V 0.1A 2.7V

Capacity measurements
BATTERY CELL TEARDOWN Discharge Capacity at 1A, RT
ANALYSIS REPORT
Cell Performance
• Capacity variation between cells

is within +/- 0.7% which
indicates tight process control
during cells manufacturing.
• Capacity measured across 8

cells within the module varies
between 4739.7mAh-4784.8mAh
• Average: 4773.5mAh

BATTERY CELL TEARDOWN Discharge Energy @ 1A, RT
ANALYSIS REPORT
Cell Performance
• Average: 17.4mAh

BATTERY CELL TEARDOWN Coulombic Efficiency
ANALYSIS REPORT
Cell Performance
• Coulombic efficiency on the level

of 99.1%-99.2% is lower than
conventional Li-ion cells. This is
probably due to the presence of
Si in the anode that improves
energy density but known for
lower stability during cell cycling.

Self-Discharge at Different Temperatures

ANALYSIS REPORT
Cell Performance
• Self-discharge rate is calculated

as a slope of linear fit of the
voltage decay over time during
last 10 hours of the 24h rest.
• Self-discharge is good and lower

than typical Li-ion battery (~5-7
mV/day at room temperature
with lower values for low
temperatures)
Self-Discharge,
Temperature, oC
mV/hour
45 0.427
30 0.200
10 0.186
0 0.002
-10 0*
-20 0.039
* noise is higher than voltage decrease

Discharge Rate Test @ 45oC

ANALYSIS REPORT
Cell Performance

Discharge Discharge Capacity
rate current, A (mAh)
C/5 0.94 4941.9
C/2 2.35 4894.2
1C 4.70 4864.5
2C 9.40 4848.4
5C 23.50 4557.3
Discharge Rate Test @ 30oC Discharge Rate Curves @ 30oC

C/5 0.94 4864.8
C/2 2.35 4820.1
1C 4.70 4790.6
2C 9.40 4792.8
5C 23.50 4626.4
10C 47.00 2131.4
• Cell’s vent ruptured during 10C

Cell rupture at 10C
discharge due to cell overheating discharge rate
and caused electrolyte ejection.
• Rates higher than 5C were not

used in subsequent tests due to
safety reasons.


ANALYSIS REPORT
Cell Performance

C/5 0.94 4438
C/2 2.35 4238
1C 4.70 4174
2C 9.40 4145
5C 23.50 4211
Discharge Rate Test @ 0oC Discharge Rate Curves @ 0oC

C/5 0.94 3645
C/2 2.35 3647
1C 4.70 3585
2C 9.40 3370
5C 23.50 3768
• Cells have to be actively cooled

Discharge anomaly due
to prevent overheating during to internal cell heating
high rate discharge.

Discharge Rate Test @ -10oC

ANALYSIS REPORT
Cell Performance
Discharge Rate Test @ -10oC

C/5 0.94 3599
C/2 2.35 3406
1C 4.70 3248
2C 9.40 2154
5C 23.50 510
Discharge Rate Test @ -20oC Discharge Rate Curves @ -20oC

C/5 0.94 2870
C/2 2.35 2161
1C 4.70 30
2C 9.40 14
5C 23.50 2
• Poor high rate performance at

low temperature.
• Cells would require heating to

perform at below -10 oC

Rate Test
BATTERY CELL TEARDOWN Graphical Summary
ANALYSIS REPORT
Cell Performance
• The cell is optimized for 5C for

temperatures above 0oC
• Very good combination of high

energy and relatively high rate
performance

Rate Test
BATTERY CELL TEARDOWN Energy (Wh)
ANALYSIS REPORT
Cell Performance
Energy Summary
Temperature, oC
Discharge Discharge
rate current, A
-20 -10 0 10 30 45
C/5 0.94 9.61 12.56 12.81 16.08 17.77 18.11
C/2 2.35 6.94 11.55 12.62 15.04 17.44 17.79
1C 4.70 0.09 10.56 12.04 14.41 17.08 17.46
2C 9.40 0.04 6.89 10.93 13.72 16.34 16.57
5C 23.50 0.00 1.44 10.60 12.48 14.64 14.03
10C 47.00 NA* NA* NA* NA* 5.95 NA*
* Protection due to voltage drop below safety limit

Cell Resistance (DC)

ANALYSIS REPORT
Cell Performance
Temperature, oC DCIR, mOhm
Cell Resistance (DC)
-20 152.75
• Internal resistance at constant
-10 79.79
current (DCIR) was calculated by
measuring immediate voltage 0 67.50
drop from open at fully charged
state after application of C/5 10 42.16
discharge current and dividing it 30 25.78
by the discharge current value.
45 18.53
• DCIR is at the usual level for this
size of cell.
• Lower internal cell resistance is better for high
rate battery performance.
• Cells with low DCIR can support higher currents

during charge and supply more power during
discharge.

HPPC Test Sequence

ANALYSIS REPORT
•Reference: FreedomCAR Battery Test Manual
Cell Performance • The Hybrid Pulse Power Characterization (HPPC) Test is
intended to determine dynamic power capability over the
cell’s usable charge and voltage range using a test profile
Test Procedure that incorporates both discharge and regen pulses.
• CCCV charge (1C);
• The primary objective of this test is to establish, as a
• Rest 4h (measure VOC);
function of depth of discharge, (a) the discharge power
• Pulse Dch@5C (10s); capability at the end of a 10-s discharge current pulse and
• Rest (3min); (b) the regen power capability at the end of a 10-s regen
• Pulse Ch@5C (10s); current pulse. These power capabilities are then used to
• Rest 3min derive other performance characteristics such as Available
Energy and Available Power.
• CCDch@1C, (6min: +10%DOD);
• Rest 1h; • Secondary objectives are to derive from the voltage
• Repeat for each 10%DOD until response curves the cell resistance as a function of state of
charge to reliably establish cell voltage response time
100%DOD constants during discharge, rest, and regen operating
regimes

HPPC @ 25℃
BATTERY CELL TEARDOWN Open Circuit Voltage
ANALYSIS REPORT
Cell Performance
• Small variation of cell resistance

across almost all DoD range.
• Sharp increase in discharge cells

resistance at high DoD.
HPPC @ 25℃
Cell Resistance

HPPC @ 25℃
BATTERY CELL TEARDOWN Pulse Power Capability
ANALYSIS REPORT
Cell Performance
• Maximum power assist goal:

40 kW
• Battery scaling factor: 474

(see next slide)
• Cell power goal: 84 W
HPPC @ 25℃
Usable Energy vs. Power

HPPC @ 25℃
BATTERY CELL TEARDOWN Usable Energy vs. Power
ANALYSIS REPORT
Cell Performance
• The Battery Size Factor (BSF) is

defined here as the minimum
number of cells of a given
design required for a device to
meet FreedomCAR energy and
power goals.*
Application BSF
Minimum Power-Assist 284
Maximum Power-Assist 474
* Reference: FreedomCAR Battery Test Manual For Power-

Assist Hybrid Electric Vehicles, DOE/ID-11069, October 2003


ANALYSIS REPORT
Cell Material Analysis


ANALYSIS REPORT
Material Analysis Summary
Item Sub-item Panasonic
Active material (Lix)Ni0.90Co0.05Al0.05O1.57
Particle size D50(um) ~7um, ~11um & ~16um
Cathode Conductive additive Carbon Black
Binder PVDF
Al foil(um) 15
Graphite and crystalline

Active material
Chemistry Silicon Particles
Analysis
Anode Particle size D50(um) 16um and 3um
Cu foil(um) 8
Separator (um) 10um
Separator Coating(um) Al2O3 ceramic (10um)
Electrolyte LiPF6

Cathode
ANALYSIS REPORT
SEM
Material Analysis: Cathode
• Densely packed globular

particles.
• Each particle consists of smaller

crystalline particles
• Each particle is covered with

conductive additive and binder

Cathode
ANALYSIS REPORT
SEM
• Cathode consists of globular

particles with three different
average sizes of globules: ~7um,
11um and ~16um (see size
distribution histogram below).
• The particles are densely packed

in the electrode with minimal
empty space inbetween
• Such dense structure is

optimized for high energy density
and may impact rate capability
due to low ionic conductivity

Cathode
ANALYSIS REPORT
SEM
• Each globule in the cathode

consists of irregularly shaped
crystalline primary particles with
average size of 0.24 um (second
pick on the histogram is likely
corresponds to aggregates of
several primary particles).

Cathode
ANALYSIS REPORT
SEM
• Cathode particles are mixed with

conductive additive.
• Conductive additive is carbon

black (fine globular morphology).
• Often flake graphite is also used

as a conductive additive along
with carbon black in cathodes.
• In this case no graphite flakes

were observed in the cathode.
• Amount of conductive additive is Active particles

(NCA)
relatively small.
• Electrode is optimized for energy

density and not for high
conductivity
Carbon black

Cathode
ANALYSIS REPORT
SEM
• Binder amount is minimal – not

clearly observable under SEM.
• Binder amount can be minimized

in case of highly compressed
electrodes to improve power
and energy characteristics of the
cell.
Imprints in AI foil Cathode particles
• Cathode material is very densely

compacted.
• Active particles are embedded

into aluminum current collector
leaving deep hemispherical
caverns
Image of aluminum foil with removed cathode

coating layer

Cathode
ANALYSIS REPORT
Cross-Section (CP)
Material Analysis: Cathode 143 um
• Al foil is 15 um thick (usual

thickness for Al foil in Li-ion
batteries)
15 um
AI foil

Cathode
ANALYSIS REPORT
EDX Results: Active: (Lix)Ni0.90Co0.05Al0.05O1.57
• Active material:
(Lix)Ni0.90Co0.05Al0.05O1.57
• No carbon detected inside

cathode particles – all
conductive additive and binder is
outside the particles.
• Cobalt content is lower than in

usual NCA cathode materials
(usually it is 0.15) that both
reduces amount of Co needed
(lower prices) and increases Ni
content (higher capacity and
energy) Average Standard Atomic
Element Comment
Atomic % Deviation Ratio
O 47.2 4.6 1.75 Active material
C 21.0 5.7 0.78 Conductive additive and binder
Ni 27.1 5.7 1.00 Active material
Co 1.5 0.3 0.06 Active material
Al 1.5 0.4 0.05 Active material
F 1.7 2.5 0.06 Binder, electrolyte

Anode
ANALYSIS REPORT
SEM
Material Analysis: Anode
Graphite
Silicon
• Anode consists of densely

packed graphite particles with
mixed in crystalline smaller
particles (silicon)

Anode
ANALYSIS REPORT
SEM
• Average graphite particle size is

16 um
• Average silicon particle size is 3

um (second peak at ~6 um is
most likely caused by
aggregates of smaller particles

Anode
ANALYSIS REPORT
SEM
• Anode consists mostly of flake

graphite particles. Many particles
look exfoliated – thin flakes
present in the anode. This is
likely done to improve fast
charging capability.
• Silicon-containing particles are

uniformly distributed inside
anode layer.
• Packing of anode particles is

very dense. Graphite crystal Silicon particle
• Some flakes are very thin and

consist only of few graphene
layers.
• This may be graphene materials

that can be used as a conductive
additive in silicon-containing
anode formulations.
• Carbon black that can be used in

anodes as conductive additive
was not observed in the case of
this electrode. Image shows copper foil surrounded with
graphite flakes.

Anode
ANALYSIS REPORT
SEM
• Binder (most likely solution

processed) covers anode
particles (small drop-like features
shown with red arrows).

Anode
ANALYSIS REPORT
Cross-Section (CP)
• Total anode thickness: 174 um
• Current collector: copper foil 8

um thick.
• This is usual foil thickness for

anode in high energy cells.
Thicker foil is typically used for
higher power cells.
Copper foil

Anode
ANALYSIS REPORT
EDX Results: Overall Composition (Surface)
• Surface composition
Element Average Atomic % Weight % Comment
C 93.5 89.10% Graphite and binder

O 4 5.08% Binder, electrolyte
Si 1.6 3.56% Active high capacity material
F 0.5 0.75% Binder and electrolyte
Cu 0.2 1.01% Current collector
P 0.2 0.49% Electrolyte

Anode
ANALYSIS REPORT
EDX Results: Silicon Particles
• Silicon – containing particle

composition:
Average Standard Weight

Element
Atomic % Deviation %
Si 31.6 6.8 48.9
O 25.8 6.8 22.8
C 42.1 11.6 27.9
F 0.5 0.3 0.5

Separator: Face to Cathode

ANALYSIS REPORT
Separator
Material Analysis: Separator – Face
to Cathode
• Separator has yellow coloration

on the cathode side where it
overlaps with the cathode.
• The yellow coloration develops

inside assembled cell and most
likely has to do with SEI
formation on the cathode during
formation process.
Separator Cross-section (CP)
• Separator is singe-layer 10 um
thick.
• Separator has ceramic

composite coating on the
cathode side.


ANALYSIS REPORT
SEM
to Cathode
• Separator has a coating on the

cathode side.
• The coating is ~ 0.5 – 1 um thick
• Ceramic layer is used for safety.

It is supposed to keep electrodes
from shorting if separator
membrane melts. It keeps
separator from shrinking at high
temperature It is also supposed
to block Li dendrite growth on
anode especially during high rate
charging.


ANALYSIS REPORT
SEM
to Cathode
• The coating consists of ceramic

particles surrounded with
polymer binder


ANALYSIS REPORT
SEM
to Cathode
• Particle size in the separator

coating is ~ 0.2 um.
• Particles are mostly aggregated

and fused together to form ~
1um size aggregates with
complex shape Ceramic particles
Binder


ANALYSIS REPORT
EDX Results: Face to Cathode
to Cathode
• Ceramic particles consist of Al

and oxygen (possibly alumina,
boehmite etc.)
Standard
Element Average Atomic % Possible Sources
Deviation
C 45.6 5.7 Binder
O 36.6 5.6 Alumina and binder
Al 12.8 2.1 Alumina
N 4.0 0.9 Most likely binder
F 1.0 0.1 May be binder, electrolyte
P 0.1 0.0 Electrolyte

Separator: Face to Anode

ANALYSIS REPORT
Separator
to Anode
• Separator is white on anode

side.
• On anode side separator is non-

coated porous polymeric
membrane.
• The membrane has isotropic

morphology typical for PE
membranes produced by wet
process. Wet process is one of
the processes used for PE
separators manufacturing.
Membranes produced by wet
process have good tensile
strength in both directions which SEM
brings safety advantage
compared to membranes
produced by alternative dry
process that have poor tensile in
lateral direction.
• The separators made by wet

process use ultrahigh-molecular-
weight polyethylene (UHMWPE).
• The use of UHMWPE gives

good mechanical properties as
well as some degree of melt
integrity (film does not
disintegrate upon melting).

Separator: Face to Anode

ANALYSIS REPORT
EDX Results: Face to Anode
to Anode
• Separator on anode side is pure

hydrocarbon
• Some silicon-containing particles

sticking to separator on anode
side

Separator DSC
ANALYSIS REPORT
Material Analysis: Separator
• Melting point of separator is

higher than typically observed for
PE separators but lower than PP.
• Most likely it is high molecular

weight PE with higher melting
point than conventional PE used
in membranes.
• Higher melting point improves

battery safety.
• The reference chart on the right

shows the difference between
melting points for PE and PP
which are most common plastics
used for separator membranes.

Electrolyte
ANALYSIS REPORT
Gas Chromatography
Material Analysis: Electrolyte Mass Spectroscopy (GC-MS)
Experimental:
• The sample was analyzed as a

10% solution in acetonitrile.
• The analysis was performed by

GC/MS using a 30-meter Rtx-
5MS capillary column (0.25 mm
ID, 0.25 μm film thickness),
interfaced to an Agilent 7890A
gas chromatograph equipped with
a 5975C mass spectrometer.
Total gas chromatogram for the electrolyte sample

Electrolyte
ANALYSIS REPORT
GC-MS Analysis
Material Analysis: Electrolyte Results
• See comments on the following

page
Product of LiPF6
decomposition
DMC
EMC
EC
MPC (additive)

Electrolyte
ANALYSIS REPORT
GC-MS Analysis
Material Analysis: Electrolyte Results
• EC:DMC:EMC (peaks #8, 4, 5)

mix is a typical solvent system
for Li-ion battery electrolyte.
This mix is beneficial for low
temperature performance.
• MPC (peak #8) is an additive

developed by J.Dahn. Addition
of MPC increases the
coulombic efficiency, reduces
charge end-point capacity
slippage rate, decreases the
self-discharge rate during
storage and improves the
capacity retention during long-
term cycling [1]
• Fluorinated silanes (peaks #2,

3, 6, 7, 10, 11) may be additives
[4] or analysis artifact of due to
reaction of the electrolyte
decomposition products with
glass of the chromatography
column. Difluorodimethyl-silane
(peak #2) as an additive
improves high-temperature
storage performance [2].
Difluorodiphenyl silane (peak
#11) as an additive improves
high-temperature performance
[3]
References:
1) Journal of Power Sources 318:228-234
2) US 2013/0136997
3) EP1938404A1, CN104892658A
4) US 9,023,536

Electrolyte
ANALYSIS REPORT
Electrolyte Salt Analyses Using
Material Analysis: Electrolyte IC and LC-MS
Analysis Set-up
 IC: The electrolyte sample, was prepared in water and analyzed using Ion
Chromatography (IC) with comparison to a mixed analytical reference standard for the
following cations: lithium (Li+ ), sodium (Na+ ), ammonium (NH4+ ), potassium (K+ ),
and magnesium (Mg2+).
 LC-MS: The electrolyte sample was prepared in water and analyzed using Liquid
Chromatography/Mass Spectroscopy (LC/MS) with comparison to analytical reference
standards for the following anions: tetrafluoroborate (BF4- ),
bis(trifluoromethane)sulfonimide (TFSI- ), bis(oxalato)borate (BOB- ),
hexafluorophosphate (PF6-), and bis(fluorosulfonyl)imide (FSI- ).
Cation Ion Chromatograms
• Li+ is the main cation in electrolyte.
• Trace amounts of Na+ and K+ detected

Electrolyte
ANALYSIS REPORT
LC-MS Screening for BF4-
No BF4- detected in electrolyte
• LiBF4 is not typically used in Li-ion batteries these days. Electrolytes with LiBF4 have
lower ionic conductivity compared to more common LiPF6 . But LiBF4 has better
thermal stability and more stable to hydrolysis compared to LiPF6 . So LiBF4 is used
sometimes if high-temperature performance is of greatest importance.

Electrolyte
ANALYSIS REPORT
LC-MS Screening for TFSI -
No TFSI- detected in electrolyte
• LiTFSI is not typically used in Li-ion batteries. LiTFSI has good thermal stability and is
used in batteries for high-temperature applications.

Electrolyte
ANALYSIS REPORT
LC-MS Screening for BOB-
No BOB- detected in electrolyte
• LiBOB is sometimes used as an additive to Li-ion battery electrolyte for improved

solid-electrolyte interface (SEI) formation on electrodes (especially cathode side) for
extended cycle life time.

Electrolyte
ANALYSIS REPORT
LC-MS Screening for PF6-
Electrolyte contains PF6-
• LiPF6 is the most commonly used salt for Li-ion battery electrolytes.

Electrolyte
ANALYSIS REPORT
LC-MS Screening for FSI-
No FSI- detected in electrolyte
• The use of LiFSI improves cycle life, charge/discharge performance, low-temperature

performance and cell bulging at high temperatures. Typically used in relatively high
concentrations of 0.2M – 0.6M together with LiPF6 to get total Li+ concentration of
1.2M(M means mol/L)


ANALYSIS REPORT
Glossary & Appendix

Glossary of Terms
Glossary Usage
CC Charge Current Charge/discharge cycling
CID Circuit Interrupt Device Battery Component
A reference view used in

CP Cross Section Polishing
SEM
CV Charging Voltage Charge/discharge cycling
DC Discharge Current Charge/discharge cycling
DCR DC (Direct Current) Resistance Charge/discharge cycling
Separator material
DSC Differential Scanning Calorimetry
analysis
DTG Derivative Thermogravimetric Analysis Binder material analysis
Separator material coating

EDS Energy Dispersive Spectroscopy
and binder analysis
Separator coating
FTIR Fourier Transform Infrared (Spectroscopy)
analysis
GC Gas Chromatography Electrolyte analysis
GC-MS Gas Chromatography – Mass Spectrometry Electrolyte analysis
GC-
Gas Chromatography - Thermal Conductivity Detector Electrolyte analysis
TCD
A measure of permeability of a membrane indicating time
Gurley (in seconds) to pass a known volume of air through the Separator testing
membrane

Glossary of Terms
Glossary Usage
Cell performance
HPPC Hybrid Pulse Power Characterization
testing
IC Ion Chromatography Electrolyte analysis
Inductive Coupled Plasma emission spectrometer

ICP Cathode analysis
for material analysis
Electrolyte material
MSD Mass Spectrometric Detection
analysis
Anode or Cathode
PSD Particle Size Dispersion active material
characterization
Common cathode
PVDF Polyvinylidene Fluoride
binder
SBR Polymerized Styrene Butadiene Rubber Common anode binder
Anode and Cathode

SEM Scanning Electron Microscopy powder grain size
determination
Cathode material
XRD X-Ray Diffraction
analysis

Additional Reports Available
Ricardo has benchmarked the following vehicles
Vehicle Architecture
2017 Ford Fusion PHEV
2017 Chevrolet Bolt EV
2017 Nissan Leaf EV
2016 Mercedes GLE 550e PHEV
2016 BMW X5 xDrive40e PHEV
2016 Tesla Model X EV
2016 Volvo XC90 T8 PHEV
2015 VW e-Golf EV
2015 Honda Civic Hybrid HEV
2014 Acura RLX HEV
2014 BMW i3 w/ Range Extender PHEV
2014 VW Jetta Hybrid HEV
2014 Chevrolet Spark EV EV
2013 Tesla Model S 60 EV
2013 Ford Fusion Hybrid HEV
2013 Ford C-Max Energi PHEV
2013 Chevrolet Malibu Eco HEV
2012 Toyota Prius Plug-in Hybrid PHEV
2011 Chevrolet Volt PHEV
2011 Nissan LEAF EV
2011 Mitsubishi i-MiEV EV
CONTACT US TO LEARN MORE ABOUT OUR xEV BENCHMARKING ACTIVITIES

Contact Information
Ricardo Strategic Consulting (RSC) is the global management consulting subsidiary of Ricardo
PLC and is a natural extension of Ricardo's high value-added engineering services. We serve a
broad range of clients in both the Automotive & Transportation sectors.
Coupling Ricardo’s significant work in the xEV sector product development and strategy consulting
with A2Mac1, the industry’s most recognized provider of web-accessible automotive benchmarking
services, provides a unique toolset that supports companies efforts to deliver innovative, high-
value services to their global automotive clients.
Hands-on workshops, interactive benchmarking tools, and battery CAD models are available for
purchase
Workshops EV/Hybrid Analysis CAD Models
EVanalysis@Ricardo.com http://estore.ricardo.com/
+01-734-394-3939 Ricardo Benchmarking
CONTACT US TO LEARN MORE ABOUT OUR xEV BENCHMARKING ACTIVITIES

BatteryCellTeardownAnalysis PDF

Uploaded by

Copyright:

Available Formats

You might also like

BatteryCellTeardownAnalysis PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BatteryCellTeardownAnalysis PDF

Uploaded by

Copyright:

Available Formats

2018MY Tesla Model 3

2018 Tesla Model 3

Battery Cell Teardown

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 1

BATTERY CELL TEARDOWN

This report is restricted and may not be distributed, re-published, sold or

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 2

BATTERY CELL TEARDOWN

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 3

BATTERY CELL TEARDOWN

Cell manufacturer Panasonic Cell capacity (Ah) 4.78 [meas avg]

Cell type 21700 Cooling medium Liquid cooled

Pack location Underbody

EC + DMC + EMC + Length (mm) 1470

Pack Box Volume (m3) 1.08

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 4

BATTERY CELL TEARDOWN

 Separator is single-layer dry-processed 10 um thick PE with polymer/ceramic coating

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 5

BATTERY CELL TEARDOWN

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 6

BATTERY CELL TEARDOWN

• Vehicle System: EV Traction

• Pack Energy: 75kWh (stated)

• Cell Mass: 0.069 kg

• Cell Height: ~70mm (meas)

Cell Module Pack

• Cell Supplier: Panasonic Cell

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 7

BATTERY CELL TEARDOWN Module Weight Repartition

Module Structural Analysis QTY/ Weig Weig

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 8

BATTERY CELL TEARDOWN Module

• All cells oriented in one direction

• Cells are connected to the BMS

• Two strips per pack. 24

• Strips are welded to the bottom of

Cell Cap Side

• On cell cap side the pack is

• All interconnects are on cell cap

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 9

BATTERY CELL TEARDOWN Module

• Cells are interconnected using

• 2 plates connected to terminals

• 22 plates make series connection

• Total number of connections: 2160

• Total number of cells: 1058

Two wires per cell (positive and negative)

• Wire diameter: 0.485 mm

• These wires act as fuses – they

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 10

BATTERY CELL TEARDOWN Module

• 3 wire bonds for the cells that are

• Two cells that are connected to

CELL ANALYSIS REPORT WWW.RICARDO.COM © RICARDO 2018 11

BATTERY CELL TEARDOWN Module

• Aluminum interconnecting plates

• The interconnect is attached to