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Lithium ion rechargable batteries are being developed for various aerospace applications under a NASA-DoD interagency program. In this paper, we report the beneficial effect of using alkyl pyrocarbonates as electrolyte additives to improve the low temperature performance of lithium ion cells.
ST5 mission requirements include validation of Lithium-ion battery in orbit. Accommodation in the power system for Li-ion battery can be reduced with smaller amp-hour size, highly matched cells when compared to the larger amp-hour size approach. Result can be lower system mass and increased reliability.
The IBM Thinkpad 760XD has been used in the Orbiter and International Space Station since 2000. The Thinkpad is powered by a Panasonic Li-ion battery that has a voltage of 10.8 V and 3.0 Ah capacity. This Thinkpad is now being replaced by the IBM Thinkpad A31P which has a Panasonic Li-ion battery that has a voltage of 10.8 V and 4.0 Ah capacity. Both batteries have protective circuit boards. The Panasonic battery for the Thinkpad 760XD had 12 Panasonic 17500 cells of 0.75 Ah capacity in a 4P3S cOnfiguration. The new Panasonic battery has 6 Panasonic 18650 cells of 2.0 Ah capacity in a 2P3S configuration. The batteries and cells for both models have been evaluated for performance and safety. A comparison of the cells under similar test conditions will be presented. The performance of the cells has been evaluated under different rates of charge and discharge and different temperatures. The cells have been tested under abuse conditions and the safety features in the cells evaluated. The protective circuit board in the battery was also tested under conditions of overcharge, overdischarge, short circuit and unbalanced cell configurations. The results of the studies will be presented in this paper.
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Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.
Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.
Develop an understanding of the safety issues relating to space use and qualification of new Li-Ion technology for manned applications. Enable use of new technology batteries into GFE equipment - laptop computers, camcorders. Establish a data base for an optimized set of cells (and batteries) exhibiting acceptable performance and abuse characteristics for utilization as building blocks for numerous applications.
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.
This presentation reviews: (1) the goals and objectives, (2) the NASA and Airforce requirements, (3) the potential near term missions, (4) management approach, (5) the technical approach and (6) the program road map. The objectives of the program include: (1) develop high specific energy and long life lithium ion cells and smart batteries for aerospace and defense applications, (2) establish domestic production sources, and to demonstrate technological readiness for various missions. The management approach is to encourage the teaming of universities, R&D organizations, and battery manufacturing companies, to build on existing commercial and government technology, and to develop two sources for manufacturing cells and batteries. The technological approach includes: (1) develop advanced electrode materials and electrolytes to achieve improved low temperature performance and long cycle life, (2) optimize cell design to improve specific energy, cycle life and safety, (3) establish manufacturing processes to ensure predictable performance, (4) establish manufacturing processes to ensure predictable performance, (5) develop aerospace lithium ion cells in various AH sizes and voltages, (6) develop electronics for smart battery management, (7) develop a performance database required for various applications, and (8) demonstrate technology readiness for the various missions. Charts which review the requirements for the Li-ion battery development program are presented.
Li-ion batteries, with longer cycle life and higher energy density features, are now more and more attractive and applied in multiple fields. The YTP 45 Ah Li-ion battery has been evaluated here and may be employed in EMU in the future. Evaluations were on: (1) Cycle life tests - 500 cycles total (completed 40 cycles in simulated shuttle use mode and 460 cycles in an accelerated use mode, and recorded differential voltage of individual cell in battery); (2) Characterization test - discharge capacity measurement in environment temperature of -10, 25, 50 C before and after 500 cycles; and (3) Thermal testing - charge and discharge at 50 C and -10 C before and after 500 cycles. The battery showed less than a 9% drop of initial discharge capacity and energy within 500 cycles with 475 cycles 59% DOD plus 25 cycles 100% DOD. The EOD voltage ranged from 16.0 to 18.0 V, which fits the requirement for operating the EMU.
Lithium-ion cells, of DD and D size, are being developed under a contract with the USAF for NASA's Mars Rover Missions. The cells contain spirally wound electrodes of LiNi02 positive electrode material and graphite anode in cylindrical stainless steel hardware.
This paper will describe the Mars 2001 Lander mission battery requirements and will contain results of the cell testing conducted to-date in support of the mission.
n early 2004 JPL successfully landed two Rovers, named Spirit and Opportunity, on the surface of Mars after traveling >300 million miles over a 6-7 month period. In order to operate for extended duration on the surface of Mars, both Rovers are equipped with rechargeable Lithium-ion batteries, which were designed to aid in the launch, correct anomalies during cruise, and support surface operations in conjunction with a triple-junction deployable solar arrays. The requirements of the Lithium-ion battery include the ability to provide power at least 90 sols on the surface of Mars, operate over a wide temperature range (-20 C to +40 C), withstanding long storage periods (e.g., cruise period), operate in an inverted position, and support high currents (e.g., firing pyro events). In order to determine the viability of Lithium-ion technology to meet these stringent requirements, a comprehensive test program was implemented aimed at demonstrating the performance capability of prototype cells fabricated by Lithion, Inc. (Yardney Technical Products, Inc.). The testing performed includes, determining the (a) room temperature cycle life, (b) pulse capability as a function of temperature, (e) self-discharge and storage characteristics mission profile capability, (f) cycle life under mission simulation conditions, (g) impedance characteristics, (h) impact of cell orientation, and (i) performance in 8-cell engineering batteries. As will be discussed, the Lithium-ion prototype cells and batteries were demonstrated to meet, as well as, exceed the requirements defined by the mission.
There has been increasing interest in developing lithium-ion electrolytes that possess enhanced safety characteristics, while still able to provide the desired stability and performance. Toward this end, our efforts have been focused on the development of lithium-ion electrolytes which contain partially and fully fluorinated carbonate solvents. The advantage of using such solvents is that they possess the requisite stability demonstrated by the hydrocarbon-based carbonates, while also possessing more desirable physical properties imparted by the presence of the fluorine substituents, such as lower melting points, increased stability toward oxidation, and favorable SEI film forming Characteristics on carbon. Specifically, we have demonstrated the beneficial effect of electrolytes which contain the following fluorinated carbonate-based solvents: methyl 2,2,2-trifluoroethyl carbonate (MTFEC), ethyl-2,2,2 trifluoroethyl carbonate (ETFEC), propyl 2,2,2-trifluoroethyl carbonate (PTFEC), methyl-2,2,2,2',2',2' -hexafluoro-i-propyl carbonate (MHFPC), ethyl- 2,2,2,2',2',2' -hexafluoro-i-propyl carbonate (EHFPC), and di-2,2,2-trifluoroethyl carbonate (DTFEC). These solvents have been incorporated into multi-component ternary and quaternary carbonate-based electrolytes and evaluated in lithium-carbon and carbon-LiNio.8Coo.202 cells (equipped with lithium reference electrodes). In addition to determining the charge/discharge behavior of these cells, a number of electrochemical techniques were employed (i.e., Tafel polarization measurements, linear polarization measurements, and electrochemical impedance spectroscopy (EIS)) to further characterize the performance of these electrolytes, including the SEI formation characteristics and lithium intercalatiodde-intercalation kinetics. In addition to their evaluation in experimental cells, cyclic voltammetry (CV) and conductivity measurements were performed on select electrolyte formulations to further our understanding of the trends in stability and ionic mobility imparted by different alkyl substituents in linear carbonates.
In order to enable future missions involving the exploration of the surface of Mars with Landers and Rovers, NASA desires long life, high energy density rechargeable batteries which can operate well at very low temperature (down to 40(deg)C). Lithium-ion technology has been identified as being the most promising chemistry, due to high gravimetric and volumetric energy densities, as well as, long life characteristics. However, the state-of-art (SOA) technology is not sufficient to meet the needs of many applications that require excellent low temperature capabilities. To further improve this technology, work at JF'L has been focused upon developing electrolytes that result in lithium-ion cells with wider temperature ranges of operation. These efforts have led to the identification of a number of ternary and quaternary, all carbonate-based electrolytes that have been demonstrated to result in improved low temperature performance in experimental three-electrode MCMB carbon/LiNio.sCoo.zOz cells. A number of electrochemical characterization techniques were performed on these cells (i.e., Tafel polarization measurements, linear polarization measurements, and electrochemical impedance spectroscopy (EIS)) to further enhance our understanding of the performance limitations at low temperature. The most promising electrolyte formulations, namely 1 .O M LiPF6EC+DEC+DMC+EMC (1 : 1: 1 :2 v/v) and 1 .O M LiPF6 EC+DEC+DMC+EMC (1 : 1 : 1 :3 v/v), were incorporated into SAFT prototype DD-size (9 Ahr) lithium- cells for evaluation. A number of electrical tests were performed on these cells, including rate characterization as a function of temperature, cycle life characterization at different temperatures, as well as, many mission specific characterization test to determine their viability to enable future missions to Mars. Excellent performance was observed with the prototype DD-size cells over a wide temperature range (-50 to 4OoC), with high specific energy being delivered at very low temperatures (i.e, over 95 WHrKg being delivered at 40(deg)C using a C/10 discharge rate).
A battery pack consisting of standard cylindrical 18650 lithium-ion cells has been chosen for small satellite missions based on previous flight heritage and compliance with NASA battery safety requirements. However, for batteries that transit through the International Space Station (ISS), additional certification tests are required for individual cells as well as the battery packs. In this manuscript, we discuss the development of generalized testbeds for testing and certifying different types of batteries critical to small satellite missions. Test procedures developed and executed for this certification effort include: a detailed physical inspection before and after experiments; electrical cycling characterization at the cell and pack levels; battery-pack overcharge, over-discharge, external short testing; battery-pack vacuum leak and vibration testing. The overall goals of these certification procedures are to conform to requirements set forth by the agency and identify unique safety hazards. The testbeds, procedures, and experimental results are discussed for batteries chosen for small satellite missions to be launched from the ISS.
Lithium-ion rechargeable batteries are being developed for various aerospace applications under a NASA-DoD interagency program. For the projected missions, lithium ion batteries need to be further improved, i.e., low temperature performance for Mars Landers, Rovers, and Penetrators and cycle life for the Orbiters and LEO and GEO satellites.
Future NASA missions require high specific energy battery technologies, greater than 400 Wh/kg. Current NASA missions are using "state-of-the-art" (SOA) Li-ion batteries (LIB), which consist of a metal oxide cathode, a graphite anode and an organic electrolyte. NASA Glenn Research Center is currently studying the physical and electrochemical properties of the anode-electrolyte interface for ionic liquid based Li-air batteries. The voltage-time profiles for Pyr13FSI and Pyr14TFSI ionic liquids electrolytes studies on symmetric cells show low over-potentials and no dendritic lithium morphology. Cyclic voltammetry measurements indicate that these ionic liquids have a wide electrochemical window. As a continuation of this work, sp2 carbon cathode and these low flammability electrolytes were paired and the physical and electrochemical properties were studied in a Li-air battery system under an oxygen environment.