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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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Use of NiF2 cathodes in medium-to-high-temperature rechargeable sodium batteries increases energy and power densities by 25 to 30 percent without detracting from potential advantage of safety this type of sodium battery offers over sodium batteries having sulfur cathodes. High-energy-density sodium batteries with metal fluoride cathodes used in electric vehicles and for leveling loads on powerlines.
Transition-metal chloride cathodes for use in high-temperature rechargeable sodium batteries prepared by sintering transition-metal powders mixed with sodium chloride. Need for difficult and dangerous chlorination process eliminated. Proportions of transition metal and sodium chloride in mixture adjusted to suit specific requirements. Cathodes integral to sodium/metal-chloride batteries, which have advantages over sodium/sulfur batteries including energy densities, increased safety, reduced material and thermal-management problems, and ease of operation and assembly. Being evaluated for supplying electrical power during peak demand and electric vehicles.
The nickel metal hydride technology for battery application is relatively immature even though this technology was made widely known by Philips' scientists as long ago as 1970. Recently, because of the international environmental regulatory pressures being placed on cadmium in the workplace and in disposal practices, battery companies have initiated extensive development programs to make this technology a viable commercial operation. These hydrides do not pose a toxilogical threat as does cadmium. Also, they provide a higher energy density and specific energy when compared to the other nickel based battery technologies. For these reasons, the nickel metal hydride electrochemisty is being evaluated as the next power source for varied applications such as laptop computers, cellular telephones, electric vehicles, and satellites. A parallel development effort is under way to look at aerospace applications for nickel metal hydride cells. This effort is focused on life testing of small wound cells of the commercial type to validate design options and development of prismatic design cells for aerospace applications.
It was concluded that rapid development in the technology of sodium metal chloride batteries has been achieved in the last decade mainly due to the: expertise available with sodium sulfur system; safety; and flexibility in design and fabrication. Long cycle lives of over 1000 and high energy densities of approx. 100 Wh/kg have been demonstrated in both Na/FeCl2 and Na/NiCl2 cells. Optimization of porous cathode and solid electrolyte geometries are essential for further enhancing the battery performance. Fundamental studies confirm the capabilities of these systems. Nickel dichloride emerges as the candidate cathode material for high power density applications such as electric vehicle and space.
Johnson Controls is a 106 year old company employing 42,000 people worldwide with $4.7 billion annual sales. Though we are new to the aerospace industry we are a world leader in automobile battery manufacturing, automotive seating, plastic bottling, and facilities environment controls. The battery division produces over 24,000,000 batteries annually under private label for the new car manufacturers and the replacement market. We are entering the aerospace market with the nickel hydrogen battery with the help of NASA's Center for Space Power at Texas A&M. Unlike traditional nickel hydrogen battery manufacturers, we are reaching beyond the space applications to the higher volume markets of aircraft starting and utility load leveling. Though space applications alone will not provide sufficient volume to support the economies of scale and opportunities for statistical process control, these additional terrestrial applications will. For example, nickel hydrogen batteries do not have the environmental problems of nickel cadmium or lead acid and may someday start your car or power your electric vehicle. However you envision the future, keep in mind that no manufacturer moves into a large volume market without fine tuning their process. The Center for Space Power at Texas A&M is providing indepth technical analysis of all of the materials and fabricated parts of our battery as well as thermal and mechanical design computer modeling. Several examples of what we are doing with nickel hydrogen chemistry to lead to these production efficiencies are presented.
The paper discusses some of the results of vehicle electrical potential from recent sounding rocket experiments involving charging of a space platform by both electron beam emission and by the application of differential bias between elements of the platform. Conclusions are presented that are applicable to the experimental parameters of the CHARGE-2 and SPEAR-1 payloads. The currents collected by HV biased collectors in the sphere show strong magnetic limiting and are close to the values predicted by Parker and Murphy (1967). No volume breakdown was observed above 100 km altitude by exposing voltages up to 45 kV to the ionosphere in the SPEAR-1 payload. The release of gas at flow rates typical of ACS systems can provide sufficient plasma to electronically neutralize space platforms biased at either positive or negative potentials.
Significant strides have been made in the development of high-temperature rechargeable sodium batteries utilizing transition metal chloride cathodes in the last decade, mainly due to the expertise available on Na/S batteries. These systems have already performed attractively in the various feasibility studies and have an excellent safety record. Despite the encouraging figures obtained for specific energies, certain design changes such as modifying the geometry of the beta alumina electrolyte and optimization of the porous cathodes for enhanced electrolyte flow need to be made to achieve high power densities required in applications such as electric vehicles and space. The chemistry of MCl2 cathodes, electrode fabrication, and design options are discussed, and performance data are examined.
Reductions in weight and volume make new application possible. Supercapacitors and improved ultracapacitors advanced electrolytic capacitors developed for use as electric-load-leveling devices in such applications as electric vehicle propulsion systems, portable power tools, and low-voltage pulsed power supplies. One primary advantage: offer power densities much higher than storage batteries. Capacitors used in pulse mode, with short charge and discharge times. Derived from commercially available ultracapacitors. Made of lightweight materials; incorporate electrode/electrolyte material systems capable of operation at voltages higher than previous electrode/electrolyte systems. By use of innovative designs and manufacturing processes, made in wide range of rated capacitances and in rated operating potentials ranging from few to several hundred volts.
Use of two hydrogen anodes in nickel/hydrogen cell reduces ohmic and concentration polarizations contributing to internal resistance, yielding cell with improved discharging performance compared to single-anode cell. Dual-anode concept incorporated into nickel/hydrogen cells of individual pressure-vessel type (for use aboard spacecraft) and common pressure-vessel type, for use on Earth to store electrical energy from photovoltaic sources, "uninterruptible" power supplies of computer and telephone systems, electric vehicles, and load leveling on power lines. Also applicable to silver/hydrogen and other metal/gas batteries.
Ovonic nickel-metal hydride (NiMH) rechargeable batteries are easily adaptable to a variety of applications. Small consumer NiMH cells were developed and are now being manufactured by licensees throughout the world. This technology was successfully scaled up in larger prismatic cells aimed at electric vehicle applications. Sealed cells aimed at satellite power applications were also built and cycle tested by OBC and other outside agencies. Prototype batteries with high specific energy (over 80 Wh/kg), high energy density (245 Wh/L), and excellent power capability (400 W/kg) were produced. Ovonic NiMH batteries demonstrated an excellent cycle life of over 10,000 cycles at 30 percent DOD. Presently, Ovonic Battery Company is working on an advanced version of this battery for space applications as part of an SBIR contract from NASA.
Eagle-Picher currently has several advanced nickel-hydrogen (NiH2) cell component and battery designs under development including common pressure vessel (CPV), single pressure vessel (SPV), and dependent pressure vessel (DPV) designs. A CPV NiH2 battery, utilizing low-cost 64 mm (2.5 in.) cell diameter technology, has been designed and built for multiple smallsat programs, including the TUBSAT B spacecraft which is currently scheduled (24 Nov. 93) for launch aboard a Russian Proton rocket. An advanced 90 mm (3.5 in.) NiH2 cell design is currently being manufactured for the Space Station Freedom program. Prototype 254 mm (10 in.) diameter SPV batteries are currently under construction and initial boilerplate testing has shown excellent results. NiH2 cycle life testing is being continued at Eagle-Picher and IPV cells have currently completed more than 89,000 accelerated LEO cycles at 15% DOD, 49,000 real-time LEO cycles at 30 percent DOD, 37,800 cycles under a real-time LEO profile, 30 eclipse seasons in accelerated GEO, and 6 eclipse seasons in real-time GEO testing at 75 percent DOD maximum. Nickel-metal hydride battery development is continuing for both aerospace and electric vehicle applications. Eagle-Picher has also developed an extensive range of battery evaluation, test, and analysis (BETA) measurement and control equipment and software, based on Hewlett-Packard computerized data acquisition/control hardware.
Reference electrodes made of nickel cores with surface layers of nickel chloride proposed for use in molten sodium tetracholoroaluminate electrolytes in experimental sodium/nickel chloride electrochemical cells. These and other sodium/metal chloride cells investigated for use in several applications, including powering electric vehicles and leveling loads in power-distribution systems. Offers potential advantages of greater durability, greater stability and reproducibility of electrochemical potentials, less sensitivity of electrochemical potentials to variations in compositions of electrolytes, and greater compatibility with cathodes, made of nickel chloride.
Lightweight cathodes for rechargeable nickel-based electrochemical cells undergoing development. In cathodes, mats of nickel fibers are substrates providing structural support of, and electrical contact with, active cathode material. Offers specific energies greater than sintered nickel plaque cathodes. Electrodes used in rechargeable batteries for applications in which weight major concern, including laptop computers, cellular phones, flashlights, soldiers' backpacks, and electric vehicles.
The nickel electrode is the specific energy limiting component in battery systems such as nickel-hydrogen, nickel-metal hydride and nickel-zinc. Lightweight, high energy density nickel electrodes have been developed which deliver in excess of 180 mAh/g at the one-hour discharge rate. These electrodes are based on a highly porous, nickel micro-fiber (less than 10 micron diameter) substrate, electrochemically impregnated with nickel-hydroxide active material. Electrodes are being tested both as a flooded half-cell and in full nickel-hydrogen and nickel-metal hydride cells. The electrode technology developed is applicable to commercial nickel-based batteries for applications such as electric vehicles, cellular telephones and laptop computers and for low-cost, high energy density military and aerospace applications.
Howard University, under the auspices of the Center for Energy Systems and Controls runs the Energy Expert Systems Institute (EESI) summer outreach program for high school/pre-college minority students. The main objectives are to introduce precollege minority students to research in the power industry using modern state-of-the-art technology such as Expert Systems, Fuzzy Logic and Artificial Neural Networks; to involve minority students in space power management, systems and failure diagnosis; to generate interest in career options in electrical engineering; and to experience problem-solving in a teamwork environment consisting of faculty, senior research associates and graduate students. For five weeks the students are exposed not only to the exciting experience of college life, but also to the inspiring field of engineering, especially electrical engineering. The program consists of lectures in the fundamentals of engineering, mathematics, communication skills and computer skills. The projects are divided into mini and major. Topics for the 1995 mini projects were Expert Systems for the Electric Bus and Breast Cancer Detection. Topics on the major projects include Hybrid Electric Vehicle, Solar Dynamics and Distribution Automation. On the final day, designated as 'EESI Day' the students did oral presentations of their projects and prizes were awarded to the best group. The program began in the summer of 1993. The reaction from the students has been very positive. The program also arranges field trips to special places of interest such as the NASA Goddard Space Center.
The bibliography contains citations concerning applications of metal-air batteries. Topics include systems that possess different practical energy densities at specific powers. Coverage includes the operation of air electrodes at different densities and performance results. The systems are used in electric vehicles as a cost-effective method to achieve reliability and efficiency. Zinc-air batteries are covered more thoroughly in a separate bibliography. (Contains 50-250 citations and includes a subject term index and title list.)
This report describes an analytical and experimental investigation of AeroVironment's Quasi-Bipolar battery concept. The modelling/battery design part of the study demonstrates that there is a trade-off between thermal and specified electrical performance. Even so, quasi-bipolar batteries can be designed, with ten times better thermal uniformity, that meet or exceed current state-of-the-art hybrid-electric vehicle battery pack performance, even using the same active materials. The thermal uniformity, power, and energy for these quasi-bipolar battery packs is projected to be very good. The experimental part of the investigation demonstrates the concept of the quasi-bipolar plate applied to a lead foil current collector wrapping around two sides of an inexpensive plastic film core. Approximately 50 quasi-biplate samples were fabricated using a hot laminating press. Hot lamination with "texture" between the plastic and lead shows some promise as a low cost method for fabricating the plates. Five of these plates were assembled into two cells plus one two-cell battery. Data from these test cells were compared with existing data for similar true bipolar batteries. The positive side of the plates exhibited corrosion where not protected by the active material.
Under an SBIR (Small Business Innovative Research) from Lewis Research Center, Precision Combustion, Inc. (PCI) developed the Advanced Technology Catalytic Combustor. The research proved the viability of efficient, cost-effective catalytic reduction of gas turbine nitrogen oxide emissions along with fuel efficiency. PCI has signed agreements with Westinghouse, other gas turbine manufacturers, including Capstone Turbine Corporation to develop a catalytic combustor for their hybrid electric vehicle.