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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Size Effects in the Thermal Conductivity of Amorphous Polymers

Manipulating thermal conductivity through nanoengineering is of critical importance to advance technologies, such as soft robotics, artificial skin, wearable electronics, batteries, thermal insulation, and thermoelectrics. Here, by examining amorphous polymers, including polystyrene, polypropylene, polyethylene, and ethylene vinyl alcohol, using molecular dynamics simulations, we find that the thermal conductivities of amorphous polymers can be reduced below their amorphous limit by size effects. Size-dependent thermal transport in amorphous materials is decomposed into crystalline, crystalline-to-amorphous, and amorphous regimes. In the amorphous regime, the mean free path of propagating heat carriers can range from tens of nanometers to more than 100 nm, contributing 16%–36% of the total thermal conductivity. A two-channel model that combines no size effect (i.e., difusons and locons) and size effect (i.e., propagons) is proposed to account for size-dependent thermal conductivity. We also find that the presence of charged molecules in polymers can significantly affect the thermal conductivity and its size effects due to electrostatic interactions. Overall, this work provides insights into the thermal conductivity of amorphous polymers that will have a broad impact on the nano- and chemical engineering of polymers for various energy-related applications.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Hybrid Power Management Program Evaluated Ultracapacitors for the Next Generation Launch Transportation Project

The NASA Glenn Research Center initiated baseline testing of ultracapacitors to obtain empirical data in determining the feasibility of using ultracapacitors for the Next Generation Launch Transportation (NGLT) Project. There are large transient loads associated with NGLT that require a very large primary energy source or an energy storage system. The primary power source used for this test was a proton-exchange-membrane (PEM) fuel cell. The energy storage system can consist of batteries, flywheels, or ultracapacitors. Ultracapacitors were used for these tests. NASA Glenn has a wealth of experience in ultracapacitor technology through the Hybrid Power Management (HPM) Program, which the Avionics, Power and Communications Branch of Glenn s Engineering Development Division initiated for the Technology Transfer and Partnership Office. HPM is the innovative integration of diverse, state-ofthe- art power devices in optimal configurations for space and terrestrial applications. The appropriate application and control of the various advanced power devices (such as ultracapacitors and fuel cells) significantly improves overall system performance and efficiency. HPM has extremely wide potential. Applications include power generation, transportation systems, biotechnology systems, and space power systems. HPM has the potential to significantly alleviate global energy concerns, improve the environment, and stimulate the economy.

Eichenberg, Dennis J.↗

DOE OSTI2023

Optimizing liquid free ionomer binders for high-temperature polymer electrolyte membrane fuel cells for heavy duty vehicles

This report documents tech transfer from Penn State to Ionomer Solutions LLC for high-temperature polymer electrolyte membrane fuel cells. High-temperature polymer electrolyte membrane (HT-PEM) fuel cells are enticing power plants for heavy-duty vehicle (HDV) transportation because their elevated temperature operation fosters greater heat rejection through larger temperature differentials. In 2021, over 6 million battery electric light duty vehicles (LDVs) were sold. Conversely, only 19,000 LDVs using fuel cell power trains were sold in 2021. Given the meteoric rise of battery-based powertrains for LDVs and its projected growth, stakeholders for fuel cell technology for transportation have shifted their focus towards HDVs rather than LDVs given fuel cells specific and volumetric energy density advantage over batteries when the vehicle is large, heavy, and/or needs to move large distances before refueling.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Engineered Wood: Sustainable Technologies and Applications

Natural wood has been used for construction, fuel, and furniture for thousands of years because of its versatility, renewability, and aesthetic appeal. However, new opportunities for wood are arising as researchers have developed ways to tune the material's optical, thermal, mechanical, and ionic transport properties by chemically and physically modifying wood's naturally porous structure and chemical composition. Such modifications can be used to produce sustainable, functional materials for various emerging applications such as automobiles, construction, energy storage, and environmental remediation. In this review, we highlight recent advancements in engineered wood for sustainable technologies, including thermal and light management, environmental remediation, nanofluidics, batteries, and structural materials with high strength-to-weight ratios. Additionally, the current challenges, opportunities, and future of wood research are discussed, providing a guideline for the further development of next-generation, sustainable wood-based materials.

36 MATERIALS SCIENCE↗

NASA NTRS1983

Space power technology into the 21st Century

The space power systems of the early 21st century are discussed. The capabilities which are anticipated to evolve from today's state of the art and the technology development programs presently in place or planned for the remainder of the century are emphasized. The power system technologies considered include: solar thermal, nuclear, radioisotope, photovoltaic, thermionic, thermoelectric, and dynamic conversion systems such as the Brayton and Stirling cycles. Energy storage technologies considered include: nickel hydrogen biopolar batteries, advanced high energy rechargeable batteries, regenerative fuel cells, and advanced primary batteries. The present state of the art of these space power and energy technologies is discussed along with their projections, trends and goals. A speculative future mission model is postulated which includes manned orbiting space stations, manned lunar bases, unmanned Earth orbital and interplanetary spacecraft, manned interplanetary missions, military applications, and Earth to space and space to space transportation systems. The various space power/energy system technologies which are anticipated to be operational by the early 21st century are matched to these missions.

Faymon, K. A.↗

DOE OSTI2023

The role of ionic liquids in resolving the interfacial chemistry for (quasi-) solid-state batteries

Interfacial issues impede the advancement of current solid state battery technology; thus, interface engineering approaches are necessary to enable solid-state configuration. The advantage of solid-state cells stems from their low flammability and high electrochemical stability. Ionic liquids are viscous and nonflammable compounds that possess the requisite physical properties while optimizing the interface between solid electrodes and solid electrolytes, accelerating interfacial ion transport and enabling the fabrication of engineered interphases via the supply of robust chemical building blocks. In conclusion, this review summarizes the roles of ionic liquids in solid-state batteries focusing on the interface, with insights into their functionality as well as highlighting their applicability in the next generation battery systems.

25 ENERGY STORAGE↗

DOE OSTI2023

Chapter 13: All-Electric Vertical Take-Off and Landing Aircraft (eVTOL) for Sustainable Urban Travel

Increasing urbanization, ground congestion, and greenhouse gas emissions have spurred aircraft pioneers to capitalize on advancements in battery technology, electric motors, software, and other advances to develop all-electric vertical take-off and landing (eVTOL) aircraft intended to save travelers time within densely populated urban regions. This study served as an example for conducting a life-cycle analysis (LCA) of an eVTOL aircraft, analyzing its manufacturing process, its in-life operation as a passenger transportation service between urban locations, and (in part) end-of-life treatment. This case study aims to provide guidance on how to accurately conduct eVTOL LCA, particularly on how to define the problem, how to obtain the right information from engineers inside and outside their own organizations, and what areas to focus on. As LCA results are only as accurate as the assumptions that were made, a more rigorous LCA that includes sensitivity analysis and uncertainty characterization can help further understand the limitations of those assumptions. New technologies such as blockchain may also play an important role in LCA, including the life-cycle inventory and improving confidence intervals. Completing a credible LCA is central to supporting the argument in favor of introducing the new technology. Completing such a study will allow companies to demonstrate to relevant stakeholders the likely impact of their aircraft on the environment by quantifying the operational climate footprint of the aircraft and the manufacturing process used to build it. To this end, this case study also provides examples of how to report and present LCA results, optimizing for communications to non-LCA experts. The LCA can also assist in identifying opportunities to improve the environmental performance at various life-cycle stages, informing decision makers as products and manufacturing processes evolve or are redesigned. Given the nascency of both eVTOL aircraft manufacturing and operations, it is strongly recommended that LCA analysts treat reports on eVTOL aircraft as works-in-progress. As new information is found, design changes are made, and the aircraft or operation gains maturity, it is inevitable that some amendments will need to be made to the LCA. It is suggested that a complete overhaul of the LCA be made every 18-24 months throughout the R&D, design, and operational scale-up phases of the project.

ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1984

Space power technology into the 21st century

This paper discusses the space power systems of the early 21st century. The focus is on those capabilities which are anticipated to evolve from today's state-of-the-art and the technology development programs presently in place or planned for the remainder of the century. The power system technologies considered include solar thermal, nuclear, radioisotope, photovoltaic, thermionic, thermoelectric, and dynamic conversion systems such as the Brayton and Stirling cycles. Energy storage technologies considered include nickel hydrogen biopolar batteries, advanced high energy rechargeable batteries, regenerative fuel cells, and advanced primary batteries. The present state-of-the-art of these space power and energy technologies is discussed along with their projections, trends and goals. A speculative future mission model is postulated which includes manned orbiting space stations, manned lunar bases, unmanned earth orbital and interplanetary spacecraft, manned interplanetary missions, military applications, and earth to space and space to space transportation systems. The various space power/energy system technologies anticipated to be operational by the early 21st century are matched to these missions.

Faymon, K. A.↗

NASA NTRS2011

Properties and Performance Attributes of Novel Co-Extruded Polyolefin Battery Separator Materials: Mechanical Properties - Part 1

As NASA prepares for its next era of manned spaceflight missions, advanced energy storage technologies are being developed and evaluated to address future mission needs and technical requirements and to provide new mission-enabling technologies. Cell-level components for advanced lithium-ion batteries possessing higher energy, more reliable performance and enhanced, inherent safety characteristics are actively under development within the NASA infrastructure. A key component for safe and reliable cell performance is the cell separator, which separates the two energetic electrodes and functions to prevent the occurrence of an internal short-circuit while enabling ionic transport. Recently, a new generation of co-extruded separator films has been developed by ExxonMobil Chemical and introduced into their battery separator product portfolio. Several grades of this new separator material have been evaluated with respect to dynamic mechanical properties and safety-related performance attributes. This paper presents the results of these evaluations in comparison to a current state-ofthe-practice separator material. The results are discussed with respect to potential opportunities to enhance the inherent safety characteristics and reliability of future, advanced lithium-ion cell chemistries.

Baldwin, Richard S.↗

NASA NTRS2002

Solar Electric Propulsion Technologies Being Designed for Orbit Transfer Vehicle Applications

There is increasing interest in employing Solar Electric Propulsion (SEP) for new missions requiring transfer from low Earth orbit to the Earth-Moon Lagrange point, L1. Mission architecture plans place the Gateway Habitat at L1 in the 2011 to 2016 timeframe. The Gateway Habitat is envisioned to be used for Lunar exploration, space telescopes, and planetary mission staging. In these scenarios, an SEP stage, or "tug," is used to transport payloads to L1--such as the habitat module, lunar excursion and return vehicles, and chemical propellant for return crew trips. SEP tugs are attractive because they are able to efficiently transport large (less than 10,000 kg) payloads while minimizing propellant requirements. To meet the needs of these missions, a preliminary conceptual design for a general-purpose SEP tug was developed that incorporates several of the advanced space power and in-space propulsion technologies (such as high-power gridded ion and Hall thrusters, high-performance thin-film photovoltaics, lithium-ion batteries, and advanced high-voltage power processing) being developed at the NASA Glenn Research Center. A spreadsheet-based vehicle system model was developed for component sizing and is currently being used for mission planning. This model incorporates a low-thrust orbit transfer algorithm to make preliminary determinations of transfer times and propellant requirements. Results from this combined tug mass estimation and orbit transfer model will be used in a higher fidelity trajectory model to refine the analysis.

Sarver-Verhey, Timothy R.↗

DOE OSTI2022

Duluth Transit Authority Battery-Electric Bus Evaluation

Duluth Transit Authority (DTA) collaborated with the U.S. Department of Energy's National Renewable Energy Laboratory (NREL) to evaluate a fleet of seven battery-electric buses (BEBs) in revenue service in Duluth, Minnesota. The focus of the evaluation was to compare performance and cost of the BEBs to that of conventional technology buses in similar service and track progress over time. DTA enlisted the help of the Center for Transportation and the Environment (CTE) to manage the project and provide technical services with the BEB fleet and infrastructure. This report summarizes the results of the BEB evaluation and contains a combination of analyses performed by NREL and by CTE during the overall data collection period of December 2018 through February 2022.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Review—Thermal Safety Management in Li-Ion Batteries: Current Issues and Perspectives

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.

25 ENERGY STORAGE↗

DOE OSTI2025

Zero-Emission Transit Bus Needs Assessment

The transition to zero-emissions vehicles (ZEVs) in public transit has gained traction due to significant federal investments from the Bipartisan Infrastructure Law (BIL) and the Inflation Reduction Act (IRA). This needs assessment, commissioned by the Joint Office of Energy and Transportation and conducted by researchers at the Idaho National Laboratory, explores the current state of electrification in transit agencies, identifying barriers to implementation, potential funding sources, and operational considerations necessary for a successful transition. The assessment involved qualitative interviews with representatives from 19 transit service providers across diverse geographic regions. Key findings highlight the challenges related to bus facilities and operations, which require careful planning for charging infrastructure and maintenance capabilities to accommodate battery electric buses (BEBs) and hydrogen fuel cell buses (HFCBs). Agencies reported operational hurdles due to the shorter range of BEBs compared to diesel buses, necessitating revised scheduling and routing strategies. Despite these challenges, many agencies expressed optimism about their capacity to adapt. Funding availability emerged as a critical factor influencing the transition to ZEVs. While agencies welcomed increased financial support, particularly from the Low or No Emission Grant Program (Lo-No), concerns about the sustainability of this funding and the ongoing operational costs were prevalent. The need for a comprehensive funding inventory was underscored to ensure transit agencies are aware of all available resources. Technological constraints were significant barriers to ZEV adoption. The limited range of BEBs was frequently cited as a concern, leading to operational challenges and reliability issues. Agencies reported difficulties in sourcing replacement parts, which exacerbated downtime and maintenance challenges. Workforce development and training were identified as pivotal for a successful transition. Many agencies rely heavily on manufacturers for technician training, highlighting the need for scalable training programs that equip staff with the necessary skills to maintain electric powertrains effectively. This assessment offers actionable recommendations for the Joint Office, including enhancing outreach to transit agencies, developing resources for effective utility partnerships, and facilitating comprehensive training programs. Establishing a zero-emission bus evaluation program to track performance metrics such as cost, range, and reliability could provide valuable insights for transit agencies. The needs assessment provides a detailed examination of the challenges and opportunities facing transit agencies in their transition to zero-emissions bus fleets. By addressing these issues through targeted support, stakeholders can collaboratively work towards a cleaner, more sustainable public transportation system that benefits all communities.

33 - ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2021

Ultra Long-Lived, Self-Surveying Autonomous Air Quality Sensing - Executive Summary

We set out to evolve ultra-low power air quality sensing technologies developed at JSC to add a highly accurate positioning sensor based on SBIR technology to give a self-surveying air quality monitoring platform with years-long lifetime on a small, disposable coin cell battery. Using Radio Frequency Identification (RFID) technology for data transport, the system can take advantage of RFID-based inventory management systems in place on lunar exploration assets to provide this capability with extremely small SWAP impacts. Years-long operational lifetimes enable flexible, autonomous environmental monitoring during lengthy intervals between and unprecedented situational awareness during crewed missions. Software integration of the localization system into the JSC RFID sensing platform was advanced, but the COVID-19 pandemic complicated and slowed maturation of the localization system SBIR product, and center closure indefinitely deferred a final hardware integration and system demonstration. In the meantime, progress was made to mature the air-quality sensing platform for flight, including hardware, software, antenna, and mechanical improvements. The underlying RFID sensing capability was also adapted to a drawer motion sensing system, which is currently (FY21) being taken toward an ISS flight demonstration as part of the RFID Enhanced Autonomous Logistics Management (REALM)-3 experiment.

Raymond Summers Wagner↗

DOE OSTI2020

Deployment of plug-in electric vehicles in China and the USA: issues and opportunities, foreword

Plug-in electric vehicles (PEVs), including battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs), have been promoted globally for their emission reductions and energy conservation. In addition to financial incentives for PEVs in many countries (Stephens et al. 2018), emission and energy regulatory systems provide additional incentives for PEVs in the USA, Europe, and China (European Union 2014; Innovation Center for Energy and Transportation 2019; U.S. EPA and NHTSA 2012). These incentives, together with PEV technology advances and cost reductions, have caused PEV sales to grow exponentially in many countries and global regions; PEV stocks totaled more than 5 million by the end of 2018 (Fig. 1). The International Energy Agency (2019) projects that PEV sales will grow even more quickly through 2030 to reach a total global PEV stock of 130 million to 250 million.

China↗

DOE OSTI2021

Structural and chemical evolution in layered oxide cathodes of lithium-ion batteries revealed by synchrotron techniques

Abstract Rechargeable battery technologies have revolutionized electronics, transportation and grid energy storage. Many materials are being researched for battery applications, with layered transition metal oxides (LTMO) the dominating cathode candidate with remarkable electrochemical performance. Yet, daunting challenges persist in the quest for further battery developments targeting lower cost, longer lifespan, improved energy density and enhanced safety. This is, in part, because of the intrinsic complexity of real-world batteries, featuring sophisticated interplay among microstructural, compositional and chemical heterogeneities, which has motivated tremendous research efforts using state-of-the-art analytical techniques. In this research field, synchrotron techniques have been identified as a suite of effective methods for advanced battery characterization in a non-destructive manner with sensitivities to the lattice, electronic and morphological structures. This article provides a holistic overview of cutting-edge developments in synchrotron-based research on LTMO battery cathode materials. We discuss the complexity and evolution of LTMO’s material properties upon battery operation and review recent synchrotron-based research works that address the frontier challenges and provide novel insights in this field. Finally, we formulate a perspective on future directions of synchrotron-based battery research, involving next-generation X-ray facilities and advanced computational developments.

25 ENERGY STORAGE↗

DOE OSTI2022

Grand challenges and opportunities in next-generation batteries and technologies

The development of advanced Li-ion batteries and technologies generally addresses one of four objectives: 1) create a higher volumetric energy density and/or specific energy/power, 2) impart intrinsically safer chemistry, 3) produce speedier charging, and 4) utilize less expensive batteries but with competitive/near-competitive performances. Certainly, other factors can play a role as well, dependent on the type of market targeted and the availability of global supplies; however, for widespread adoption, the above points/criteria remain salient. Li-ion is commercially well entrenched in industry for communication and transportation (EV) applications. Nowadays, slight iterations, mostly electrolyte-defined, are incrementally improving safety, cost, and cycle or calendar life. The last point, calendar life, is one that is often overlooked for very high-energy dense Li-ion batteries, because of their reactivity at higher charge (OCV conditions) and elevated temperatures. While cycle life is debated with respect to capacity/energy performance decline, attempts to re-purpose the battery itself or recycle the internal chemical constituents at end of life have considerably grown in the field. Hopefully, energy-neutral processes are also considered in the recycling loop. Nevertheless, the energy storage arena is quite large, and this pursuit hinges on pushing the field in one of many directions, toward loftier objectives. The pursuit of next-generation batteries and technologies must thus delve deeper into new and novel chemistry and electrochemistry to create a world with a neutral, carbon-free environment, and one that is solely sufficient on energy-producing renewables such as the Sun and wind-derived means. The application of electricity and chemistry within our world is thus a 21st century opus.

25 ENERGY STORAGE↗

NASA NTRS2011

Energy Storage Technology Development for Space Exploration

The National Aeronautics and Space Administration is developing battery and fuel cell technology to meet the expected energy storage needs of human exploration systems. Improving battery performance and safety for human missions enhances a number of exploration systems, including un-tethered extravehicular activity suits and transportation systems including landers and rovers. Similarly, improved fuel cell and electrolyzer systems can reduce mass and increase the reliability of electrical power, oxygen, and water generation for crewed vehicles, depots and outposts. To achieve this, NASA is developing non-flow-through proton-exchange-membrane fuel cell stacks, and electrolyzers coupled with low permeability membranes for high pressure operation. The primary advantage of this technology set is the reduction of ancillary parts in the balance-of-plant fewer pumps, separators and related components should result in fewer failure modes and hence a higher probability of achieving very reliable operation, and reduced parasitic power losses enable smaller reactant tanks and therefore systems with lower mass and volume. Key accomplishments over the past year include the fabrication and testing of several robust, small-scale non-flow-through fuel cell stacks that have demonstrated proof-of-concept. NASA is also developing advanced lithium-ion battery cells, targeting cell-level safety and very high specific energy and energy density. Key accomplishments include the development of silicon composite anodes, lithiatedmixed- metal-oxide cathodes, low-flammability electrolytes, and cell-incorporated safety devices that promise to substantially improve battery performance while providing a high level of safety.

Mercer, Carolyn R.↗