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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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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

Development and fabrication of large vented nickel-zinc cells

A preliminary cell design for a 300AH vented nickel-zinc cell was established based on volume requirements and cell component materials selected by NASA Lewis Research Center. A 100AH cell configuration was derived from the 300AH cell design utilizing the same size electrodes, separators, and cell terminal hardware. The first cells fabricated were four groups of three cells each in the 100AH size. These 100AH experimental nickel-zinc cells had as common components the nickel positive electrodes (GFM), flexible inorganic separator (GFM) bags on the negative electrodes, pressed powder zinc oxide electrodes, and cell containers with hardware. The variations introduced were four differing electrolyte absorber (interseparator) systems used to encase the nickel positive electrodes of each cell group. The four groups of 100AH experimental vented nickel-zinc cells were tested to determine, based on cell performance, the best two interseparator systems. Using the two interseparator systems, two groups of experimental 300AH cells were fabricated. Each group of three cells differed only in the interseparator material used. The six cells were filled, formed and tested to evaluate the interseparator materials and investigate the performance characteristics of the 300AH cell configuration and its components.

Donnel, C. P., III↗
NASA NTRS1991

Hubble Space Telescope battery background

The following topics are presented in viewgraph form and include the following: the MSFC Hubble Space Telescope (HST) Nickel-Hydrogen Battery Contract; HST battery design requirements; HST nickel-hydrogen battery development; HST nickel-hydrogen battery module; HST NiH2 battery module hardware; pressure vessel design; HST NiH2 cell design; offset non-opposing vs. rabbit ear cell; HST NiH2 specified capacity; HST NiH2 battery design; and HST NiH2 module design.

Standlee, Dan↗
NASA NTRS2005

Investigation of the Carbon Arc Source as an AM0 Solar Simulator for Use in Characterizing Multi-Junction Solar Cells

The operation of multi-junction solar cells used for production of space power is critically dependent on the spectral irradiance of the illuminating light source. Unlike single-junction cells where the spectral irradiance of the simulator and computational techniques may be used to optimized cell designs, optimization of multi-junction solar cell designs requires a solar simulator with a spectral irradiance that closely matches AM0.

Xu, Jianzeng↗
NASA NTRS1995

Electrolyte management considerations in modern nickel hydrogen and nickel cadmium cell and battery designs

In the early 1980's the NASA Lewis group addressed the topic of designing nickel hydrogen cells for LEO applications. As published in 1984, the design addressed the topics of gas management, liquid management, plate expansion, and the recombination of oxygen during overcharge. This design effort followed principles set forth in an earlier Lewis paper that addressed the topic of pore size engineering. At about that same time, the beneficial effect on cycle life of lower electrolyte concentrations was verified by Hughes Aircraft as part of a Lewis funded study. A succession of life cycle tests of these concepts have been carried out that essentially verified all of this earlier work. During these past two decades, some of the mysteries involved in the active material of the nickel electrode have been resolved by careful research efforts carried out at several laboratories. At The Aerospace Corporation, Dr. Zimmerman has been developing a sophisticated model of an operating nickel hydrogen cell which will be used to model certain mechanisms that have contributed to premature failures in nickel hydrogen and nickel cadmium cells. During the course of trying to understand and model abnormal nickel hydrogen cell behaviors, we have noted that not enough attention has been paid to the potassium ion content in these cells, and more recently batteries. Several of these phenomenon have been well known in the area of alkaline fuel cells, but only recently have they been examined as they might impact alkaline cell designs. This paper will review three general areas where the potassium ion content can impact the performance and life of nickel hydrogen and nickel cadmium devices, Once these phenomenon are understood conceptually, the impact of potassium content on a potential cell design can be evaluated with the aid of an accurate model of an operating cell or battery. All three of these areas are directly related to the volume tolerance and pore size engineering aspects of the components used in the cell or battery design: (1) The gamma phase uptake of potassium ion can result in a lowering of the electrolyte concentration. This leads to a higher electrolyte resistance as well as electrolyte diffusional limitations on the discharge rate. This phenomenon will also impact the response of the cell to a reconditioning cycle. (2) The impact of low level shunt currents in multi-cell con figurations will result in the movement of potassium ion from one part of the battery to another. This will impact the electrolyte volume/vapor pressure relationships within the cell or battery. (3) The transport of water vapor from place to place under the driving force of a tempetature gradient has already impacted cells for the case where water vapor is condensed on a colder cell wall. The paper will explore the convective and diffusive movement of gases saturated with water vapor from a warmer plate pack to a cooler one - both with and without liquid communication.

Thaller, L. H.↗
NASA NTRS2014

Characterization of Commercial Li-ion Cells in Pouch Format

The li-ion pouch design cells exhibit similar behavior under off-nominal conditions as those in metal cans that do not have the internal safety devices. Safety should be well characterized before batteries are designed. Some of the li-ion pouch cell designs studied in this program reacted most violently to overcharge conditions at the medium rates but were tolerant to overcharge at very low rates. Some pouch cell designs have higher tolerance to vacuum exposures than some others. A comparison of the pouch material itself does not show a correlation between this tolerance and the number of layers or composition of the pouch indicating that this is a property of the electrode stack design inside the pouch. Reduced pressure (8 to 10 psi) test environments show that the extent of capacity degradation under reduced pressure environments is much less than that observed under vacuum conditions. Lithium-ion Pouch format cells are not necessarily true polymer cells.

Jeevarajan, Judith↗
DOE OSTI2026

Investigation of a thermocapacitive cycle by aqueous supercapacitors for multifunctional heat pump and energy storage

Thermocapacitive cycles are promising thermal and energy storage cycles using supercapacitors, which can achieve thermal efficiencies over 50% of the Carnot limit. There is a lack of work investigating the use of thermocapacitive effects in practical heat pumps. Here, this paper explores the design of thermocapacitive cells with higher temperature changes to be better suited for heat pumping applications. To evaluate the cell designs on temperature changes, pouch type cells are prototyped and modeled, and tested using a micro-calorimeter. A peak adiabatic temperature span of a LiCl aqueous cell is 2.7 °C. By arranging the cells in a cascade manner, the projected adiabatic temperature span can reach up to 12 °C with a heating density of 15 kW m −3 and an energy storage density of 0.83 kWh m −3 . Models predict that this could be increased to 30 °C and 1.65 kWh m −3 through improvements to cell capacitance and thermopower. Incorporating the energy storage capabilities into heating and cooling devices can be beneficial to building thermal management as energy storage becomes increasingly important for energy system integration.

25 ENERGY STORAGE↗
NASA NTRS1976

Solar cell array design handbook, volume 1

Twelve chapters discuss the following: historical developments, the environment and its effects, solar cells, solar cell filters and covers, solar cell and other electrical interconnections, blocking and shunt diodes, substrates and deployment mechanisms, material properties, design synthesis and optimization, design analysis, procurement, production and cost aspects, evaluation and test, orbital performance, and illustrative design examples. A comprehensive index permits rapid locating of desired topics. The handbook consists of two volumes: Volume 1 is of an expository nature while Volume 2 contains detailed design data in an appendix-like fashion. Volume 2 includes solar cell performance data, applicable unit conversion factors and physical constants, and mechanical, electrical, thermal optical, magnetic, and outgassing material properties. Extensive references are provided.

Rauschenbach, H. S.↗
NASA NTRS1990

Factors affecting pressure in Li-SOCl2 cells

A model was developed to describe internal pressure in a Li-SOCl2 cell as a function of state of charge and temperature. The model was used to generate sets of predicted pressure variations in a hypothetical 250-Ah cell with assumed ranges of cell design variables including initial void volume and inert gas pressure. Results were assessed to establish values of the cell design parameters that would yield a vent pressure within a temperature range that was deemed safe and also adequate for cell performance. Results indicate that a suitable design for this cell would require an initial void volume near 112 cu cm and inert gas pressure near 40 psi.

Frank, H.↗
NASA NTRS1978

Block 4 solar cell module design and test specification for residential applications

Near-term design, qualification and acceptance requirements are provided for terrestrial solar cell modules suitable for incorporation in photovoltaic power sources (2 kW to 10 kW) applied to single family residential installations. Requirement levels and recommended design limits for selected performance criteria are specified for modules intended principally for rooftop installations. Modules satisfying the requirements of this specification fall into one of two categories, residential panel or residential shingle, both meeting general performance requirements plus additional category peculiar constraints.

Source record↗
DOE OSTI2024

Li-ion battery design through microstructural optimization using generative AI

Lithium-ion batteries are used across various applications, necessitating tailored cell designs to enhance performance. Optimizing electrode manufacturing parameters is a key route to achieving this, as these parameters directly influence the microstructure and performance of the cells. However, linking process parameters to performance is complex, and experimental or modeling campaigns are often slow and expensive. This study introduces a fast computational optimization framework for electrode manufacturing parameters. A generative model, trained on a small dataset of microstructural images associated with different manufacturing parameters, efficiently generates representative microstructures for new parameters. This model is integrated into a Bayesian optimization loop that includes microstructure generation, characterization, and simulation, aiming to find optimal manufacturing parameters for a particular application. Significant improvement in the energy density of a 4680 cell is achieved through bespoke cell design, highlighting the importance of cell-scale normalization. The framework’s modularity allows its application to various advanced materials manufacturing scenarios.

batteries↗
DOE OSTI2025

Porous transport electrodes for oxygen evolution reaction in proton exchange membrane water electrolysis -cells: Materials, designs, and diagnoses

H 2 production using proton exchange membrane (PEM) water electrolysis (PEMWE) cells has received considerable attention because of the high efficiencies of these cells and no harmful emissions from the related process. In PEMWE cells, porous transport electrodes (PTEs) composed of a catalyst layer (CL) comprising O 2 evolution reaction (OER) catalysts, porous transport layer (PTL), and PEM play key roles in the stack performance and lifetime. Herein, Ir-based and non-precious-metal OER catalysts that are highly active and stable at low pH values and high anodic potentials are reviewed to understand their OER mechanisms. Various strategies are proposed for engineering CLs and PTLs to improve the interfacial properties and mass transfers of reactants and products to and from the active sites. Additionally, diagnoses of PTEs is significantly crucial for interpreting electrochemical processes and addressing their current challenges. Therefore, half-cell analyses, including diffusion electrode (DE), floating electrode (FE), and modified rotating disk electrode (MRDE) techniques, are explored, and membrane electrode assembly (MEA)-based analyses, such as the polarization technique, electrochemical impedance spectroscopy, and magnetic field analysis, are established. In conclusion, this study aims to provide an overview of recent technologies used for the engineering and diagnostic tools of PEMWE cells and insights into the advanced components and systems to be developed in this field.

Diagnosis of PEMWE Cells↗
NASA NTRS1978

Block 4 solar cell module design and test specification for intermediate load center applications

Requirements for performance of terrestrial solar cell modules intended for use in various test applications are established. During the 1979-80 time period, such applications are expected to be in the 20 to 500 kilowatt size range. A series of characterization and qualification tests necessary to certify the module design for production, and the necessary performance test for acceptance of modules are specified.

Source record↗
NASA NTRS1995

Advanced Dependent Pressure Vessel (DPV) nickel-hydrogen spacecraft cell and battery design

The dependent pressure vessel (DPV) nickel-hydrogen (NiH2) battery is being developed as a potential spacecraft battery design for both military and commercial satellites. Individual pressure vessel (IPV) NiH2 batteries are currently flying on more than 70 Earth orbital satellites and have accumulated more than 140,000,000 cell-hours in actual spacecraft operation. The limitations of standard NiH2 IPV flight battery technology are primarily related to the internal cell design and the battery packaging issues associated with grouping multiple cylindrical cells. The DPV cell design offers higher specific energy and reduced cost, while retaining the established IPV NiH2 technology flight heritage and database. The advanced cell design offers a more efficient mechanical, electrical and thermal cell configuration and a reduced parts count. The internal electrode stack is a prismatic flat-plate arrangement. The flat individual cell pressure vessel provides a maximum direct thermal path for removing heat from the electrode stack. The cell geometry also minimizes multiple-cell battery packaging constraints by using an established end-plateltie-rod battery design. A major design advantage is that the battery support structure is efficiently required to restrain only the force applied to a portion of the end cell. As the cells are stacked in series to achieve the desired system voltage, this increment of the total battery weight becomes small. The geometry of the DPV cell promotes compact, minimum volume packaging and places all cell terminals along the length of the battery. The resulting ability to minimize intercell wiring offers additional design simplicity and significant weight savings. The DPV battery design offers significant cost and weight savings advantages while providing minimal design risks. Cell and battery level design issues will be addressed including mechanical, electrical and thermal design aspects. A design performance analysis will be presented at both the cell and battery level. The DPV is capable of delivering up to 76 Watt-hours per kilogram (Wh/kg) at the cell level and 70 Wh/kg at the full battery level. This represents a 40 percent increase in specific energy at the cell level and a 60 percent increase in specific energy at the battery level compared to current IPV NiH2 technology.

Coates, Dwaine↗
DOE OSTI2025

Bridging the Gap Between Pure and Mixed-Gas Performance of Thin-Film Composite Membranes

This study examines the influence of cell design on mixed-gas testing with PolyActive™ TFC membranes, featuring pure-gas CO₂ permeance of 1700–3100 GPU, representative of state-of-the-art CO₂/N₂ separation membranes. By designing and 3D-printing a counter-current permeation cell with optimized flow efficiency, we achieved a 33–41% increase in mixed-gas CO₂ permeance compared to traditional cells. Additionally, a comparison of sweep-gas and vacuum permeation methods revealed that vacuum operation mitigates downstream polarization, enhancing mixed-gas CO₂ permeance by 41%. These results underscore the critical role of permeation cell design and testing methods in accurately evaluating membrane performance, with significant implications for scaling up TFC membranes and optimizing industrial processes.

3D printing↗
NASA NTRS1993

Lithium D-cell study

The purpose of this contract is to evaluate parametrically the effects of various factors including the electrolyte type, electrolyte concentration, depolarizer type, and cell configuration on lithium cell electrical performance and safety. This effort shall allow for the selection and optimization of cell design for future NASA applications while maintaining close ties with WGL's continuous improvements in manufacturing processes and lithium cell design. Taguchi experimental design techniques are employed in this task, and allow for a maximum amount of information to be obtained while requiring significantly less cells than if a full factorial design were employed. Acceptance testing for this task is modeled after the NASA Document EP5-83-025, Revision C, for cell weights, OCV's and load voltages. The performance attributes that are studied in this effort are fresh capacity and start-up characteristics evaluated at two rates and two temperatures, shelf-life characteristics including start-up and capacity retention, and iterative microcalorimetry measurements. Abuse testing includes forced over discharge at two rates with and without diode protection, temperature tolerance testing, and shorting tests at three rates with the measurement of heat generated during shorting conditions.

Size, P.↗
DOE OSTI2022

Lithium-Ion Battery Design for Grid-Scale Energy Storage App

A software that delivers parameters from energy storage system (ESS) to container, rack, module and single cell design, as well as data analysis on arbitrage energy and frequency regulation of ESS in different regions, has been developed. The Lithium-ion Battery Design for Grid-scale Energy Storage App V1.0 has the capability to output the system, module and cell design with the energy, power, capacity, group method, cost of single cell, and single cell test protocol which break down from input energy storage system data in different regions. The default chemistry of the battery is LiFePO4 and graphite. The energy density of the graphite/LiFePO 4 pouch cell ranges from 100 Wh/kg to 200 Wh/Kg in the software. Graphite/LiFePO 4 pouch cell (up to 1Ah in lab) manufacturing line is also built and can be used to evaluate the test protocol, moreover, for electrolyte evaluation in other ESMI seedling projects. The software enables rapid prototyping to accelerate energy storage research, development, and manufacturing.

Liu, Dianying [Pacific Northwest National Laborato↗