Engineering topics

Darst, Jacob

Publications and source records attributed to Darst, Jacob.

6 records

DOE OSTI2024

The battery failure databank: Insights from an open-access database of thermal runaway behaviors of Li-ion cells and a resource for benchmarking risks

The thermal response of Li-ion cells can greatly vary for identical cell designs tested under identical conditions, the distribution of which is costly to fully characterize experimentally. The open-source Battery Failure Databank presented here contains robust, high-quality data from hundreds of abuse tests spanning numerous commercial cell designs and testing conditions. Data was gathered using a fractional thermal runaway calorimeter and contains the fractional breakdown of heat and mass that was ejected, as well as high-speed synchrotron radiography of the internal dynamic response of cells during thermal runaway. The distribution of thermal output, mass ejection, and internal response of commercial cells are compared for different abuse-test conditions, which when normalized on a per amp-hour basis show a strong positive correlation between heat output from cells, the fraction of mass ejected from the cells, their energy- and power-density. Ejected mass was shown to contain 10x more heat per gram than non-ejected mass. The causes of 'outlier' thermal and ejection responses i.e., extreme cases, are elucidated by high-speed radiography which showed how occurrences such as vent clogging can create more hazardous conditions. High-speed radiography also demonstrated how the time-resolved interplay of thermal runaway propagation and mass ejection influences the total heat generated.

25 ENERGY STORAGE↗

DOE OSTI2022

The Effect of Cell Geometry and Trigger Method on the Risks Associated with Thermal Runaway of Lithium-Ion Batteries

Consideration of thermal runaway heat output variability is paramount for the development of safe lithium-ion battery assemblies. This study utilizes data gathered from fractional thermal runaway calorimetry (FTRC) experiments to conduct a comparative analysis of thermal runaway heat output for three cell formats (18650, 21700, and 33600) as a function of trigger method (heaters, internal short-circuiting device, and nail penetration). The analysis is based on comparisons for the calculated total energy yield, fractional energy yield, heat rate, and heat flux. This study reveals that nail penetration tends to result in higher thermal runaway heat output for larger cells (21700 & 33600); these experiments also tended to result in higher fractions of the total energy being released through the cell body. The smaller cells (18650) did not appear to have significant variation in heat output as a function of trigger method. This finding suggests that, for this cell type, worst-case scenario heat output could be achievable in assembly level testing regardless of the utilized trigger method. This study also demonstrates successful translation of FTRC results, as recorded in the Battery Failure Databank, into meaningful analysis that breaks down the influence of specific conditions on thermal runaway heat output.

calorimetry↗

NASA NTRS2019

Safe, High Power / Voltage Battery Design Challenges

NASA seeks safe, high performing battery module designs that can deliver 3C discharge rates continuously, achieve 160 Wh/kg, and is passively propagation resistant to a single cell thermal runaway event. One solution is presented that uses a patented oscillating heat pipe technology for thermal management. Combined with light weight packaging and a new commercially available gas permeable vent port, all 5 preliminary safety tests results performed to date are showing ample margins.

High power↗

NASA NTRS2019

Metallized Plastic Current Collectors

Metallized plastic current collectors are an innovation patented by the Soteria Battery Innovation Group with the promise of isolating active material involved in an internal short by vaporizing and isolating the short from the rest of the cell electrode jellyroll or stack. Partnering with NREL, UCL, Coulometrics, and Soteria, NASA is leading a research effort into demonstrating the merits and understanding the phenomena of this safety innovation using prototype 18650 cylindrical cells vs control cells with standard metal foil current collectors. Cells with and without the plastic collector, with and without the on-demand internal short circuit device, and with polymer or cellulose separators were made. Safety evaluations were done with driving cells into thermal runaway (TR) with thermal and nail penetration triggers while inside our TR calorimeter and with ultra high speed X-ray videography provided at Synchrotrons. Preliminary results suggests that the thermally unstable plastic current collector innovation has great promise for preventing TR or reducing the severity of the TR output.

Li-ion cell↗

NASA NTRS2019

Safe, High Power/Voltage Battery Module Design Challenges

NASA seeks to demonstrate a path for achieving safe, high power, and high performing Li-ion battery designs for the purpose of establishing design guidelines for our aeronautic and spacecraft applications. Safe means passively resistant to thermal runaway propagation of any single cell catastrophic thermal runaway. High power means capable of 3C continuous discharge without overheating. High performing means achieving > 160 Wh/kg, 200 Wh/L. The biggest challenge has been balancing a high flux light weight path for cell heat dissipation during the high rate discharge that minimizes thermal gradients between cells and also protects adjacent cells from the heat load of thermal runaway cell. Our solution includes an oscillating heat pipe spine that contacts every 18650 cell in the pack and careful cell design selection to maximize the range of initial temperatures conditions where the battery can safely complete the 3C discharge.

Thermal runaway↗

NASA NTRS2018

Driving Design Factors for Safe, High Power Batteries for Space Applications

Final Document is attached. New design features and test methods are in development at NASA to take advantage of the newest high power and energy dense commercial Li-ion cell designs and to achieve passively thermal runaway (TR) propagation resistant (PPR) designs for manned missions requiring high power/voltage. The goal is to minimize the parasitic mass and volume of the battery components; thus reaching a balance between high battery specific power (W/kg) and energy (Wh/kg) as well as power (W/L) and energy density (Wh/L). Current 18650 cell designs achieve greater than 275 Wh/kg, greater than 725 Wh/L, but present high risks of side wall breaching during TR which can defeat many other safety features resulting in nearly immediate TR propagation. This work seeks to better understand the phenomena of cell side wall breaches and to determine the effectiveness of promising battery design features for achieving safe, high performing battery designs for high voltage/power applications.

Li-ion↗