Safety and abuse testing
A series of abuse tests on large lithium thionyl chloride cells was initiated. Performance data obtained in testing rectangular 2,000 and 10,000 ampere-hour cells are discussed and graphically presented.
Younger, G.↗
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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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Safety and Abuse Testing of Energizer LiFeS2 AA Cells
The LiFeS2 test program was part of the study on state-of-the-art batteries/cells available in the commercial market. It was carried out in an effort to replace alkaline AA cells for Shuttle and Station applications. A large number of alkaline cells are used for numerous Shuttle and Station applications as loose cells. Other government agencies reported good performance and abuse tolerance of the AA LiFeS2 cells. In this study, only abuse testing was performed on the cells to determine their tolerance. The tests carried out were over-discharge, external short circuit, heat-to-vent, vibration and drop.
Jeevarajan, Judith A.↗
Reserve Li/SOC12 Battery Safety Testing
A reserve Lithium/Thionyl Chloride Battery concept is developed and undergoing feasibility testing in terms of performance, safety and abusive conditions. The feasibility of employing a battery of this type to replace thermal batteries in certain applications is demonstrated. Excellent performance of a Li/SOCl2 reserve battery is obtained across the temperature range from 0 C to +44 C. Performance improvement over the thermal battery usage is greater by a factor of 3 when discharge time and energy density are compared. Performance over an expanded temperature range is also possible. Safety and abusive testing is accomplished successfully on a series of five units. Further performance improvements can be achieved with regard to battery weight and volume reductions.
Dils, C. T.↗
The USAF Phillips Laboratory sodium-sulfur battery technology program: Results and status
Tests performed on NaS batteries are reported. The results of safety and abuse testing, shock and vibration tests, cell failure on warm-up, freeze thaw, overtemperature conditions, electrolyte fracture, overdischarge, and short circuit tests are presented along with GEO and LEO cycle tests and the status of the NaS cell flight tests.
Rainbow, Marc E.↗
A Novel Lithium-ion Laminated Pouch Cell Tested For Performance And Safety
A new Li-ion 4.0 Ah pouch cell from GS Yuasa has been tested to determine its performance and safety. The cell is of a laminate pouch design with liquid electrolyte. The rate, thermal and vacuum performance capabilities have been tested to determine the optimum parameters. Under vacuum conditions, the cells were cycled under restrained and unrestrained configurations. The burst pressure of the laminate pouch was also determined. The overcharge, overdischarge into reversal and external short circuit safety tests were also performed to determine the cell s tolerance to abuse. Key Words: Li-ion, safety, vacuum test, abuse, COTS batteries, rate capability
Jeevarajan, Judith A.↗
A Comparison of Two Panasonic Lithium-Ion Batteries and Cells for the IBM Thinkpad
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.
Jeevarajan, Judith A.↗
Performance and Safety Tests on Samsung 18650 Li-ion Cells: Two Cell Designs
In order to meet the applications for space shuttle in future, two types of Samsung cells, with capacity 1800 mAh and 2000 mAh, have been investigated. The studies focused on: (1) Performance tests: completed 250 cycles at various combinations of charge/discharge C rates and discharge capacity measurements at various temperatures; and (2) Safety tests: overcharge and overdischarge, heat abuse, short circuit, internal and external short, and vibration, vacuum, and drop tests
Deng, Yi↗
Safety Evaluation of Two Commercial Lithium-ion Batteries for Space Applications
Lithium-ion batteries have been used for applications on the Shuttle and Station for the past six years. A majority of the li-ion batteries flown are Commercial-off-the-shelf (COTS) varieties. The COTS batteries and cells were tested under nominal and abusive conditions for performance and safety characterization. Within the past six months two batteries have been certified for flight and use on the Space Station. The first one is a Hand Spring PDA battery that had a single prismatic li-ion cell and the second is an Iridium satellite phone that had a two-cell pack with prismatic li-ion cells.
Jeevarajan, Judith A.↗
Test results of JPL LiSOCl sub 2 cells
In the development of high rate Li-SO-Cl2 cells for various applications, the goal is to achieve 300 watt-hours per kilogram at the C/2 (5 amp) rate in a D cell configuration. The JPL role is to develop the understanding of the performance, life, and safety limiting characteristics in the cell and to transfer the technology to a manufacturer to produce a safe, high quality product in a reproducible manner. The approach taken to achieve the goals is divided into four subject areas: cathode processes and characteristics; chemical reactions and safety; cell design and assembly; and performance and abuse testing. The progress made in each of these areas is discussed.
Halpert, G.↗
Performance and Safety Testing of Cylindrical Moli Lithium-Ion Cells
The Moli lithium-ion cells were tested under normal and abuse conditions. The cells exhibit only 50% of their original capacity at about -10 C. The optimum charge/discharge rate with the least percentage loss in capacity is C/2 charge and C/4 discharge. The cells did not explode or go into a thermal runaway during venting at very high temperatures. They exhibited good tolerance under the vibration conditions tested and could potentially be used in the build up of large batteries that have high current pulse (up to 3C) applications.
Jeevarajan, Judith A.↗
Evaluation of advanced high rate Li-SOCl2 cells
Under NASA sponsorship, JPL is developing advanced, high rate Li-SOCl2 cells for future space missions. As part of this effort, Li-SOCl2 cells of various designs were examined for performance and safety. The cells differed from one another in several aspects, such as: nature of carbon cathode, catalysts, cell configuration, case polarity, and safety devices. Performance evaluation included constant-current discharge over a range of currents and temperatures. Abuse-testing consisted of shortcircuiting, charging, and over-discharge. Energy densities greater than 300 Wh/Kg at the C/2 rate were found for some designs. A cell design featuring a high-surface-area carbon cathode was found to deliver nearly 500 Wh/Kg at moderate discharge rates. Temperature influenced the performance significantly.
Deligiannis, F.↗
Use of COTS Batteries on ISS and Shuttle
This presentation focuses on COTS Battery testing for energy content, toxicity, hazards, failures modes and controls for different battery chemistries. It also discusses the current program requirements, challenges with COTS Batteries in manned vehicle COTS methodology, JSC test details, and gives a list of incidents from consumer protection safety commissions. The Battery test process involved testing new batteries for engineering certification, qualification of batteries, flight acceptance, cell and battery, environment, performance and abuse. Their conclusions and recommendations were that: high risk is undertaken with the use of COTS batteries, hazard control verification is required to allow the use of these batteries on manned space flights, failures during use cannot be understood if different scenarios of failure are not tested on the ground, and that testing is performed on small sample numbers due to restrictions on cost and time. They recommend testing of large sample size to gain more confidence in the operation of the hazard controls.
Jeevarajan, Judith A.↗
Advanced Lithium-ion Batteries with High Specific Energy and Improved Safety for Nasa's Missions
High Energy Materials ( Cathodes, anodes and high voltage and safe electrolyte are required to meet the needs of the future space missions. A. Cathodes: The layered layered composites of of Li2MnO3 and LiMO2 are promising Power capability of the materials, however requires further improvement. Suitable morphology is critical for good performance and high tap (packing) density. Surface coatings help in the interfacial kinetics and stability. B. Electrolytes: Small additions of Flame Retardant Additives improves flammability without affecting performance (Rate and cycle life). 1.0 M in EC+EMC+TPP was shown to have good performance against the high voltage cathode; Performance demonstrated in large capacity prototype MCMB- LiNiCoO2 Cells. Formulations with higher proportions are looking promising. Still requires further validation through abuse tests (e.g., on 18650 cells).
NASA Missions↗
Improvements in safety testing of lithium cells
A systematic approach was developed for evaluating the basic safety parameters of high power lithium soluble cathode cells. This approach consists of performing a series of tests on each cell model during the design, prototype and production phases. Abusive testing is performed in a facility where maximum protection is given to test personnel.
Stinebring, R. C.↗
Modification to area navigation equipment for instrument two-segment approaches
A two-segment aircraft landing approach concept utilizing an area random navigation (RNAV) system to execute the two-segment approach and eliminate the requirements for co-located distance measuring equipment (DME) was investigated. This concept permits non-precision approaches to be made to runways not equipped with ILS systems, down to appropriate minima. A hardware and software retrofit kit for the concept was designed, built, and tested on a DC-8-61 aircraft for flight evaluation. A two-segment approach profile and piloting procedure for that aircraft that will provide adequate safety margin under adverse weather, in the presence of system failures, and with the occurrence of an abused approach, was also developed. The two-segment approach procedure and equipment was demonstrated to line pilots under conditions which are representative of those encountered in air carrier service.
Source record↗
Safety testing of lithium cells
Safety testing is intended to simulate, under laboratory conditions and controls, situations that will subject a cell to externally induced stress. The stresses can occur at any time during the useful life of the cell, from the time of manufacture until it is expended during mission deployment. Abuse testing can be divided into three major categories: Electrical, Mechanical, and Thermal. Although electrical abuses are generally found to occur during handling or deployment, Mechanical and Thermal stresses can be induced during transportation and storage. Therefore, it would be prudent to include predicted environmental exposure as part of the test plan. In the selection of a test program. specific test requirements should be tailored to meet the predicted mission requirements.
Liberto, Nick↗
Accelerating rate calorimetry: A new technique for safety studies in lithium systems
The role of exothermic reactions in battery test modes is discussed. The exothermic reactions are characterized with respect to their time-temperature and time-pressure behavior. Reactions occuring for any major exotherm were examined. The accelerating rate calorimetry methods was developed to study lithium cells susceptibility to thermal runaway reactions following certain abuse modes such as forced discharge into reversal and charging.
Ebner, W. B.↗
Development of microcomputer-based mental acuity tests
Recent disasters have focused attention on performance problems due to the use of alcohol and controlled substances in the workplace. Environmental stressors such as thermal extremes, mixed gases, noise, motion, and vibration also have adverse effects on human performance and operator efficiency. However, the lack of a standardized, sensitive, human performance assessment battery has probably delayed the systematic study of the deleterious effects of various toxic chemicals and drugs at home and in the workplace. The collective goal of the research reported here is the development of a menu of tests embedded in a coherent package of hardware and software that may be useful in repeated-measures studies of a broad range of agents that can degrade human performance. A menu of 40 tests from the Automated Performance Test System (APTS) is described, and the series of interlocking studies supporting its development is reviewed. The APTS tests, which run on several versions of laptop portables and desktop personal computers, have been shown to be stable, reliable, and factorially rich, and to have predictive validities with holistic measures of intelligence and simulator performances. In addition, sensitivity studies have been conducted in which performance changes due to stressors, agents, and treatments were demonstrated. We believe that tests like those described here have prospective use as an adjunct to urine testing for the screening for performance loss of individuals who are granted access to workplaces and stations that impact public safety.
Non-NASA Center↗