i10 Electric – the Blue DriveTM EV

At the Frankfurt Motor Show, Hyundai Motor Company unveiled its i10 Electric zero-emissions urban commuter which will see the start of limited series production in 2010. The newcomer is the latest model to appear under the company’s Blue DriveTM eco-program, which aims to move Hyundai to the position of world leader in clean auto technology.

On a single charge, the i10 Electric is capable of a driving range of 160km. To bring down the vehicle weight to 1000kg, x-by-wire systems have been developed to replace the bulky and heavy hydraulic components commonly associated with cars powered by conventional internal combustion engines. Steering, for example, is performed by wire while an electric vacuum pump provides braking power. Motor and battery cooling duties are now handled by an electric water pump while the air conditioning compressor is also electric.

The fundamental architecture of the i10 Electric is already fixed centering around a 49kW electric motor and a 16kW battery using innovative LiPoly (Lithium Ion Polymer) technology which offers numerous advantages over other battery types.

The vehicle accommodates dual recharging cycles: a 220V household current which is slower but potentially advantageous if recharging is done during off-peak hours when utility rates are lower and a 413V industrial-strength current which promises quicker recharging speeds. Under the quick cycle, the battery can be recharged to within 85 percent of its capacity within 15 minutes. Under the normal cycle using a 220V household current, 100 percent power will be attained within five hours.
The i10 Electric’s advanced LiPoly batteries are more durable and space-efficient than other batteries. Compared with nickel-metal hydride batteries, LiPoly delivers the same power with 30 percent less weight, 40 percent less volume and 12 percent greater efficiency.

LiPoly batteries offer more than twice the energy density of nickel-metal hydride batteries, and 175 percent greater volumetric energy density, meaning Hyundai engineers can devote less space and weight to the battery pack. LiPoly batteries also hold their charge 20 times longer; they are more resistant to changes in temperature, which improves cycle life; and their self-discharge rate is less than a third of that of a nickel-metal hydride battery.

LiPoly has significant advantages over lithium-ion technology, including higher energy density and lower manufacturing costs. LiPoly is more resistant to physical damage and can handle more charge-discharge cycles before storage capacity begins to degrade. LiPoly technology also offers significant advantages in thermal robustness and safety compared with typical Li-Ion batteries.

Another key difference between traditional Li-Ion batteries and Hyundai’s LiPoly solution is the overall superiority of LiPoly packaging. The LiPoly battery pack is about 20 percent smaller than a Li-Ion battery pack, making it much easier to change the cell footprint to fit the nooks and crannies of available vehicle space.

Hyundai has spent hundreds of hours testing Hybrid Blue Drive’s LiPoly battery system with its battery supplier, LG Chem. This testing has proven that Hyundai’s LiPoly technology has greater thermal and mechanical stability than existing systems, meaning better safety. Thermal imaging testing shows LiPoly batteries run cooler compared to today’s NiMH or Li-Ion batteries.