A new high rate lead acid battery

A new approach to the design of lead acid batteries has been developed based on the use of very thin lead foil current collectors. The basic cell construction and the performance characteristics for the new cell are described. Spiral wrap cells based on this electrode concept exhibit extremely high power output with excellent capacity maintenance. Additionally, these cells exhibit very flat voltage at all currents, and are capable of very rapid recharge. Applications for this high power technology cover a broad spectrum such as portable power tools, UPS systems, electrically heated catalytic converters, military pulse power applications and electric and hybrid vehicles     

Thin-film Li-LiMn2O4 batteries

Thin-film rechargeable Li-LiMn₂O₄ batteries have been fabricated and characterized. Following deposition by electron beam evaporation of LiMn₂O₄, the amorphous as-deposited cathode films 1 cm² in area by 0.3to 4-μm thick were annealed at 700°C to 800°C in oxygen in order to form the crystalline spinet phase. The specific capacity of the cells between 4.5 V to 3.8 V ranged from 50 μAh/mg to 120 μAh/mg. When cycled over this range, the batteries exhibited excellent secondary performance with capacity losses as low as 0.001% per cycle. On charging to 5.3 V, a plateau with a median voltage of 5.1 V was observed. The total charge extracted between 3.8 V to 5.3 V corresponded to about 1 Li/Mn₂ O₄     

Validation test of 125 Ah advanced design IPV nickel-hydrogenflight cells

An update of validation test results confirming the advanced design nickel-hydrogen cell is presented. An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed for storing and delivering energy for long-term, low-earth-orbit (LEO) spacecraft missions. The new features of this design are: the use of 26% rather than 31% potassium hydroxide (KOH) electrolyte; a patented catalyzed wall wick; serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while maintaining physical contact with the wall wick for electrolyte management; and a floating rather than a fixed stack to accommodate nickel electrode expansion. The resulting improvements include extended cycle life and enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. Six 125-Ah flight cells based on this design are in the process of being evaluated in a LEO cycle life test     

Nickel-hydrogen multicell common pressure vessel batterydevelopment update

Flight qualification of the multicell common pressure vessel (CPV) nickel-hydrogen (Ni-H₂) battery is discussed. The battery has completed full flight qualification, including random vibration at 19.5 g for two minutes in each axis, electrical characterization in a thermal vacuum chamber, and mass-spectroscopy vessel leak detection. A first launch is scheduled in 1992. Several design variations, ranging from 9 Ah to 125 Ah and 12 to 32 V, have been developed and prototypes fabricated. Designs for smaller capacity, smaller diameter (6.4-8.9 cm), and higher voltage (up to 100 V) are in progress. The CPV battery offers cost and weight savings of up to 30% as compared to traditional nickel-cadmium (Ni-Cd) and individual pressure vessel (IPV) Ni-H₂ batteries. The fully qualified design provided a 50% weight savings over its Nd-Cd predecessor for the same application. Its reduced volume also provides a significant advantage over IPV technology. Resistance data show a further advantage     

Performance characteristics of lithium-ion cells for NASA's Mars2001 Lander application

NASA requires lightweight rechargeable batteries for future missions to Mars and the outer planets that are capable of operating over a wide range of temperatures, with high specific energy and energy densities. Due to the attractive performance characteristics, lithium-ion batteries have been identified as the battery chemistry of choice for a number of future applications, including Mars rovers and landers. The Mars 2001 Lander (Mars Surveyor Program MSP 01) will be one of the first missions which will utilize lithium-ion technology. This application will require two lithium-ion batteries, each being 28 V (eight cells), 25 Ah and 8 kg. In addition to the requirement of being able to supply at least 200 cycles and 90 days of operation on the surface of Mars, the battery must be capable of operation (both charge and discharge) at temperatures as low as -20°C. To assess the viability of lithium-ion cells for these applications, a number of performance characterization tests have been performed, including: assessing the room temperature cycle life, low temperature cycle life (-20°C), rate capability as a function of temperature, pulse capability, self-discharge and storage characteristics, as well as mission profile capability. This paper describes the Mars 2001 Lander mission battery requirements and contains results of the cell testing conducted to-date in support of the mission,     

High reliability lithium rechargeable batteries for specialties

Since their development in the late 1980s, lithium rechargeable batteries have enjoyed rapid growth and wide use as a commodity battery known for its higher energy density storage and lightweight convenience. These same attributes are emerging as a strong platform in power source development for the medical and aerospace sectors with highly customized applications and narrowly defined criteria. Accordingly, this new generation of lithium rechargeables must be hermetically sealed, have long-term storage capability, and zero-fault tolerances for common causes of field failures such as electrolyte leakage or short circuits from mechanical deformation. Quallion has been developing and manufacturing highly reliable lithium rechargeable cells for medical, aerospace, and specialty applications. Summarized in this paper are some key technologies developed at Quallion for designing and manufacturing of this new class of lithium rechargeable batteries. They include: 1) leakage reliability; 2) self-extinguishing electrolyte system; 3) mechanical impact resistance; 4) deep discharge storage; and 5) high reliability manufacturing.     

Advanced lithium ion battery charger

A lithium ion battery charger has been developed for four and eight cell batteries or multiples thereof. This charger has the advantage over those using commercial lithium ion charging chips in that the individual cells are allowed to be taper charged at their upper charging voltage rather than be cutoff when all cells of the string have reached the upper charging voltage limit. Since 30-60% of the capacity of lithium ion cells may be restored during the taper charge, this charger has a distinct benefit of fully charging lithium ion batteries by restoring all of the available capacity to all of its cells     

Bipolar nickel-metal hydride batteries for aerospace applications

Electro Energy Inc. (EEI) is developing high power, long life, bipolar nickel-metal hydride batteries for aerospace applications. Bipolar nickel-metal hydride designs allow for high energy and high power designs with a 25 percent reduction in both weight and volume as compared to prismatic and/or cylindrical Ni-MH designs. Utilizing a sealed wafer cell design EEI has demonstrated a 1.2 kW/kg power capability. Prototype designs have achieved 70 Wh/kg. Designs studies show 80 Wh/kg are achievable with EEI's state-of-the-art technology. The sealed wafer cell is the building block for EEI's high power and high voltage bipolar batteries making the assembly easy and significantly lower in cost. Satellite and aircraft batteries are being developed which provide high power and long life. Sealed cells now show excellent rate capability and life. Cells tested in a low earth orbit (LEO) cycle have reached 9000 cycles and continue on test. High power, bipolar battery designs are ideal in applications where using conventional aerospace battery technology would require excessive capacity; weight and volume, thereby reducing usable payload on the vehicle     

Life cycle testing of a sealed 24-V, 42-Ah nickel-cadmium aircraftbattery

Extensive research has been conducted in the design and manufacture of very long life sealed maintenance free nickel-cadmium aircraft batteries. This study presents data on a 100% depth of discharge (DOD) life test performed on a nominal capacity 42-Ah battery. The purpose of this study is to validate design concepts, determine the life characteristics of the newly designed sealed Ni-Cd batteries, and develop baseline information on failure rates and mechanisms. The data from this experiment can be used to compare depth of discharge versus battery life with similar tests such as the lower DOD experiments performed on spacecraft batteries. This information is important in the ongoing development of long life batteries and in developing failure models for life prediction     

Military qualification of a high-reliability, light-weight 24 V/30Ah aircraft battery

The United States Navy has flown Valve Regulated Lead-Acid Batteries (VRLA) for approximately 18 years. The first VRLA aircraft batteries were cylindrical cell design and evolved to a prismatic design to save weight, volume, and to increase rate capability. This paper discusses the next generation of the VRLA aircraft battery. The HORIZON composite grid VRLA design reduces weight, increases high rate performance, and is expected to increase service life. This paper discusses the weight reduction over the present 30 Ah prismatic VRLA aircraft battery design; improvements in high rate engine start performance, and present status of the development effort. Finally, the paper discusses the applications for the 30 Ah composite grid VRLA aircraft battery, and shows the future application opportunities for light-weight VRLA, both in the military and commercially     

Advanced lithium ion solid polymer electrolyte battery development

Lockheed Martin Missiles & Space (LMMS), Ultralife Batteries, Inc. (UBI), Eagle Picher Technologies, LLC (EPT), Sandia National Laboratories (SNL) and Rentech, Inc. (RTI) are developing lithium ion solid polymer electrolyte (Li-ion SPE) batteries. Under a new Advanced Technology Program (ATP), this team will develop new high-energy density cells and batteries for space and portable electronics applications. These new batteries will utilize new high-energy density anode and cathode active materials developed by SNL and RTI. UBI will incorporate these new materials into an optimized Li-ion SPE electrode laminate. EPT will develop batteries for aerospace applications based on this electrode laminate technology while LMMS will design the battery charge management controller and provide system expertise     

Fuel cell status, 1994

The high efficiency environmental benefits and other attributes of fuel cells have attracted world-wide attention to the technology. Approximately 250 phosphoric acid fuel cell (PAFC) power units, 35 molten carbonate fuel cell (MCFC) stacks, and 12 solid oxide fuel cell (SOFC) modules have been or are being operated. Total capacity installed or operating is close to 45 MW. Fuel cell development has progressed to where complete power plants have reached nearly 16,000 operating hours and this continues to increase. Developers in the U.S. and Japan have embarked on extensive government and private programs to commercialize the technology in those countries and abroad. By mid-1994, the U.S. sold and shipped to other countries at least 33 PAFC 200 kW plants, 20 675 kW PAFC stacks, two SOFC 25 kW modules, and one MCFC system. Additional units have been produced for the domestic market. There is intense interest in Japan where there are very stringent environmental regulations and fuel prices are high. The fuel cell can respond with its combined attributes of low emissions and relative high efficiency. In Europe, the environmental cleanliness of fuel cell power units holds the promise of preserving the quality of life, motivating support and development of the technology. Canada and Australia have spawned important development programs. Interest continues to increase in other parts of the world. The author reviews the 1994 status and outlines the future development trends in this area     

Need and effect of reconditioning of nickel/hydrogen batteries

There has been a debate about the need for reconditioning nickel/hydrogen batteries in geosynchronous satellites. A study was done as part of life cycling, to determine the necessity of reconditioning and its effect on the cell performance. A 36 Ah nickel/hydrogen cell was put on a GEO simulated cycling at 15°C without reconditioning up to four eclipse seasons. The effect of reconditioning on the fifth and sixth eclipse seasons was studied. The study has conclusively proven the need for reconditioning and has shown the benefits of a high rate reconditioning. It has also been possible to draw some conclusions about the effect of a long duration trickle charge on the positive electrode     

Hubble performance on-orbit

A summary of the Hubble Space Telescope (HST) nickel-hydrogen (NiH/sub 2/) battery performance from launch to the present. Over the life of HST vehicle configuration, charge system degradation and failures, together with thermal design limitations, have had a significant effect on the capacity of HST batteries. Changes made to the charge system configuration to protect against power system failures and to maintain battery thermal stability resulted in undercharging of the batteries. This undercharging resulted in decreased usable battery capacity as well as battery cell voltage/capacity divergence. This cell divergence was made evident during on-orbit battery capacity measurements by a relatively shallow slope of the discharge curve following the discharge knee. Early efforts to improve battery performance have been successful. On-orbit capacity measurement data indicates increases in the usable battery capacity of all six batteries as well as improvements in the battery cell voltage/capacity divergence. Additional measures have been implemented to improve battery performance, however, failures within the HST Power Control Unit (PCU) have prevented verification of battery status.     

Lithium micro-battery development at the Jet Propulsion Laboratory

Recent successes in the effort to miniaturize spacecraft components using MEMS technology, integrated passive components, and low power electronics have driven the need for very low power, low profile, low mass micro-power sources for micro/nanospacecraft applications. Recent work at JPL has focused upon developing thin film/micro-batteries compatible with temperature sensitive substrates. A process to prepare crystalline LiCoO₂ films with RF sputtering and moderate (<700°C) annealing temperature has been developed. Thin film batteries with cathode films prepared with this process have specific capacities approaching the practical limit for LiCoO₂, with acceptable rate capabilities and discharge voltage profiles. Solid-state micro-scale batteries have also been fabricated with feature sizes on the order of 50 microns     

Aerospace and military battery applications

This paper gives a review of the papers presented at the IEEE 17th Annual Battery Conference on Applications and Advances, Long Beach, CA, USA, 2002. The topics covered are: Li batteries for satellites, capacity fade of Li-ion cells cycled at different temperatures, Ni-H/sub 2/ battery lifetime, batteries for Mars-exploring vehicles, Li-ion cell performance enhancement at low temperatures, navy service batteries, and US Army man portable applications and mobile power challenges.     

Hubble Space Telescope at twelve years of age

The Hubble Space Telescope was deployed from the Space Shuttle Discovery into a 380-mile high Earth orbit on April 25, 1990. It subsequently made outstanding astronomical discoveries with its 8-foot (2.4-meter) telescope and other scientific instruments. Critical to the successful observations was continuous availability of power from its solar arrays during sunlit periods, and from nickel-hydrogen batteries when the satellite was in the Earth's shadow. The adopted nickel-hydrogen batteries were carefully selected and tested to confirm their depth-of-discharge and operating temperature that delivered the longest life in charge/discharge cycling service. These batteries had a design life of 7 years. At 12 years after launch the Hubble batteries have delivered more charge/discharge cycles than any other batteries in low-Earth orbit. However, the Hubble batteries have been subjected to many unexpected stresses, and peculiar reductions in battery capacity have been observed. Battery replacement requires a costly trip to the Hubble Space Telescope by astronauts, so the remaining useful life of the batteries must be predicted. Already in four servicing missions, astronauts have replaced or modified optics, solar arrays, a power control unit, and various science packages. A fifth servicing mission is scheduled in 2004. This paper discusses battery charging hardware and software controls, history of battery events in Hubble, cell performance model and spare battery tests, and capacity walkdown.     

Perspective on ultracapacitors for electric vehicles

Recent advances in performance of chemical double layer capacitors (DLC) with aqueous and non-aqueous electrolytes have made it possible to seriously consider them for commercialization. Non-aqueous (organic) carbon based laboratory monopolar devices have recently met key U.S. Department of Energy (DoE) mid-term specifications (> 5 WNkg, >500 W/kg and >100,000 life cycles) for load-leveling electric vehicles batteries. All DLC technologies currently under development by DoE are discussed. Each technology has distinct advantages and none are clear winners at this time. A study has been completed by the General Electric Company on the interface electronics needed to best utilize the energy of capacitors for load-leveling batteries. System costs are presented based on this study, several battery technologies, and capacitor projections     

Fast equalization for large lithium ion batteries

Slight differences between the series connected cells in a lithium ion (Lilon) battery pack can produce imbalances in the cell voltages, and this greatly reduces the charge capacity. These batteries cannot be trickle-charged like a lead acid battery since this would slightly overcharge some cells and may cause these cells to ignite. Therefore, an electronic equalizer (EQU) should be used to balance the cell voltages individually. The targeted EQU described herein can be connected to any cell via a set of sealed relays to provide much faster equalization and higher efficiency than previous methods.