Under the contract, Johnson Controls will complete previously begun development work on lithium-ion batteries technology for plug-in hybrid electric vehicle applications to meet USABC goals for low-cost, long-life, high-power and high energy vehicle systems.

The focus of this 24-month program is to further increase the volumetric energy density of a hard-cased prismatic cell technology developed in a preceding USABC-Johnson Controls program through a combination of innovative material and processing advances.

The improved energy density is aimed at reducing cost, volume and mass. All cells will be built either in Johnson Controls Battery Technology Center in Milwaukee or its Li-ion manufacturing facility in Holland, Mich.

The U.S. Department of Energy is helping fund the contract, which includes a 50% cost share by Johnson Controls.

USABC is a subsidiary of the United States Council for Automotive Research LLC (USCAR). Enabled by a cooperative agreement with the U.S. Department of Energy, USABC’s mission is to develop electrochemical energy storage technologies that support commercialization of hybrid, plug-in hybrid, electric and fuel cell vehicles.  As such, USABC has developed mid- and long-term goals to guide its projects and measure its progress.

The new contract is USABC’s third with Johnson Controls, whose previous research with USABC included competitively bid contracts for the development of battery cell, module and pack technology for PHEV applications and lithium-ion battery systems development for hybrid electric vehicles.

The two auto giants will try to increase the performance and capacity of lithium-ion battery cells through the use of new combinations of materials for cathodes, anodes and electrolytes.

In addition to the collaborative research agreement between BMW Group and Toyota Motor Corp., Toyota Motor Europe and BMW Group entered into a contract—also announced on December 1, 2011—under which BMW Group is to supply highly efficient 1.6 liter and 2.0 liter diesel engines to Toyota Motor Europe starting in 2014.

When commercialized, this 400 Wh/kg battery is expected to slash the price of a 300 mile range electric car by cutting the cost of the battery pack by more than 50 percent.

Envia said its batteries were tested at 400 watt-hours per kilogram at a projected cost of $125 per kilowatt-hour, which is more energy dense than most batteries and less than half of what automakers are paying today, according to the company.

The testing of Envia’s next-generation lithium-ion battery was performed by the Electrochemical Power Systems Department at the Naval Surface Warfare Center (NSWC) in Crane, Ind., under the sponsorship of ARPA-E.

Tests at various cycling rates at NSWC confirmed that Envia’s automotive battery cell demonstrated energy density between 378-418 Wh/kg for rates between C/3 to C/10 for a 45 Amp-hour (C/3) cell. Similar cells have been cycling in Envia’s test labs for over 300 cycles.

Envia is at a prototype phase and foresees it taking at least three years before commercial production.

Envia Systems is a Silicon Valley startup founded in 2007, headquartered in Newark CA, and with a prototyping and manufacturing plant in Jiaxing China.

The company received a $4 million ARPA-E award in the High Energy Density Lithium Batteries program.

General Motors is one of Envia’s high profile investors, and invested $7 million into Envia about a year ago. GM has said that Envia will provide battery technology for future generations of GM’s Volt plug-in hybrid. Other investors in Envia include Japanese giant Asahi Kasei, Pangaea Ventures, and Redpoint Ventures.

The company received a $4 million ARPA-E award in the High Energy Density Lithium Batteries program.

A123 Systems said the new plant in Livonia, Mich. is expected to expand A123′s manufacturing capabilities by up to 600 MW hours a year when fully operational, contributing to the company’s plan to expand global final cell assembly capacity to more than 760 MW hours annually by the end of 2011.

A123 Systems received a $249-million U.S. Department of Energy grant as part of the American Recovery and Reinvestment Act and $125 million in state incentives from the 21st Century Job Fund.

A123 will focus on manufacturing prismatic cells and systems at the new 291,000-square-foot Livonia facility. The factory is designed to enable the complete production process, including research and development, manufacturing of high-value components, cell fabrication, module fabrication and the final assembly of complete battery packs ready for vehicle integration.

As part of its continuing U.S. manufacturing ramp up, A123 also plans to open a coating plant in Romulus, Mich., expected to come on line during the first half of 2011

Fisker Automotive will use batteries from A123 Systems to power its $87,900 Karma plug-in hybrid, which is expected to debut late this year.

A123’s customer list also includes BAE, Eaton, Navistar, Shanghai Automotive Industry Corporation (SAIC) and other global automakers and heavy-duty vehicle manufacturers.

The company has also delivered more than 20MW of its Smart Grid Stabilization Systems (SGSS) to customers worldwide, making it currently the largest producer of lithium ion batteries for ancillary services for the power grid, according to the company.

“Over the next several years, we expect to create thousands of jobs in greater Detroit and plan to continue our expansion in the area as we do our part in helping the U.S. emerge as a global leader in the production of advanced lithium ion batteries,” said David Vieau, president and CEO of A123 Systems.

The warranty will be transferable at no cost to other vehicle owners and cover all 161 battery components, GM said.

In addition, the warranty also includes the battery’s thermal management system, charging system and electric-drive components.

GM already offers a 100,000 mile, 5 year warranty on the engines and transmissions in all of its other models, so this warranty adds a small degree of greater protection for the Volt’s battery pack and related parts.

The Volt’s gasoline engine, which generates electricity should a driver want to travel beyond 40 miles after charging, will be covered by the standard 5-year, 100,000 mile warranty.

The Chevrolet Volt will go on sale later this year in California, Washington, D.C., Austin, Texas, and around New York City. Additional Volts will go on sale next year in Michigan, New Jersey, Connecticut and the rest of New York and Texas.

GM plans to produce 10,000 Volts by the end of the 2011 calendar year and an additional 30,000 in 2012.

The automaker has provided some additional specifications on the battery pack. Key battery features include:

– Thermal management for durability and reliability: The Volt is the only mass-market electric vehicle with a battery that can be warmed or cooled. The battery is designed to provide reliable operation, when plugged in, at temperatures as low as -13 degrees Fahrenheit (-25 C) and as high as 122 degrees Fahrenheit (+50 C). In cold weather, the battery will be preheated during charging to provide full power capability. In hot weather – the most challenging environment for a battery – the Volt’s battery can be chilled during charging. The Volt’s liquid thermal management system can also be powered during driving by the battery or engine/generator.

– Diagnostics for safety and performance: The Volt’s battery management system continuously monitors the battery real-time for optimum operations.  More than 500 diagnostics run at 10 times per second, keeping track of the Volt’s battery pack; 85 percent of the diagnostics ensure the battery pack is operating safely, while the remaining 15 percent keep track of battery performance and life.

- Cell design and chemistry for performance and efficiency: GM’s selection of a prismatic cell design and LG Chem’s manganese spinel lithium-ion chemistry is designed to provide long life and high power output, with a properly maintained temperature. This enables better vehicle acceleration and increased regenerative braking capability for improved vehicle efficiency.

- Energy management for durability: Fully charging or fully depleting a battery shortens its life. The Volt’s energy management system never fully charges or depletes the battery. The Volt’s battery has top and bottom “buffer zones” to help ensure long life.

Toshiba has developed a fast-charging long life lithium-ion battery called SCiB (Super Charge ion Battery), which it plans to adapt for electric cars.

The use of new oxide-based materials in the current SCiB cells results in capacity loss after 3000 charge-discharge cycles of less than 10%; SCiB cells achieve more than 6000 charge-discharge cycles. The SCiB can recharge up to 90 percent of full capacity in less than five minutes.

Presently, batteries for Mitsubishi’s i-MiEV electric cars are being supplied by Lithium Energy Japan, which is a joint venture between Mitsubishi Motors, battery maker GS Yuasa Corp., and trading house Mitsubishi Corp.

Toshiba, meanwhile, is also cooperating with Volkswagen to develop automaker’s next-generation electric cars.

The 22 kWh lithium-ion battery for the THINK City EV pack is being supplied by Ener1 subsidiary, Indiana-based EnerDel which owns an equity stake in Think.

The latest generation THINK City is a purpose-built, all-electric car designed for urban environments. It can travel at highway speeds and cover 100 miles (160 kilometers) on a single charge (via any conventional household outlet). It also supports fast charging to 80 percent of capacity in 15 minutes.

The RHINK City EV is the world’s first EV to be granted certification with the European CE conformity mark and EU homologation requirements (M1 certificate). To achieve these exacting standards, the THINK City has successfully completed very thorough testing and validation procedures.

European production of the THINK City is underway in Finland with manufacturing partner Valmet Automotive, which will also be assembling the Fisker Karma starting early next year. Think also plans to add U.S. production of the City EV sometime in 2011 in Elkhart County, Indiana.

First customer deliveries are taking place across Europe in selected key EV markets such as The Netherlands, Norway, Spain, Sweden, Austria and then the United States later this year.

The battery plant is part of a $1.7 billion investment in electric car battery and LEAF assembly capacity in Smyrna, funded mainly by a $1.4 billion U.S. government loan. The $1.4 billion federal loan to Nissan is part of a $25 billion Advanced Technology Vehicles Manufacturing Loan Program authorized by Congress as part of the Energy Independence and Security Act of 2007.

By the time it opens in 2012, the factory will be able to supply lithium-ion battery packs for 200,000 electric cars annually, topping Nissan’s plan to build as many as 150,000 rechargeable LEAF electric cars a year in Smyrna.

“Nissan is committed to affordable, sustainable mobility. What we’re doing here will radically transform the automotive experience for consumers. Today is a major step in helping create a green economy in the United States,” said Carlos Ghosn, president and CEO of Nissan Motor Co., Ltd. “Production of Nissan LEAF and lithium-ion batteries in Smyrna brings the United States closer to its goal of energy independence, creates green jobs and helps sustain American manufacturing. Nissan is a leader in global manufacturing innovation, and this state-of-the-art battery plant will strengthen that leadership.”

Nissan said the LEAF will be the world’s first affordable zero emissions car. It will run completely on electricity and will fully charge in eight hours. It can reach up to 90 miles per hour and travel 100 miles on a complete charge.

The orders are piling up. Nissan has received 13,000 reservations for the $32,780 LEAF since last month, when it started to take $99 refundable deposits from customers to reserve a vehicle. With a federal tax credit, the price of the LEAF falls to about $25,000.

LG Chem has already teamed up with home market giant Hyundai Motor Co Ltd, Ford and General Motors from the U.S. and China’s Changan New Energy Automobile on auto batteries.

“LG Chem predicts that it will sign four additional deals to supply the EV batteries at the end of this year,” Peter Bahnsuk Kim, a vice chairman of the company, said in a statement.

LG Chem will start the construction of a US$303 million EV battery plant in Michigan in July with the aim of starting mass production of EV batteries by 2012.

The new factory will start producing 3.1Ah battery cells, the highest energy density cells available in the market. The facility will produce more than 300 million cells per year.

“These cutting-edge Panasonic batteries will combine with Tesla’s battery pack technology to produce the highest-energy density EV battery packs in the world,” said Tesla Chief Technology Officer JB Straubel.

Tesla announced Wednesday that its Roadster model will be available to selected customers in Japan. Earlier this year,  Tesla announced a partnership with Panasonic to accelerate the development of next generation EV cells.

The company said it has delivered more than 1,000 two-seat Roadsters to customers in North America.