Blade – cell to pack LFP

The Blade Battery consists of a single-cell battery with a length of 96cm, a width of 9cm and a height of 1.35cm, which can be placed in an array and inserted into a battery pack like a blade. BYD claimed that due to its optimized battery pack structure, the volume utilization of the Blade Battery is also more than 50% greater compared to past products, with its cruising range reaching the same level as ternary lithium batteries.

The Blade battery is manufactured at FinDreams battery factory of BYD, located at Bishan district of Chongqing in China. It has a total investment of 10 billion yuan with an annual production capacity of 20GWH. “The nearly one-meter-long pole piece can achieve tolerances of within +/-0.3mm, and the accuracy and speed of a single-piece lamination have an efficiency of 0.3s/pcs. This is the first of its kind in the world. This form of lamination comes from BYD’s completely independent development of its equipment and cutting-edge solutions – aspects that are uncopiable,” he said.

BYD Blade Battery
BYD argues that conventionally, only about 40% of the battery pack volume is batteries. In the case of the new Blade Battery approach – cell-to-pack (CTP) technology – the batteries take 60% of pack volume, which is a 50% improvement.
While undergoing nail penetration tests, the Blade Battery emitted neither smoke nor fire after being penetrated, and its surface temperature only reached 30 to 60°C. Under the same conditions, a ternary lithium battery exceeded 500°C and violently burned, and while a conventional lithium iron phosphate block battery did not openly emit flames or smoke, its surface temperature reached dangerous temperatures of 200 to 400°C. This implies that EVs equipped with the Blade Battery would be far less susceptible to catching fire – even when they are severely damaged.
BYD Blade prismatic battery cell specs and possibilities (update)
BYD Blade prismatic battery cell. If you’re wondering why Tesla is still using thousands of tiny cylindrical battery cells to assemble complex battery packs, it’s because when the automaker introduced the Roadster in 2008, high energy density battery cells were only available in that format (mostly used in laptops). Only in late 2016, high energy density battery cells started to be available in pouch format, like the LGX E63 made by LG Chem.
The first electric car to use the BYD Blade Battery is the BYD Han EV that’ll be available with two battery capacities (65 and 77 kWh). 605 km range, 0-100 km/h in 3.9 seconds
The 65 kWh battery pack will give a NEDC range of 506 km – 101 or 102 cells, 1.377 x 905 x 118 mm, 400 kg, 147L.
The 77 kWh battery pack will give a NEDC range of 605 km – 120 cells, 1.620 x 905 x 118 mm, 470kg, 173L.

Yes, a smaller electric car could accommodate a BYD Blade Battery. The 2020 Chevrolet Bolt EV gets an EPA range of 259 miles (417 km) from a 66 kWh battery whose size is 285 L and weighs 430 kg. Given the high weight of the 77 kWh BYD Blade Battery, the 65 kWh version would be more suited for the Chevrolet Bolt EV. It would have an EPA range around 250 miles (402 km), but with a good TMS the LFP battery could be fast charged from 0 to 80 % in less than 30 minutes. Moreover, with 80 euros per kWh at the battery pack level, the battery would cost 5.200 euros. The BYD cobalt-free Blade Battery helps the BYD Han EV to be great electric car and so far it’s the best alternative to the Tesla Model S.

The BYD cobalt-free Blade Battery helps the BYD Han EV to be great electric car and so far it’s the best alternative to the Tesla Model S. Moreover, with 80 euros per kWh at the battery pack level, the battery would cost 5.200 euros.
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he “blade battery” solution (i.e. the long cell solution): by increasing the length of the cell, the flat and long iron phosphate lithium cell was designed to facilitate integration. the length of the cell can be customized. Globally, Tesla, Ningde times, BYD and beehive energy have successively started to develop and announce the mass production of CTP related products. The modular free power battery pack is becoming the mainstream technology route. 
The height of the Blade Battery is reduced by ~50 mm, compared with regular LFP battery back with modules, providing more space to the passengers and decreasing the coefficient of drag (0.233 cd for BYD Han).
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In the Z direction, the structure of the Blade Battery is completely different from conventional module-based battery packs. The lower profile of the Blade Battery offers more flexibility in optimizing between design and capacity. Each cell is used for not only energy storage but also structural support of the battery pack. The array design provides extremely high strength in the Z axis.
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The strength of Blade Battery combined with the honey-combed structural panels provide sufficient support to the battery pack. This breakthrough enables the space to be utilized more effectively, solving the fixing and strength issues at the same time without modules.

The BYD Blade Cell to Module-Free Battery Pack could be fhe Next-Generation Battery Pack Design. Although the Blade Battery shows a lot of promise, the blade geometry is not perfect . For example, the Blade Battery has a challenging manufacturing process. With an electrode roll dimension larger than 500 mm, roll-to-roll alignment and lamination and quality control will be very difficult. Manufacturing inconsistencies in the cells could blunt many of the advantages of this CTP design. This module-free design is also not the only option for CTP. Another popular solution involves substituting traditional smaller modules with larger ones. CATL and SVOLT, among others, have chosen this path. Using large modules can save weight and volume by reducing the number of inactive connectors between modules. CTP technology seeks to improve energy density by reducing the weight and volume of the inactive materials, such as module shells and connectors. BYD’s Blade Battery design explored a bold CTP concept through its module-free pack. High quality control in materials and cell manufacturing, however, remain critical prerequisites of CTP.

BYD is the world‘s biggest manufacturer of electric vehicles.

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