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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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NASA NTRS1985

Bipolar nickel-hydrogen battery development

A comparison of the bipolar Ni-H2 battery with other energy systems to be used in future high-power space systems is presented. The initial design for the battery under the NASA-sponsored program is described and the candidate stack components are evaluated, including electrodes, separator, electrolyte reservoir plate, and recombination sites. The compressibility of the cell elements, electrolyte activation, and thermal design are discussed. Manufacturing and prototype test results are summarized.

Koehler, C. W.↗

NASA NTRS2014

Method for Making a Fuel Cell

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which an electrolyte layer is supported between porous electrodes. The porous electrodes may be made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze-drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that, subsequent to sintering, is made into either an anode or a cathode. The electrode scaffold comprising the anode includes a layer of liquid metal. The pores of the electrode scaffolds gradually increase in diameter as the layer extends away from the electrolyte layer. As a result of this diameter increase, any forces that would tend to pull the liquid metal away from the electrolyte are reduced while maintaining a diffusion path for the fuel. Advantageously, the fuel cell of the invention may utilize a hydrocarbon fuel without pre-processing to remove sulfur.

Cable, Thomas L.↗

NASA NTRS1991

Measurements of the effects of thermal contact resistance on steady state heat transfer in phosphoric-acid fuel cell stack

The influence of the thermal contact resistance on the heat transfer between the electrode plates, and the cooling system plate in a phosphoric-acid fuel-cell stack was experimentally investigated. The investigation was conducted using a set-up that simulates the operating conditions prevailing in a phosphoric acid fuel-cell stack. The fuel-cell cooling system utilized three types of coolants, water, engine oil, and air, to remove excess heat generated in the cell electrode and to maintain a reasonably uniform temperature distribution in the electrode plate. The thermal contact resistance was measured as a function of pressure at the interface between the electrode plate and the cooling system plate. The interface pressure range was from 0 kPa to 3448 kPa, while the Reynolds number for the cooling limits varied from 15 to 79 for oil, 1165 to 6165 for water, and 700 to 6864 for air. Results showed that increasing the interface pressure resulted in a higher heat transfer coefficient.

Abdul-Aziz, Ali↗

NASA NTRS2015

Ni-BaTiO3-Based Base-Metal Electrode (BME) Ceramic Capacitors for Space Applications

A multi-layer ceramic capacitor (MLCC) is a high-temperature (1350C typical) co-fired ceramic monolithic that is composed of many layers of alternately stacked oxide-based dielectric and internal metal electrodes. To make the dielectric layers insulating and the metal electrode layers conducting, only highly oxidation-resistant precious metals, such as platinum, palladium, and silver, can be used for the co-firing of insulating MLCCs in a regular air atmosphere. MLCCs made with precious metals as internal electrodes and terminations are called precious-metal electrode (PME) capacitors. Currently, all military and space-level applications only address the use of PME capacitors.

Ceramic Capacitors↗

NASA NTRS1976

Metal structures with parallel pores

Four methods of fabricating metal plates having uniformly sized parallel pores are studied: elongate bundle, wind and sinter, extrude and sinter, and corrugate stack. Such plates are suitable for electrodes for electrochemical and fuel cells.

Sherfey, J. M.↗

NASA NTRS1994

Amorphous silicon thin films: The ultimate lightweight space solar cell

Progress is reported with respect to the development of thin film amorphous (alpha-Si) terrestrial solar cells for space applications. Such devices promise to result in very lightweight, low cost, flexible arrays with superior end of life (EOL) performance. Each alpha-Si cell consists of a tandem arrangement of three very thin p-i-n junctions vapor deposited between film electrodes. The thickness of this entire stack is approximately 2.0 microns, resulting in a device of negligible weight, but one that must be mechanically supported for handling and fabrication into arrays. The stack is therefore presently deposited onto a large area (12 by 13 in), rigid, glass superstrate, 40 mil thick, and preliminary space qualification testing of modules so configured is underway. At the same time, a more advanced version is under development in which the thin film stack is transferred from the glass onto a thin (2.0 mil) polymer substrate to create large arrays that are truly flexible and significantly lighter than either the glassed alpha-Si version or present conventional crystalline technologies. In this paper the key processes for such effective transfer are described. In addition, both glassed (rigid) and unglassed (flexible) alpha-Si cells are studied when integrated with various advanced structures to form lightweight systems. EOL predictions are generated for the case of a 1000 W array in a standard, 10 year geosynchronous (GEO) orbit. Specific powers (W/kg), power densities (W/sq m) and total array costs ($/sq ft) are compared.

Vendura, G. J., Jr.↗

NASA NTRS1994

Proton exchange membrane fuel cells for space and electric vehicle applications: From basic research to technology development

The proton exchange membrane fuel cell (PEMFC) is one of the most promising electrochemical power sources for space and electric vehicle applications. The wide spectrum of R&D activities on PEMFC's, carried out in our Center from 1988 to date, is as follows (1) Electrode Kinetic and Electrocatalysis of Oxygen Reduction; (2) Optimization of Structures of Electrodes and of Membrane and Electrode Assemblies; (3) Selection and Evaluation of Advanced Proton Conducting Membranes and of Operating Conditions to Attain High Energy Efficiency; (4) Modeling Analysis of Fuel Cell Performance and of Thermal and Water Management; and (5) Engineering Design and Development of Multicell Stacks. The accomplishments on these tasks may be summarized as follows: (1) A microelectrode technique was developed to determine the electrode kinetic parameters for the fuel cell reactions and mass transport parameters for the H2 and O2 reactants in the proton conducting membrane. (2) High energy efficiencies and high power densities were demonstrated in PEMFCs with low platinum loading electrodes (0.4 mg/cm(exp 2) or less), advanced membranes and optimized structures of membrane and electrode assemblies, as well as operating conditions. (3) The modeling analyses revealed methods to minimize mass transport limitations, particularly with air as the cathodic reactant; and for efficient thermal and water management. (4) Work is in progress to develop multi-kilowatt stacks with the electrodes containing low platinum loadings.

Srinivasan, Supramaniam↗

NASA NTRS1979

Redox flow cell energy storage systems

NASA-Redox systems are electrochemical storage devices that use two fully soluble Redox couples, anode and cathode fluids, as active electrode materials separated by a highly selective ion exchange membrane. The reactants are contained in large storage tanks and pumped through a stack of Redox flow cells where the electrochemical reactions (reduction and oxidation) take place at porous carbon felt electrodes. A string or stack of these power producing cells is connected in series in a bipolar manner. Redox energy storage systems promise to be inexpensive and possess many features that provide for flexible design, long life, high reliability and minimal operation and maintenance costs. These features include independent sizing of power and storage capacity requirements and inclusion within the cell stack of a cell that monitors the state of charge of the system as a whole, and a rebalance cell which permits continuous correction to be made for minor side reactions that would tend to result in the anode fluid and cathode fluids becoming electrochemically out of balance. These system features are described and discussed.

Thaller, L. H.↗

NASA NTRS1981

Design and assembly considerations for Redox cells and stacks

Individual redox flow cells are arranged electrically in series and hydraulically in parallel to form a single assembly called a stack. The hardware currently being tested in the laboratory has an active electrode area of either 310 sq cm or 929 sq cm. Four 310 sq cm stacks, each consisting of 39 active cells, were incorporated into a 1.0 kW preprototype system. The physical design of the stack is very critical to the performance and efficiency of the redox storage sytem. This report will discuss the mechanical aspects of the cell and stack design for the current Redox hardware, with regard to sealing the stack internally as well as externally, minimizing shunt currents and minimizing the electrical resistance of the stack.

Stalnaker, D. K.↗

NASA NTRS1977

Self discharge of nickel-hydrogen cells

Values for the capacity loss with time, naturally on open circuit stand, and information regarding the minimum amount of circuit charge needed to keep the cell charged can be determined from the self-discharge behavior of nickel hydrogen cells. Furthermore, the rate of reaction between hydrogen and a charged nickel electrode is also open for nickel cadmium batteries. In a nickel hydrogen cell, the hydrogen is stored as pressurized gas and the cell stack with the charge that is oxidized nickel-hydroxide electrode is in direct contact with the hydrogen. Therefore, the rate of reaction can be measured easily and precisely by monitoring the charge, the change in hydrogen pressure with time. Measures made on twelve 15 ampere hour nickel hydrogen cells of different stack configurations built for COMSAT are discussed.

Holleck, G.↗

NASA NTRS1967

High-temperature /1100 degrees F/ capacitors operate without supplement cooling

Multilayered capacitor with one-mil thick pyrolytic boron nitride and wrap around sputtered electrodes achieves parallel electrical interconnections in a stacked configuration of 3 to 9 wafers. These capacitors are compact, lightweight, and suitable for operation in high temperatures without supplemental cooling.

Stapleton, R. E.↗

NASA NTRS1984

Advanced designs for IPV nickel-hydrogen cells

Advanced designs for individual pressure vessel nickel-hydrogen cells have been concieved which should improve the cycle life at deep depths-of-discharge. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Smithrick, J. J.↗

NASA NTRS1985

Initial performance of advanced designs for IPV nickel-hydrogen cells

Advanced designs for individual pressure vessel nickel hydrogen cells were conceived which should improve the life cycle at deep depths of discharge and improve thermal management. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) the use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Smithrick, J. J.↗

NASA NTRS1985

Initial performance of advanced designs for IPV nickel-hydrogen cells

Smithrick, J. J.↗

NASA NTRS1984

Advanced designs for IPV nickel-hydrogen cells

Advanced designs for individual pressure vessel nickel-hydrogen cells have been conceived which should improve the cycle life at deep depths-of-discharge. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Smithrick, J. J.↗

NASA NTRS1985

Initial performance of advanced designs for IPV nickel-hydrogen cells

Smithrick, J. J.↗

NASA NTRS1986

Initial performance of advanced designs for IPV nickel-hydrogen cells

Advanced designs for individual pressure vessel nickel-hydrogen cells have been conceived which should improve the cycle life at deep depths-of-discharge and improve thermal management. Features of the designs which are new and not incorporated in either of the contemporary cells (Air Force/Hughes, Comsat) are: (1) use of alternate methods of oxygen recombination, (2) use of serrated edge separators to facilitate movement of gas within the cell while still maintaining required physical contact with the wall wick, and (3) use of an expandable stack to accommodate some of the nickel electrode expansion. The designs also consider electrolyte volume requirements over the life of the cells, and are fully compatible with the Air Force/Hughes design.

Smithrick, John J.↗

NASA NTRS1991

Some recent studies with the solid-ionomer electrochemical capacitor

Giner, Inc. has developed a high-energy-density, all-solid-ionomer electrochemical capacitor, completely free of liquid electrolyte. The novel features of this device include 1) a three-dimensional metal oxide-particulate-ionomer composite electrode structure, and 2) a unitized repeating cell element. The composite electrode structures are bonded to opposite sides of a thin sheet of a solid proton-conducting ionomer membrane and form an integrally bonded membrane and electrode assembly (MEA). Individual MEAs can be stacked in series as bipolar elements to form a multiple cell device. The discharge characteristics and energy storage properties of these devices are described. Typical capacitance measured for a unit cell is 1 F/cm(exp 2). Life testing of a multicell capacitor on an intermittent basis has shown, that over a 10,000 hour period, the capacitance and resistance of the cell has remained invariant. There has been no maintenance required on the device since it was fabricated. Other multicell units of shorter life duration have exhibited similar reliable performance characteristics. Recent work has focused on increasing the capacitance of the unitized structure and improving the low-temperature characteristics. The approaches and experimental results will be presented. Some possible advanced NASA applications for these unique all-solid-ionomer devices will be discussed.

S Sarangapani↗