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Powering Hybrids

Johnson Controls’ expertise results in breakthroughs in hybrid battery technology

Over the years, Johnson Controls has made itself into a global leader in the production of batteries for hybrid electric vehicles.
The company sold 400,000 batteries for start/stop microhybrids (cars that stop engine idle when they slow down or stop) in Europe in 2007. Those batteries helped achieve a 5- to 8-percent fuel savings per vehicle and collectively emit 130,000 fewer metric tons of carbon dioxide. In 2008, sales in Europe are expected to grow to more than 1 million units.
In the United States, Johnson Controls-Saft Advanced Power Solutions (JCS) has been awarded an $8.2 million USABC contract, funded by the U.S. Department of Energy contract to develop lithium-ion (Li-Ion) batteries for 10- and 40-mile range plug-in hybrids (PHEVS). Johnson Controls, through its joint venture with Saft, has been awarded a production contract to supply Li-Ion modules for the Mercedes-Benz S-Class mild hybrid sedan. The car, which will go into production in 2009, is expected to be the world’s first serial production hybrid using Li-Ion technology.
JCS recently announced that it will supply Li-Ion batteries to Ford Motor Company for a demonstration fleet of 20 PHEV Escapes. JCS and Ford are partners in this program with the Electric Power Research Institute (EPRI) and one of the nation’s largest electric utilities, Southern California Edison.
The expertise and advancements in hybrid batteries are the result of serious commitment.
“Our investment in research and development for advanced battery technology has nearly tripled since 2006, when we spent $13 million on research and development for hybrids,” says Alex Molinaroli, president of Johnson Controls’ Power Solutions. “In 2008 we plan to spend $37 million on research and development alone, and $56 million overall on our hybrid business.”

Research and Development
Innovations in batteries are critical for bringing more hybrid vehicles into the marketplace and improving their efficiencies.
Johnson Controls-Saft has research and development centers in Milwaukee, Wis., and Bordeaux, France. JCS has hybrid battery systems engineering, validation and vehicle integration facilities in Milwaukee, Wisc., Hannover, Germany, and Shanghai, China.
The Milwaukee site is more than an R&D facility—it’s a full battery systems engineering and validation facility that integrates development with system engineering, testing and integration.

Manufacturing
Johnson Controls-Saft, a joint venture with Saft batteries of France, recently opened a new plant in Nersac, France, dedicated to the manufacture of advanced lithium-ion batteries for hybrid, plug-in, fuel cell and electric vehicles for global customers. It is the first of its kind in the world.
Together these facilities and experts around the world continue to make Johnson Controls a core contributor to improvements in hybrid capabilities.