Kokam EV Pack Brochure V 1.9-Compressed PDF

Xpand Battery Solution
For Transportation Application

Xpand Modular Pack
Electrifying Transport For High Performance E-Mobility
Xpand Battery System is designed for use in commercial truck,

Customizable Design
bus, tram, and heavy duty transportation. The system can be
integrated in parallel and in series to create very high energy and
high voltage systems. Furthermore, the “Variable Bulkhead”
design allows to customize the packs’ electrical and cooling
interfaces without having to retool the entire systems.
Single Unit Scalable Modular Design
Features
· Variable bulkhead design · Advanced ultrasonic welding of cell tabs to busbars

Superior Lithium Ion Battery · Advanced liquid cooling system · Durable and safe under the toughest conditions
· High power performance · New BMS, BDU and MCU · Available with high energy or high power cells
· Safe and wide range of operating temperature
· A function to prevent spreading a fire out · All external connections at front panel
Compact and High Reliability Battery Packs of the pack in case of internal fire · Low and stable impedance
· Efficient direct liquid cooling
· Ease of installation
· Customizable solution
· IP67 Compliant (with connectors mated)
State-of-the-Art Battery Management Systems XMP 76P XMP 111E
· ISO-26262 compatible RTOS Cell Configuration 43HP - 2P24S 63UHE - 2P24S

· Highly configurable for any chemistry Discharge Energy (kWh) 7.6kWh (Rated @ C/2) 11.1kWh (Rated @ C/10)
· 12V and 24V compatible Specific Energy (Wh/kg) ≥99 ≥144
· Designed for system voltages up to 1,000V
Capacity (Ah) 86 (Rated @ C/2) 126 (Rated @ C/10)
Complete System Design and Component Selection Voltage (Nominal; V) 88.8 88.3
Mass (kg) 76.8 77.0
· Battery disconnect unit, System controller, Master controller
· Controls up to 300 cells in series; 24 strings in parallel Dimensions (L x W x H) 753 x 303 x 282 (mm)
Certification ISO 12405, ISO 20653, ISO 16750, GMW 16390,
Extensive R&D, Engineering, and Test & Validation Resources UNDOT 38.3, ECE R100 8E, IEC 62281, J2929, UN 38.3
Fully Automated Production Line
Xpand EV Battery System From Manufacturing Cells to Pack Assembly
Certified & Guaranteed
Advantages
· Easy to customize high voltage, low voltage and cooling interfaces to each application
· All connections at front panel; rear access not needed for installation
· Designed for use in very large strings and pack combinations
(Up to 1,000V per string, and up to 24 strings in parallel)
· Allows upgrades to connector styles, fuses, VTBs without tooling entire pack
· Robust, highly serviceable BDU with integrated SCU; standalone MCU
· Available with or without internal fuse (tested both ways for safety)
· Highly robust tab-to-busbar joint survives the harshest vibration & shock environments while maintaining
ultra-low DCIR
· Direct cooling to cell face; 50-75% less mass than competing technology; maximizes volumetric efficiency
· Enhanced cell separator eliminates the need for thermal barriers
EV Battery Pack Validation
Test Conditions Reference
Ingress Protection Mated: IP67, IPXXD, Unmated IPXXB ISO 20653

Mechanical Shock (XMP76P) 50G, 6ms, 3 axis, 10 each
ISO 12405
Mechanical Shock (XMP111E) 20.7G, 11ms, 3 axis, 10 each
Vibration Random, 3 Axis, 21 hr/axis ISO 12405
Composite Heat & Humidity RH 93%, 25°- 65°C, 28 day ISO 16750
Thermal Shock 85°C to-40°C within 30 min ISO 12405
UNDOT UN T1, T2, T3, T4, T5 UN 38.3
Housing Load Knee 150kN/m²; Foot 356kN/m² GMW16390
External Fuel Fire 130 sec over fuel fire ECE R100 8E
Drop Test 1.2m onto cement on corner IEC 62281
Unbalanced Overcharge 1 cell @ 200% forced overcharge
Forced Internal Coolant Leak Rotate and hold around each axis
External Short Circuit, Fused 5mΩ, 100 mΩ J2929, UN 38.3
External Short Circuit, Unfused 5mΩ J2929
Xpand EV Battery System-based Safety
Under Voltage Over Voltage
Certified & Guaranteed Cell (43Ah HP & 63Ah UHE)

Critical Threshold
Over
Block Operation Temperature
Reduced Performance
Reduced Performance
Reduced Performance
Temperature
Normal
Function
Reduced Performance
Blocked Charge Under
Blocked Operation Temperature
The cell incorporates ceramic coated separator and builds upon proven NMC
Open Circuit Voltage V chemistry. The tests cells, modules and systems were tested in its own test labs
Critical Threshold
Blocked Operation Blocked Operation or in certified regional test agency labs. Development and test of battery systems
(FETs or Contactors open) Critical Threshold are done according to the following standards :
Integrated, multiple layers of protection : Passive and active safety Obtained Additional Test & Certifications
UN transport test ST/SG/AC.10/11/Rev.6
Passive safety per many industry standards : Crush UN 38.3 T6, QC/T 743, GBT**, SAE J2464**
· ECE R100, R17; FMVSS; ISO 6469; UNDOT 38.3 Ellicert / INERIS Safety Tests Nail penetration SAE J2464, QC/T 743, GBT**
(French Automotive Consortium), ISO 12405-2 / EN 60068-2 / ISO 20653 / ISO 11452-2 Thermal stability SAE J2464
Analysis of hazardous substances during USABC (SAND2005‐3123)**
cell opening without thermal runaway
Active safety follows methods defined in ISO 26262 and IEC 61508 :
· Develop, execute, and maintain, safety plan through the entire product lifecycle Analysis of hazardous substances during USABC (SAND2005‐3123)**
cell opening with thermal runaway
· Strategies, activities, and procedures for achieving product safety
· Utilize tools, methods, and procedures from relevant industry standards, regulations, FTIR analysis of escaping gases in free space USABC (SAND2005‐3123)**
and best known practices of industry ** testing performed on similar chemistry cells having non ceramic coated separator
- DISCLAIMERS OF WARRANTIES
ALL MATERIALS AND SERVICES ON THIS DOCUMENT ARE PROVIDED “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OR THE WARRANTY OF NON-INFRINGEMENT. THIS DOCUMENT COULD INCLUDE TECHNICAL
OR OTHER MISTAKES, INACCURACIES OR TYPOGRAPHICAL ERRORS. KOKAM ASSUMES NO RESPONSIBILITY FOR ERRORS OR OMISSIONS IN THE INFORMATION, DOCUMENTS,
SOFTWARE, MATERIALS AND/OR SERVICES WHICH ARE REFERENCED BY OR LINKED TO THIS DOCUMENT. KOKAM DOES NOT GRANT ANY EXPRESS OR IMPLIED RIGHT TO ANY PERSON
www.kokam.com
OR BUSINESS ENTITY UNDER ANY PATENTS, COPYRIGHTS, TRADEMARKS, OR TRADE SECRET INFORMATION WITH RESPECT TO THE MATERIALS AND SERVICES. NO PORTION OF THE battery@kokam.com
INFORMATION OR DOCUMENTS MAY BE REPRODUCED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF KOKAM. IN NO EVENT SHALL KOKAM BE LIABLE
TO ANY PERSON OR BUSINESS ENTITY FOR ANY SPECIAL, PUNITIVE, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES BASED ON ANY USE OF THIS DOCUMENT.

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Xpand Battery Solution

For Transportation Application

Xpand Battery System is designed for use in commercial truck,

Single Unit Scalable Modular Design

· Variable bulkhead design · Advanced ultrasonic welding of cell tabs to busbars

State-of-the-Art Battery Management Systems XMP 76P XMP 111E

· ISO-26262 compatible RTOS Cell Configuration 43HP - 2P24S 63UHE - 2P24S

EV Battery Pack Validation

Test Conditions Reference

Ingress Protection Mated: IP67, IPXXD, Unmated IPXXB ISO 20653

Certified & Guaranteed Cell (43Ah HP & 63Ah UHE)

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