Plug-In Conversions and Nilar Team Up

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Nilar Distributor

Plug-In Conversions Corporation is the U.S distributor for Nilar, Inc. NiMH batteries for PHEV and EV applications. Founded in 2000 and with facilities located in Stockholm and Denver, Nilar developed a patented membrane technology for bi-polar batteries that has enabled performance breakthroughs surpassing the standard NiMH chemistry in terms of power density, weight, and volume. Batteries are manufactured at Nilar facilities in Centennial, Colorado.

A Paradigm shift
”Based on years of experience in battery development and production, we set out to re-engineer the battery to remove common failure modes and construction limitations that plague existing high performance batteries. We focused on reducing the internal resistance, not only at the cell level, but in the complete battery pack. Our new construction approach provides lower internal resistance, uniform voltage and temperature conditions, and good heat transfer. This allows us to produce a very long cycle life battery with superior power and energy density. Newly developed automated production equipment provides consistent quality at a competitive cost.”

Neil Puester, Co-founder

The technology
Battery cells are stacked in series to produce the desired voltage. A conductive membrane is assembled between adjacent cells, acting as a cell wall and the electrical connection. The anode of one cell contacts one side of the membrane and the cathode of the adjacent cell contacts the other side. This results in negligible transportation resistance of current between the cells, and uniform voltage across the entire electrode. When Nilar's construction techniques are combined with Philips' time tested Nickel Metal Hydride chemistry, the packaging density of energy and potential power output are greatly increased.

Nilar technology

Traditional technology
Prismatic or cylindrical

The basic Nilar battery module is a 24V, 9Ah unit with nominal power density of 277 W/kg and 560 W/liter. According to CalCar’s Ron Gremban, the Nilar pack will provide about 20-25 miles EV range in a Prius and weigh around 104 kg (230 lb), with an expected cycle life of up to 2,000 cycles (6 years of daily use).

Why Nickel Metal Hydride?
The Nilar team has extensive experience from all commercial and many experimental battery chemistries. Nilar chose Nickel Metal Hydride for a variety of reasons, including:

Environmentally friendly material
Proven and stable electrochemistry
Favorable cost/performance factors
Long cycle life
Long calendar life
Safe
Fully recyclable
No regulatory issues

Nilar NiMH battery modules use pressure sensing switches to signal end-of-charge and end-of-discharge, greatly simplifying battery management.

For PHEV Applications…

The need to cut greenhouse gases caused by carbon emissions from the world’s vehicle fleet is a global concern. Plug-In Hybrid Electric Vehicles provide a solution that creates a zero emissions vehicle for short trips and a high gas mileage solution for longer trips.

Nilar batteries are lighter and take up less volume than other competing batteries, allowing for greater flexibility in sizing energy solutions for various zero emissions ranges.

Because Nilar’s Membrane technology battery is based on the NiMH chemistry, it is inherently safe for use in the vehicle and has outstanding cycle life to provide zero emissions driving pleasure now and many years in the future.

Key Advantages

Greater power
Safety
Less weight
Less volume
Longer cycle life
Longer calendar life
Competitive price

Environmentally friendly

For EV Applications…

For the EV conversion owner, Nilar Membrane batteries with Smart Switch technology provide freedom from the lead-acid replacement cycle while leveraging the existing charger and controller infrastructure. A drop-in replacement solution for the lead acid packs provides all the benefits of Nilar's NiMH battery with none of the hassles traditionally associated with the chemistry conversion.

As an added benefit, the Nilar Membrane battery delivers substantially increased vehicle range. Conversion from advanced lead acid technologies have been able to achieve up to a threefold range increase by leveraging Nilar's higher energy density construction and customizable size and shape.

Compared to traditional batteries which cannot withstand excessive long range cycling and require periodic replacement, Nilar Membrane batteries can be expected to last the life of the EV essentially making it a maintenance free vehicle.

Pricing…

Retail pricing for a single 24V 9Ah module starts at $250. A surcharge may be added depending on the market price of Nickel when the order is placed. At your request, we will configure modules into series packs for your application. Pack Parts, pressure switches, assembly, and testing are an additional 10% per module.

Please contact us for larger quantity discount pricing.

Specifications…

Nilar Membrane Battery 24V

Nilar 24V Battery

Main advantages

Maintenance-free operation
High power/energy ratio
Fast charging
98%+ recyclable
More than 2,000 charge/discharge cycles
Low internal resistance
Less volume

Lighter weight

Nilar Membrane Battery 24V 9Ah
Thanks to its revolutionary design, the lightweight Nilar membrane battery provides an extremely high power rate.

Electrical characteristics

Rated capacity at C/2 rate (4.5 A) 9 Ah

Nominal power 1,080 W

Nominal power densities 277 W/kg
560 W/litre

Energy density at C/2 rate (4.5 A) 55 Wh/kg
112 Wh/litre

Peak pulse power 1,500 W

Peak pulse power densities 385 W/kg
777 W/litre

Mechanical characteristics

Dimensions (mm): L x W x H 279 x 129 x 55

Weight (kg) 3.9

Typical volume (litre) 1.93

Operating conditions

Operating temperature range (°C) -10 to 45

Transport/storage temperature range (°C) -20 to 45

Charge conditions

Fast 2C (18 A)

Standard C/2 (4.5 A)

Maximum discharge current

Continuous (A) at + 20°C 2C 18A

Nominal (A) at + 20°C 5C 45A

Peak (A) at + 20°C 10C 90A for 10 sec

These specifications, while representative, are subject to change at any time. Actual performance will depend upon the specific application and environment of the battery.