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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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This paper describes a novel thermal control system for future Mars landers and rovers designed to keep battery temperatures within the -10 degrees C temperature range.
Energy storage, primarily in the form of electrochemical batteries, is critical for enabling integration of marine energy (e.g., power from waves and currents) with end-use applications at sea due to the periodicity of the resources and requirement of consistent, smooth power delivery. Powering high-latitude coastal or ocean-based observing systems has been identified as a high value-proposition use case, exemplifying the concept of Powering the Blue Economy. An existing power system implementation for such a platform uses solar panels coupled to rechargeable lithium-ion batteries, augmented by a non-rechargeable backup bank used to power heaters in winter months. As wave energy is a potential resource for powering this and similar use cases and is strongest when solar power is most limited, it was hypothesized that integration of wave power would alleviate some of the challenges in cold climates related to energy storage. In this work, we investigate the use case scenario in simulation and perform a comparative test of commercially-available lithium-ion battery chemistry formulations to determine the most appropriate choice for the application. The experiment compared the most commonly-used lithium-based battery types (NCM, NCA, and LFP) in laboratory conditions emulating a battery enclosure thermally coupled to freezing seawater using an industrial battery performance tester in PNNL's arctic simulation lab. Battery strings were repeatedly cycled (i.e., charged, discharged, rested) and their usable capacity was measured. Both NCM and NCA strings exhibited degradation upon cycling, while the LFP string maintained stable operation through over 700 complete cycles. Though lower in baseline capacity, LFP are recommended for this and similar low-temperature applications with access to high levels of bulk charging current (e.g., from high-energy wave events) and their use may reduce the cost and complexity of battery conditioning and protection apparatus.
A composite material has been developed, consisting of a blend of metal and fluorocarbon particles, which behaves as an electronic conductor at room temperature and which abruptly becomes an insulator at a predetermined temperature. This switching behavior results from the difference in thermal expansion coefficients between the conductive and non-conductive portions of the composite. This material was applied as a thin film between the carbon cathode in Li/SOCl2 cells, and the metallic cathode current collector. Using test articles incorporating this feature it was shown that lithium cells externally heated or internally heated during a short circuit lost rate capability and the ability to overheat well below the melting point of lithium (180 C). Thus, during an internal or external cell short circuit, the potential for thermal runaway involving reactions of molten lithium is avoided.
The following are discussed: NiH2 battery mission and environment; NiH2 cell heat dissipation; Nodal software; model development general philosophy; NiH2 battery model development; and NiH2 experimental developments.
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A two-dimensional thermal model for spirally wound batteries has been developed. The governing equation of the model is the energy balance. Convective and insulated boundary conditions are used, and the equations are solved using a finite element code called TOPAZ2D. The finite element mesh is generated using a preprocessor to TOPAZ2D called MAZE. The model is used to estimate temperature profiles within a spirally wound D-size cell. The model is applied to the lithium/thionyl chloride cell because of the thermal management problems that this cell exhibits. Simplified one-dimensional models are presented that can be used to predict best and worst temperature profiles. The two-dimensional model is used to predict the regions of maximum temperature within the spirally wound cell. Normal discharge as well as thermal runaway conditions are investigated.
Approaches for thermal management of lithium-ion (Li-ion) batteries do not always keep pace with advances in energy storage and power delivering capabilities. Root-cause analysis and empirical evidence indicate that thermal runaway (TR) in cells and cell-to-cell thermal propagation are due to adverse changes in physical and chemical characteristics internal to the cell. However, industry widely uses battery management systems (BMS) originally designed for aqueous-based batteries to manage Li-ion batteries. Even the "best" BMS that monitor both voltage and outside-surface temperature of each cell are not capable of preventing TR or TR propagation, because voltage and surface-mounted temperature sensors do not track fast-emerging adverse events inside a cell. Most BMS typically include a few thermistors mounted on select cells to monitor their surface temperature. Technology to track intra-cell changes that are TR precursors is becoming available. Simultaneously, the complex pathways resulting in cell-to-cell TR propagation are being successfully modelled and mapped. Innovative solutions to prevent TR and thermal propagation are being advanced. These include modern BMS for rapid monitoring the internal health of each individual cell and physical as well as chemical methods to reduce the deleterious effects of rapid cell-to-cell heat and material transport in case of TR.
Thermal management for battery is important for electric aircraft because battery temperature is critically important to vehicle safety, and it also has direct impact on the efficiency of the battery system. Because ambient air is a readily available resource for aircraft, this paper considers an active cooling concept with forced convection of ambient air through the battery pack. Conjugate heat transfer analysis is used to solve the coupled aero-thermal problem, which consists of a finite-volume computational fluid dynamics solver for the fluid domain, and a conduction heat transfer solver for the solid domain. A mixed Neumann and Dirichlet boundary condition is developed for the fluid-solid interface, which allows the solid domain to completely submerge in the fluid domain. A gradient-based optimization method is adopted, and the discrete adjoint approach implemented in DAFoam is used to efficiently compute the gradients. The aero-thermal coupling for primal analysis and gradient computation is handled using the OpenMDAO-based MPhys framework. A constant heat source is prescribed for the battery cells, and the battery shape (design variable) is optimized to minimize cooling pump power and battery weight (composite objective function) while keeping the battery temperature below a threshold (constraint). The optimized design achieves a 44.6% and 1.5% reduction in the cooling pump power and battery weight, respectively, and the maximal temperature constraint is satisfied. This work has the potential to reduce battery-pack weight, improve performance, and reduce the weight of thermal management systems for electric vertical take-off and landing aircraft.
Thermal management for battery is important for electric aircraft because battery temperature is critically important to vehicle safety, and it also has direct impact on the efficiency of the battery system. Because ambient air is a readily available resource for aircraft, this paper considers an active cooling concept with forced convection of ambient air through the battery pack. Conjugate heat transfer analysis is used to solve the coupled aero-thermal problem, which consists of a finite-volume computational fluid dynamics solver for the fluid domain, and a conduction heat transfer solver for the solid domain. A mixed Neumann and Dirichlet boundary condition is developed for the fluid-solid interface, which allows the solid domain to completely submerge in the fluid domain. A gradient-based optimization method is adopted, and the discrete adjoint approach implemented in DAFoam is used to efficiently compute the gradients. The aero-thermal coupling for primal analysis and gradient computation is handled using the OpenMDAO-based MPhys framework. A constant heat source is prescribed for the battery cells, and the battery shape (design variable) is optimized to minimize cooling pump power and battery weight (composite objective function) while keeping the battery temperature below a threshold (constraint). The optimized design achieves a 44.6% and 1.5% reduction in the cooling pump power and battery weight, respectively, and the maximal temperature constraint is satisfied. This work has the potential to reduce battery-pack weight, improve performance, and reduce the weight of thermal management systems for electric vertical take-off and landing aircraft.
NASA has traditionally sought to reduce the likelihood of a single cell thermal runaway (TR) in their aerospace batteries to an absolute minimum by employing rigorous screening program of the cells. There was generally a belief that TR propagation resulting in catastrophic failure of the battery was a forgone conclusion for densely packed aerospace lithium-ion batteries. As it turns out, this may not be the case. An increasing number of purportedly TR propagation-resistant batteries are appearing among NASA partners in the commercial sector and the Department of Defense. In the recent update of the battery safety standard (JSC 20793) to address this paradigm shift, the NASA community included requirements for assessing TR severity and identifying simple, low-cost severity reduction measures. Unfortunately, there are no best-practice guidelines for this work in the Agency, so the first project team attempting to meet these requirements would have an undue burden placed upon them. A NASA engineering Safety Center (NESC) team set out to perform pathfinding activities for meeting those requirements. This presentation will provide contextual background to this effort, as well as initial results in attempting to model and simulate TR heat transfer and propagation within battery designs.
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One of the most challenging aspects of developing high-energy lithium-based batteries is the structural and (electro)chemical stability of Ni-rich active cathode materials at thermally-abused and prolonged cell cycling conditions. Here, we report in situ physicochemical characterizations to improve the fundamental understanding of the degradation mechanism of charged polycrystalline Ni-rich cathodes at elevated temperatures (e.g., ≥ 40 °C). Using multiple microscopy, scattering, thermal, and electrochemical probes, we decouple the major contributors for the thermal instability from intertwined factors. Our research work demonstrates that the grain microstructures play an essential role in the thermal stability of polycrystalline lithium-based positive battery electrodes. We also show that the oxygen release, a crucial process during battery thermal runaway, can be regulated by engineering grain arrangements. Furthermore, the grain arrangements can also modulate the macroscopic crystallographic transformation pattern and oxygen diffusion length in layered oxide cathode materials.
Thermal properties of electrochemical cells from calorimetry of nickel-cadmium battery
Preventing cell-cell thermal runaway propagation and flames/sparks from exiting battery enclosure is possible with proper thermal & electrical design and cell thermal runaway ejecta/effluent management and can be had with minimal mass/volume penalty.
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