Fisker Karma Joins Chevy Volt With Potential Battery Temperature Problems

Video: A123 Systems

Originally published at Cars In Depth

Just as the flurry of news about the potential fire risk in the Chevy Volt’s battery pack was dying down, Bloomberg reports that the battery manufacturer for another high profile electric vehicle, the Fisker Karma luxury extended range hybrid, has revealed what it called a “potential safety issue” in the cooling system of the batteries that it makes for the car, currently assembled in Finland using a $529 million loan from the U.S. Dept. of Energy.

A123 Systems, a leading producer of Lithium-Ion batteries that supplies Daimler and General Motors in addition to Fisker, said that hose clamps connecting parts of the Karma battery pack’s internal cooling system were not aligned properly, creating a the potential for leakage of the coolant, which might cause overheating and also possibly short circuit the batteries, causing a fire.

Because current Li-Ion batteries are flammable, battery temperature control and cooling is a critical process. Concerns over EV fire safety were raised when a crash-tested Volt later caught fire in a NHTSA facility. Short circuits caused by leaking battery coolant is suspected to be the cause. While GM uses a different battery supplier, LG Chem, for the Volt, A123 will be the battery vendor for the EV version of the Chevy Spark subcompact, to go on sale in 2013.

The news was made public in a letter from company CEO David Vieau published on A123’s investor-relations website. Since production of the Karma started only recently, less than 50 cars are said to be affected by the problem. Vieau said that a “confirmed repair” for the potential leak has been developed and that A123 has already started to fix the defective batteries. The cost to A123, Vieau said, will be “minimal” and the company’s relationship with Fisker “remains strong”. Last week the Anaheim based luxury hybrid car company announced that it has shipped 225 Karmas to Fisker dealers, with another 1,200 in the pipeline. Currently put together by Valmet in Finland, Fisker says that production of the Karma will eventually be moved to a former GM assembly plant in Wilmington, Delaware.

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