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Technical capabilities

Power density

Johnson Matthey Battery Systems has delivered the highest power density battery pack in a production road-going car:

  • P1 Pack135kW (180kW peak) of additional power at the press of a button
  • ~180 horsepower instantaneously at the press of a button, and maximum torque at 0rpm
  • A step change in performance giving >40kW/kWh, more than 3 times that of a conventional PHEV application
  • The pack is designed to capture maximum power under regenerative braking >40C

Electrochemistry

Application performance is dictated by the battery materials chemistry, the cell technology and the integration engineering into the end application battery pack.

  • With strong electrochemistry expertise and experience we maintain an active technology roadmap for battery materials, specifically in the area of electro-active energy storage materials.
  • Our in-house cell testing and validation forms the basis of our calibration and control strategy.
  • We model electrochemical safety, building this in from cell selection through pack design and safety and BMS control strategy.

Electronics

We offer a range of Battery Management Systems (BMS) depending on the application.

  • Hybrid BatteryWe offer high performance hardware, which has gone through full DV/PV validation to automotive standards and is in series production.
  • It has active cell balancing, which shuttles charge around the pack to maintain accurate balance throughout the power pack and ensure optimum performance and durability.
  • Complex BMS architecture and functions.
  • Our novel use of flexi circuits that include temperature and voltage sensing makes them part of the BMS and further reduces weight.

Lightweighting

Johnson Matthey Battery Systems delivers innovative solutions for smaller and lighter batteries, while maintaining the safety case:

  • P1 Cell ArrayInnovative lightweight salt bath dipped brazed aluminium structure developed for high power hybrid battery systems
  • Minimised weight on innovative BEV battery by use of new materials such as Aluminium hybrid foam sandwich for the battery housing and smart integration.  The prototype pack offers an industry-leading 148Wh/kg at the pack level for a 23kWh pack.
  • Prestige PHEV low weight battery pack is packaged in the spare wheel-well in an EMI-shielded polycarbonate enclosure and weighs ~176kg

Power management

  • Control and management systems are designed to provide performance over life of vehicle
  • Our advanced cooling system maintains cell thermal stability to maximise electrochemical power transfer to motive power
  • Our high performance thermal management and control systems have been deployed in both hybrid supercars and PHEV luxury saloons

Simulation

  • Electro-thermal – our Modelling and Simulation of Li-ion cells aids pack design, thermal management assessment and validation
  • Extensive CFD Simulation was used to analyse coolant liquid flow through high performance hybrid pack
  • We analyse usage pattern, drive cycle and life, at Cell and Pack level
  • Crash tests conducted on our battery systems correlate well to predictions from simulation
  • We conduct performance evaluation / validation against real drive profiles, e.g. Nordschleife

Safety

  • Smart Battery CrashStrong safety capability is built into our battery systems through electrochemistry, cells, controls, electronics, mechanical and systems design. 
  • Our battery systems meet all UN testing requirements.
  • Through our advanced BMS our battery systems communicate with other vehicle systems, including control systems.
  • Our packs are developed and built to meet rigorous Crash/Crush requirements.

Quality

  • We follow full automotive APQP/PPAP/PSW Quality processes and Supply Chain Management.
  • All safety and legal requirements are validated and verified through either test or analysis.

Manufacturing Technology

  • Co-located product and manufacturing technology teams ensure that manufacturability is built in at the design stage, incorporating DFM and DFT (design for manufacture and design for test) principles.

Please contact us to discuss your requirements for advanced automotive battery systems.

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