Insights into Optimizing Battery Design to Create Value and Improved Performance for Consumer Products

Lisa KingSr. Manager, Battery Technology

34th International Battery SeminarFt. Lauderdale, FL

March 23, 2017

Overview

• Stanley Black and Decker is the home of market-leading storage, hand tool, consumer home, outdoor and tradesman products, professional power and automotive tool brands

• Research feedback shapes the innovation, design and physical testing of the products to be launched into the market.

• The shift from Ni-Cad to Li-ion technology has enhanced customer-desired features such as convenience, portability, longer run time, shorter charge time and power

Battery Technology at SBD

• Over 150 m2 Lab for Cell & Pack Test• Cell Supplier Development• Technology Assessment• Cell Construction & Failure Analysis• Charger & Tool Application Risk Evaluation and

Testing• Cell and Pack Abuse, Performance & Life

Evaluation and Qualification• Provide internal support to Packs, Charger,

Motors, Reliability, Compliance, Quality, Innovation, Global Supply Chain teams

• Continued Area of Growth & Investment

• If a Stanley Black & Decker branded product has a battery cell in it, our team touches it

Power Cell System Safety ConsiderationsCell DesignCurrent Interrupt Device (CID)VentFusible positive tabShutdown separator

Pack DesignOver-voltage protectionFusible linkThermistor

Charger DesignPack identificationUnder-voltage protectionOver-voltage protectionOver-temperature protection

Tool DesignOver-current protectionUnder-voltage protectionOver-temperature protection

Applications:

5 – 15C

Short Circuit:50C +

Battery Supply Risks

Cordless Dependent on Battery Supply Chain#1 Risk:global demand for Li-Ion materials

#2 Risk:supplier cell capacity < demand

Battery Supply Chain

• More than 3x demand increase for battery materials expected over next 10 years

• Lithium +16% AGR, cost >100% since 2015 demand +250% over next 10 years

• Cobalt Cost rising every month Ongoing DRC conflict minerals

debate• Recycling is slow taking off

xxCordless Pet Solutions… Wet Cleaning Solutions…Allergy Solutions…

Upright ExpansionLeverage SBD Technology

BLACK+DECKER: Addressing Categories That Meet Customer Needs

Category Creation

Category Focus: Home Products

Global Market Leader in Hand Vacs

1978

User Insights Drive Innovation

• This Modern Lifestyle:• Busy home with kids and pets

• Larger homes• Would rather do a little each

day than larger tasks• Environmental awareness

• Allergies, hard flooring vs. carpet, cadmium

• Portable and cordless• Lighter weight, adaptable to

different areas of home• Minimizing time and effort for

household chores while maximizing results!

Battery Chemistry Changed the Game

• 2014 90% of Home Products was Nickel-Cadmium• User Insights Driving System Approach Redesign of Product Line

• Benefits of Lithium over Nickel• Always ready: Low self-discharge• Better calendar life/maintenance charging• Ergonomics• Cost neutral• Voltage regulation can be used to extend runtime

Example: 2-in-1 Stick Vac Battery Optimization27 Wh Walk Based on Ni-Cd 21.6 Wh New Options

Cell Type SC Ni-Cd 18650 Li-Ion 18650 Li-Ion 18650 Li-Ion 18650 Li-Ion

Cell Quantity 15 5 3 4 3

Capacity (Ah) 1.5 1.5 2.5 1.5 2.0

Battery Voltage (V) 18 18 10.8 14.4 10.8

Battery Weight (g) 740 215 129 172 129

Battery Volume (cm3) 268 83 50 66 50

Advantage -70%Wt. & Vol.

-80%Wt. & Vol.

-25%Wt. & Vol.

2, 3, 4 and 5 Cell Platform Pack

Platform pack developed through Gen 10 Project

• Modular Cell Carriers allowing multiplepack configurations

• Cell Strap design to facilitate automatedsoldering process in manufacturing

• 2, 3, 4 and 5 cell platform to be used inmultiple products reducing base electronics development time –opportunity for additional feature development

Leveraging B+D Platform Pack Automation

Cell

PROCESS

Housing

Cell insert Date Code Cell Welding

AUTOMATION

Automated Soldering Test

PCBA

Attach Foam Locate PCBA

GEN ‘9’FLEXIVACS PIVOTORB

210mA timer (3 versions to suit different cell capacities)

100mA / 130mA / 150mA / 200mA LINEAR ADAPTORS USED IN NON CEC MARKETS UP TO 15.6V

(EVERY VOLTAGE = UNIQUE CHARGER).

EPP

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 - Cell QTY

85mA* /100mA / 210mA C.C

SWITCHING ADAPTOR CEC WITH TIMER

SWITCHING ADAPTOR NON CEC

Multiple generations across product range

Hand Vac Ni-Cd & Ni-MH Chargers: 110 Variations!

HPPORA6 & 9 CELL

GEN 92 - 5 CELL

GEN2FLEXI3 - 5 CELL

GEN3PIVOT3 - 5 CELL

ORB2 CELL

GEN 102 - 5 CELL

EPP1 - 2 CELL

150 mA C.C (1 – 3 Cell)500 mA C.C 6 & 9 Cell

400 mA C.C (2-3 Cell) & (4-5 Cell)

All Lithium Vacuum Charger Platforms – Now Only 24 Variations

TactileSwitchvs. Slide

SOCIndicator

2-SpeedOperation

FilterIndicator

Same hand vac product, different customer ratings

14-cellSC Nickel-Cadmium

3-cell18650 Lithium-Ion

4-cell18650 Lithium-Ion

And stick vacs too

Lithium-Ion has allowed B+D to get into stick vac market with good reception

5-cell18650 Lithium-Ion

2015 2016 20172014

Li-Ion 25%

Ni-Cd or MH75%

Li-Ion 60%

Ni-Cd or MH40%

Li-Ion 90%

Ni10%

Li-Ion 99%

Ni1%

Hand Vacuum Cell Chemistry Conversion

65% US Household Pet Ownership

Spot & Wet Cleaning2018

Product Innovation Merchandising

Rubberized Anti Tangle

Large 1 Liter Dust Bin

Wide Beater BarScented Filter

2017 Cordless Pet Solutions

Strongest New Product Deck Ever In BLACK+DECKER Home Products

Emerging Trends + B+D Advantage Robust Product Roads

Hand Vacs

Stick Vacs

Robotic Vacs

Wet CleaningTechnology

=Home Products Market Trends & Future

Stanley Black & Decker

Acknowledgements• Professional Products Group Shared Services Battery Technology Team• Black + Decker Home Products Group Engineering & Marketing

Thank You!