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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Battery Thermal Characterization

A well-designed thermal management system is critical to the life and performance of electric-drive vehicles (EDVs) hybrids (HEVs), plug-in hybrids (PHEVs), and all-electric vehicles (EVs). Temperature and temperature uniformity both significantly affect the performance, lifespan, and safety of vehicle energy storage devices. NREL conducts thermal management research and development (R&D) to optimize battery performance and extend useful life. A recognized leader in battery thermal analysis and characterization, NREL evaluates electrical and thermal performance of battery cells, modules, and packs, full energy storage systems, and the interaction of these systems with other vehicle components. The lab's performance assessments factor in the design of the thermal management system, the thermal behavior of the cell, battery lifespan, and safety of the energy storage system, as well as full integration into a vehicle. The lithium-ion (Li-ion) batteries found in most of today's electric-drive vehicles are smaller and more lightweight than previous nickel-metal hydride (NiMH) technology, but they are also more sensitive to overheating, overcharging, and extreme spikes in temperature known as thermal runaway. High temperatures diminish battery life and increase battery replacement costs, while low temperatures decrease battery power and capacity, all of which impact vehicle range, performance, and affordability. NREL's breakthrough research is focused on reducing thermal barriers to achieve more uniform temperatures. NREL uses its R&D 100 Award-winning Isothermal Battery Calorimeters, the only instruments in the world capable of such precise thermal measurements, for much of this research. Calorimeter readings are paired with thermal imaging of batteries using infrared cameras to evaluate battery temperature distribution. In addition, NREL is working with industry to develop computer-aided engineering software tools to optimize thermal management of batteries. NREL's analysis for the U.S. Advanced Battery Consortium (USABC) show that optimized thermal management can increase battery power by more than 10%. Without proper thermal management, an EDV battery can last more than 10 years in a temperate climate, like in Minnesota, but only 7 years in a hot climate, such as in Arizona. In extreme instances, battery overheating can pose safety hazards, including fires. Performance: Maintaining desired temperature ranges is critical in optimizing EDV battery storage capacity, lifespan, and performance, and eventually impacts cost and consumer acceptance. NREL's breakthrough research focuses on achieving more uniform temperatures while a vehicle is in motion and actively generating heat, as well as when it is parked and exposed to ambient temperatures over prolonged periods of time. Safety: Most energy storage systems deliver maximum performance at higher temperatures. However, this extreme heat can overload systems and create dangerous conditions. NREL evaluation helps to more effectively regulate thermal characteristics, providing greater safeguards and stronger performance. NREL has invented a device that emulates internal short circuits in batteries to better understand how to prevent future failures and related hazards.

25 ENERGY STORAGE↗
NASA NTRSDate not supplied

Design and Analysis of Battery Thermal Management Systems

Thermal management of battery cell packs is a critically needed technology. The purpose of this work is to design new and improved Battery Thermal Management Systems (BTMS) for use in electric airplanes. The BTMS should be 3D printable and hold twelve to sixteen 18650 batteries. To minimize aircraft’s weight, an actively air-cooled battery pack was chosen to avoid the excess weight of water-cooled and phase change material (PCM) cooled packs. As a result, significant changes were made to remove all metal in the pack and replace it with lower density polymer matrix composites (PMCs) which can be additively manufactured. Two air cooled battery pack configurations (traditional propeller fans & bladeless fans) were designed, modeled, and compared. These packs were first modeled in SolidWorks 2021 3D CAD, then imported into COMSOL MultiPhysics to be studied using the “Heat Transfer in Solids and Fluids” module. The design with the bladeless fans eliminated the need to use high conductivity heavy metal to remove unwanted thermal energy. These bladeless fans were designed entirely out of PMCs. This thermal pack design weighs 0.04 kg less than that of the traditional propeller fans design and has increased the battery pack energy density by 8.25 Wh/kg.

Thermal Management System for Battery Packs↗
NASA NTRSDate not supplied

Thermal Analysis on Large Format Lithium-Ion Batteries in Thermal Runaway

Lithium-ion (Li-ion) batteries can deliver electrical power across a large range of applications, and large format versions of these batteries are common in aerospace for their low mass and energy dense properties. Li-ion cells usage has increased as they are more power dense than fuel cells and have overall higher performance over lead-acid/NiCd batteries. However, Li-ion cells can experience Thermal Runaway (TR) via electro-chemical, mechanical, or thermal abuse. TR is a phenomenon where the stored energy in a cell is rapidly released along with vented gases and other effluents. A cell is generally determined to be in TR if its internal heat generation has surpassed its ability to dissipate that heat. If a Li-ion cell enters TR, propagation within the battery may occur. Propagation is the chain reaction that can occur to nearby cells due to a cell that has entered TR initially. Understanding a battery’s susceptiveness to propagation is necessary to evaluate risks associated with TR phenomenon. To determine if a battery is designed in a sufficient manner to prevent battery propagation if single cell TR occurs, testing and thermal analysis of the battery must be conducted. The presentation for TFAWS 2026 will cover considerations for battery TR thermal analysis, such as: testing methods, influences on the cells, failure mechanisms, and TR parameters. This presentation will include a walkthrough of an example battery TR thermal analysis, and the results thereof.

Lithium Ion Batteries↗
DOE OSTI2024

Thermal battery cost scaling analysis: minimizing the cost per kW h

Thermal and cost-scaling analyses provide the tools to optimize the geometry of thermal batteries based on cost. Figures-of-merit comprised of storage material properties are derived as the quantities that should be maximized when different components dominate cost.

25 ENERGY STORAGE↗
DOE OSTI2022

Thermal design analysis for SuperTruck II lithium-titanate battery pack

Here, this paper presents a systematic thermal management analysis for a new lithium-titanate-oxide battery pack to be installed in a SuperTruck II, Class 8 hybrid truck. The authors investigate the feasibility of mounting the battery pack inside the vehicle and air-cooling it with fans supplying conditioned air from the cabin. Moreover, the cells within each module are to be immersed in a heat-transfer fluid to improve temperature homogeneity. A multi-stage thermal analysis is performed to ensure adequate thermal regulation of the battery under the proposed design, considering installation and operational constraints. The authors perform thermal and electrical characterization tests on a single cell. Results inform the development of computational fluid dynamics models of the cells, modules, and pack. Module-level analysis shows that the cell temperatures can be maintained below their upper operational limit of 55 °C with module wall-to-air heat transfer coefficients between 10 and 20 Wm -2 K -1 . Pack-level analysis of distinct configurations determines effective airflow paths for adequate heat transfer and delivers a final battery pack design that achieves sufficient cooling and temperature uniformity. A reduced-order electrothermal model is developed to rapidly predict the transient battery performance and to develop a temperature control strategy.

25 ENERGY STORAGE↗
DOE OSTI2023

Mechanically induced thermal runaway severity analysis for Li-ion batteries

Thermal runaway is one of the most important safety concerns in the deployment of Li-ion batteries. For this study, we developed a standardized single-side indentation test protocol to induce an internal short-circuit. Cell voltage, temperature, and applied compressive force are monitored as a function of time. Each cell is given an observed hazard severity (OHS in five categories) modified from the EUCAR table. Meanwhile a calculated hazard severity (CHS) is obtained solely based on temperature and voltage curves. The calculation formula considers the cell temperature, rate of temperature increase, cell capacity, state of charge (SOC), voltage drop, and voltage drop rate. Each term is assigned with an appropriate weight to scale the calculated score from 0 to100. This method was applied to >100 Li-ion batteries with various SOCs and chemistries, and their OHS and CHS were displayed against SOC. The purpose is to provide battery designers, manufacturers, and end-users a clear comparison of thermal runaway severity of different batteries.

25 ENERGY STORAGE↗
NASA NTRS1989

A thermal analysis of a spirally wound battery using a simple mathematical model

A two-dimensional thermal model for spirally wound batteries has been developed. The governing equation of the model is the energy balance. Convective and insulated boundary conditions are used, and the equations are solved using a finite element code called TOPAZ2D. The finite element mesh is generated using a preprocessor to TOPAZ2D called MAZE. The model is used to estimate temperature profiles within a spirally wound D-size cell. The model is applied to the lithium/thionyl chloride cell because of the thermal management problems that this cell exhibits. Simplified one-dimensional models are presented that can be used to predict best and worst temperature profiles. The two-dimensional model is used to predict the regions of maximum temperature within the spirally wound cell. Normal discharge as well as thermal runaway conditions are investigated.

Evans, T. I.↗
DOE OSTI2019

Active lithium analysis for the elimination of battery thermal runaway

Active lithium that is still present in end-of-life batteries poses threats of flammability and reactivity, making disposal and transportation unsafe and costly. OnTo’s deactivation method uses supercritical CO2 to eliminate the hazards of active lithium. Until now, there has been no quantitative method to determine the active lithium content within a battery. The objective of this project is to demonstrate a simple, rapid measurement of active lithium to evaluate battery treatment processes and eliminate class 9 hazards.

battery safety↗
NASA NTRS2008

Operationally Responsive Space Standard Bus Battery Thermal Balance Testing and Heat Dissipation Analysis

The focus of this paper will be on the thermal balance testing for the Operationally Responsive Space Standard Bus Battery. The Standard Bus thermal design required that the battery be isolated from the bus itself. This required the battery to have its own thermal control, including heaters and a radiator surface. Since the battery was not ready for testing during the overall bus thermal balance testing, a separate test was conducted to verify the thermal design for the battery. This paper will discuss in detail, the test set up, test procedure, and results from this test. Additionally this paper will consider the methods taken to determine the heat dissipation of the battery during charge and discharge. It seems that the heat dissipation for Lithium Ion batteries is relatively unknown and hard to quantify. The methods used during test and the post test analysis to estimate the heat dissipation of the battery will be discussed.

Marley, Mike↗
DOE OSTI2024

Exploring thermal runaway propagation in Li-ion batteries through high-speed X-ray imaging and thermal analysis: Impact of cell chemistry and electrical connections

Battery safety design is important to consider from the individual Li-ion cell to the level of the macro-system. On the macro-level, failure in one single cell can lead to propagation of the thermal runaway and rapidly set a whole battery pack on fire. Factors that can impact the propagation outcome, such as cell model/chemistry and electrical connection are here investigated using a combination of measurements. Several abusive tests were conducted, combining two different cell models (Molicel P42A and LG M50, both 21700s) in series and parallel connections (16 tests per configuration). Overall, a propagation outcome of 56% was measured from the 32 conducted tests, a minimum temperature of 150 °C was required to initiate propagation, and the fastest propagation occurred in 123 s. Temperature measurements were higher in series connected cells, initiating the discussion of cell chemistry and internal resistance on this effect. The difference in current-flow during thermal runaway in series and parallel connections, and how this can affect the temperature evolution is further discussed. Spatio-temporal mapping of X-ray radiography allowed us to derive the speed of thermal runaway evolution inside the battery and has shown that series connected cells, in particular P42A, occur faster. It was further observed that deviant sidewall behaviors such as temperature-induced breaches and pressure-induced ruptures occurred in P42As only respective nail-penetrated cells only.

25 ENERGY STORAGE↗
DOE OSTI2023

Geological Thermal Energy Storage Using Solar Thermal and Carnot Batteries: Techno-Economic Analysis

Energy storage is increasingly necessary as variable renewable energy technologies are deployed. Seasonal energy storage can shift energy generation from the summer to the winter, but these technologies must have extremely large energy capacities and low costs. Geological thermal energy storage (GeoTES) is proposed as a solution for long-term energy storage. Excess thermal energy can be stored in permeable reservoirs such as aquifers and depleted hydrocarbon reservoirs for several months. In this article, we describe a techno-economic model that has been developed to evaluate GeoTES systems. The models are developed by combining the output of specialist models, which enables the performance and cost of both the subsurface and surface systems to be captured. Off-design models are developed so that the performance can be evaluated at each hour of the year. GeoTES can be charged with two different energy sources: (1) concentrating solar thermal and (2) renewable electricity using heat pumps (henceforth known as a "Carnot Battery"). The stored thermal energy can be used to generate electricity and, uniquely, also directly produce heat that can be used by industrial processes. Furthermore, Carnot Battery GeoTES can also be used to form a cold storage reservoir. Preliminary results that quantify the technical and economic performance of these two GeoTES systems are presented.

carnot battery↗
DOE OSTI2023

Geological Thermal Energy Storage Using Solar Thermal and Carnot Batteries: Techno-Economic Analysis: Preprint

Energy storage is increasingly necessary as Variable Renewable Energy (VRE) technologies are deployed. Seasonal energy storage can shift energy generation from the summer to the winter, but these technologies must have extremely large energy capacities and low costs. Geological Thermal energy storage (GeoTES) is proposed as a solution for long-term energy storage. Excess thermal energy can be stored in permeable reservoirs such as aquifers and depleted hydrocarbon reservoirs for several months. In this article, we describe a techno-economic model that has been developed to evaluate GeoTES systems. The models are developed by combining the output of specialist models which enables the performance and cost of both the subsurface and surface systems to be captured. Off-design models are developed so that the performance can be evaluated at each hour of the year. GeoTES can be charged with two different energy sources: (1) concentrating solar thermal and (2) renewable electricity using heat pumps (henceforth known as a "Carnot Battery"). The stored thermal energy can be used to generate electricity and - uniquely - also directly produce heat that can be used by industrial processes. Furthermore, Carnot-Battery-GeoTES can also be used to form a cold storage reservoir. Preliminary results that quantify the technical and economic performance of these two GeoTES systems are presented.

carnot battery↗
NASA NTRS1981

Characterization of the physico-chemical properties of polymeric materials for aerospace flight

Electrodes and electrolytes of nickel cadmium sealed batteries were analyzed. Different thermal analysis of negative and positive battery electrodes was conducted and the temperature ranges of occurrence of endotherms indicating decomposition of cadmium hydroxide and nickel hydroxide are identified. Atomic absorption spectroscopy was used to analyze electrodes and electrolytes for traces of nickel, cadmium, cobalt, and potassium. Calibration curves and data are given for each sample analyzed. Instrumentation and analytical procedures used for each method are described.

Rock, M.↗