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Results for “battery thermal efficiency”

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 OSTI2024

Li-Ion Battery Thermal Characterization for Thermal Management Design

Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing the thermal profile of battery cells, are crucial for balancing the trade-offs between battery performance and lifetime. Designing such systems requires accounting for the multitude of heat sources within battery cells and packs. This paper provides a summary of heat generation characterizations observed in several commercial Li-ion battery cells using isothermal battery calorimetry. The primary focus is on assessing the impact of temperatures, C-rates, and formation cycles. Moreover, a module-level characterization demonstrated the significant additional heat generated by module interconnects. Characterizing heat signatures at each level helps inform manufacturing at the design, production, and characterization phases that might otherwise go unaccounted for at the full pack level. Further testing of a 5 kWh battery pack revealed that a considerable temperature non-uniformity may arise due to inefficient cooling arrangements. To mitigate this type of challenge, a combined thermal characterization and multi-domain modeling approach is proposed, offering a solution without the need for constructing a costly module prototype.

25 ENERGY STORAGE↗
DOE OSTI2017

Battery Thermal Characterization

The operating temperature is critical in achieving the right balance between performance, cost, and life for both Li-ion batteries and ultracapacitors. The chemistries of advanced energy-storage devices - such as lithium-based batteries - are very sensitive to operating temperature. High temperatures degrade batteries faster while low temperatures decrease their power and capacity, affecting vehicle range, performance, and cost. Understanding heat generation in battery systems - from the individual cells within a module, to the inter-connects between the cells, and across the entire battery system - is imperative for designing effective thermal-management systems and battery packs. At NREL, we have developed unique capabilities to measure the thermal properties of cells and evaluate thermal performance of battery packs (air or liquid cooled). We also use our electro-thermal finite element models to analyze the thermal performance of battery systems in order to aid battery developers with improved thermal designs. NREL's tools are used to meet the weight, life, cost, and volume goals set by the U.S. Department of Energy for electric drive vehicles.

25 ENERGY STORAGE↗
DOE OSTI2017

Enabling fast charging – Battery thermal considerations

Battery thermal barriers are reviewed with regards to extreme fast charging. Present-day thermal management systems for battery electric vehicles are inadequate in limiting the maximum temperature rise of the battery during extreme fast charging. If the battery thermal management system is not designed correctly, the temperature of the cells could reach abuse temperatures and potentially send the cells into thermal runaway. Furthermore, the cell and battery interconnect design needs to be improved to meet the lifetime expectations of the consumer. Each of these aspects is explored and addressed as well as outlining where the heat is generated in a cell, the efficiencies of power and energy cells, and what type of battery thermal management solutions are available in today’s market. Here, thermal management is not a limiting condition with regard to extreme fast charging, but many factors need to be addressed especially for future high specific energy density cells to meet U.S. Department of Energy cost and volume goals.

25 ENERGY STORAGE↗
DOE OSTI2017

Thermal Implications for Extreme Fast Charge

Present-day thermal management systems for battery electric vehicles are inadequate in limiting the maximum temperature rise of the battery during extreme fast charging. If the battery thermal management system is not designed correctly, the temperature of the cells could reach abuse temperatures and potentially send the cells into thermal runaway. Furthermore, the cell and battery interconnect design needs to be improved to meet the lifetime expectations of the consumer. Each of these aspects is explored and addressed as well as outlining where the heat is generated in a cell, the efficiencies of power and energy cells, and what type of battery thermal management solutions are available in today's market. Thermal management is not a limiting condition with regard to extreme fast charging, but many factors need to be addressed especially for future high specific energy density cells to meet U.S. Department of Energy cost and volume goals.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1973

Battery cell thermal-conductive coating increases efficiency

Thin coating of high-temperature epoxy resin provides necessary electrical insulation, as well as good thermal conductivity between battery cells. Insulation increases efficiency of nickel-cadmium battery, as it would any multicell battery assembly in which cell-to-cell thermal balance is critical.

Doyle, H. M.↗
DOE OSTI2017

Energy efficiency evaluation of a stationary lithium-ion battery container storage system via electro-thermal modeling and detailed component analysis

Energy efficiency is a key performance indicator for battery storage systems. A detailed electro-thermal model of a stationary lithium-ion battery system is developed and an evaluation of its energy efficiency is conducted. The model offers a holistic approach to calculating conversion losses and auxiliary power consumption. Sub-models for battery rack, power electronics, thermal management as well as the control and monitoring components are developed and coupled to a comprehensive model. The simulation is parametrized based on a prototype 192 kWh system using lithium iron phosphate batteries connected to the low voltage grid. The key loss mechanisms are identified, thoroughly analyzed and modeled. Generic profiles featuring various system operation modes are evaluated to show the characteristics of stationary battery systems. Typically the losses in the power electronics outweigh the losses in the battery at low power operating points. The auxiliary power consumption dominates for low system utilization rates. For estimation of real-world performance, the grid applications Primary Control Reserve, Secondary Control Reserve and the storage of surplus photovoltaic power are evaluated. Conversion round-trip efficiency is in the range of 70-80%. Finally, overall system efficiency, which also considers system power consumption, is 8-13 percentage points lower for Primary Control Reserve and the photovoltaic-battery application. However, for Secondary Control Reserve, the total round-trip efficiency is found to be extremely low at 23% due to the low energy throughput of this application type.

25 ENERGY STORAGE↗
DOE OSTI2026

Dual Purpose – Heating & Cooling – Thermal Battery for Flexible and Energy-Efficient Heat Pump Systems

The integration of heat pumps with thermal energy storage (HP-TES) systems is gaining attention as a viable solution for managing peak building demand driven by immense cooling and heating loads. With growing reliance on renewable energy sources, thermal energy storage offers an excellent opportunity to mitigate mismatches in thermal load between energy supply and demand. The use of phase-change material (PCM) TES is especially promising, as PCMs offer significant latent energy storage capacity with smaller temperature glides in smaller volumes compared to other TES technologies. However, challenges arise because current HP-TES architectures can load-shift only cooling or heating, not both, requiring two systems and thus doubling cost, weight, and footprint. Furthermore, current research efforts lack specific tools and techniques to advance integrated systems from concept design to end-user application, focusing on only discharge performance. To address these challenges, this research proposes a dual-mode (heating and cooling) integrated HP-TES system that uses room-temperature PCM-TES as a high-temperature heat source in heating mode and a low-temperature heat sink in cooling mode, thereby reducing temperature lifts and compressor power. Design criteria for PCM-TES heat exchangers were developed, balancing thermal-hydraulic performance with practical constraints such as available building space and weight requirements along with PCM selection considerations such as shipping conditions, moisture exposure, and number of available cycles. A detailed transient model for HP-TES systems was developed to enable rapid annual performance assessments in any US climate zone.

42 ENGINEERING↗
NASA NTRS2015

Airvolt Aircraft Electric Propulsion Test Stand

Development of an electric propulsion test stand that collects high-fidelity data of motor, inverter, and battery system efficiencies; thermal dynamics; and acoustics independent of manufacturer reported values will improve understanding of electric propulsion systems to be used in future aircraft. A buildup approach to this development reveals new areas of research and best practices in testing, and attempts to establish a standard for testing these systems.

propulsion↗
DOE OSTI2018

Efficient thermal management of Li-ion batteries with a passive interfacial thermal regulator based on a shape memory alloy [A passive interfacial thermal regulator based on shape memory alloy and its application to battery thermal management]

The poor performance of lithium-ion batteries in extreme temperatures is hindering their wider adoption in the energy sector. A fundamental challenge in battery thermal management systems (BTMSs) is that hot and cold environments pose opposite requirements: thermal transmission at high temperature for battery cooling, and thermal isolation at low temperature to retain the batteries’ internally generated heat, leading to an inevitable compromise of either hot or cold performances. Here, we demonstrate a thermal regulator that adjusts its thermal conductance as a function of the temperature, just as desired for the BTMS. Without any external logic control, this thermal regulator increases battery capacity by a factor of 3 at an ambient temperature (T ambient ) of -20 °C in comparison to a baseline BTMS that is always thermally conducting, while also limiting the battery temperature rise to 5 °C in a very hot environment (T ambient = 45 °C) to ensure safety. The result expands the usability of lithium-ion batteries in extreme environments and opens up new applications of thermally functional devices.

25 ENERGY STORAGE↗
DOE OSTI2022

Community Resilience through Low-Temperature Geothermal Reservoir Thermal Energy Storage

Submitted data include simulations related to underground thermal battery (UTB) simulations described in Modeling and efficiency study of large scale underground thermal battery deployment, presented at GRC, October 2021. The UTB is comprised of a tank of water, a helical heat exchanger in the center of tank and connected to a water source heat pump, and a phase change material (PCM). Compared to a conventional VBGHE, the UTB is designed to be installed at a much shallower depth, therefore, with a cheaper cost. In addition, the GSHP efficiency is improved due to natural convection of water and additional load capacity provided by PCM. The goal of this study is to explore factors that may affect the efficiency of large-scale UTB deployment. The simulations found in this submission relate to the report on UTB deployment.

15 GEOTHERMAL ENERGY↗
NASA NTRS2023

Long Life Molten Salt Battery for NASA Venus Application

A development program is being conducted at Advanced Thermal Batteries (ATB) to create a low discharge rate, long life, molten salt battery for a NASA Venus surface probe. Battery goals are 60 days continuous operation at +25V +0/-6 volts and -25V +6/-0 Volts under severe environments of 465°C, 92 atm pressure, and corrosive sulfur dioxide in a super critical carbon dioxide atmosphere. Conveniently, molten salt thermal battery electrochemistry starts to operate efficiently at 330°C. However, a major barrier to direct application of existing thermal battery technology is the high self-discharge rate, resulting in lifetimes in only minutes, not days. The best performance to date, which meets the required voltage regulation, has been a lithium silicon (LiSi) alloy anode discharging through all three voltage plateau versus an iron monosulfide (FeS) cathode. In order to perform reproducibly, additional engineering controls within the battery design are required to limit cell–to–cell parasitic discharge mechanisms. Results of these trials have improved the efficiency and manufacturability of the design.

Thermal Battery↗
DOE OSTI2026

Multi-physics Preconditioning for Thermally Activated Batteries

Thermal batteries, also known as molten-salt batteries, are single-use reserve power systems activated by pyrotechnic heat generation, which transitions the solid electrolyte into a molten state. The simulation of these batteries relies on multiphysics modeling to evaluate performance and behavior under various conditions. This paper presents advancements in scalable preconditioning strategies for the Thermally Activated Battery Simulator (TABS) tool, enabling efficient solutions to the coupled electrochemical systems that dominate computational costs in thermal battery simulations. We propose a hierarchical block Gauss-Seidel preconditioner implemented through the Teko package in Trilinos, which effectively addresses the challenges posed by tightly coupled physics, including charge transport, porous flow, and species diffusion. The preconditioner leverages scalable subblock solvers, including smoothed aggregation algebraic multigrid (SA-AMG) methods and domain-decomposition techniques, to achieve robust convergence and parallel scalability. Strong and weak scaling studies demonstrate the solver’s ability to handle problem sizes up to 51.3 million degrees of freedom on 2048 processors, achieving near sub-second setup and solve times for the end-to-end electrochemical solve. These advancements significantly improve the computational efficiency and turnaround time of thermal battery simulations, paving the way for higher-resolution models and enabling the transition from 2D axisymmetric to full 3D simulations.

25 ENERGY STORAGE↗
NASA NTRS1992

Resonant mode controllers for launch vehicle applications

Electro-mechanical actuator (EMA) systems are currently being investigated for the National Launch System (NLS) as a replacement for hydraulic actuators due to the large amount of manpower and support hardware required to maintain the hydraulic systems. EMA systems in weight sensitive applications, such as launch vehicles, have been limited to around 5 hp due to system size, controller efficiency, thermal management, and battery size. Presented here are design and test data for an EMA system that competes favorably in weight and is superior in maintainability to the hydraulic system. An EMA system uses dc power provided by a high energy density bipolar lithium thionyl chloride battery, with power conversion performed by low loss resonant topologies, and a high efficiency induction motor controlled with a high performance field oriented controller to drive a linear actuator.

Schreiner, Ken E.↗
DOE OSTI2023

System efficiency and power assessment of the all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) use low-temperature (T < 100 °C) heat to provide stationary energy and power with higher power densities and efficiency relative to other waste heat devices. TRABs are an active area of research in waste heat devices, but currently there is little consensus on what aspect of the system is limiting TRAB performance and what maximum efficiencies are possible. Experiments and numerical models were used here to examine the sensitivity of the battery and distillation column in a TRAB system to key operating variables, thereby establishing practical limits and identifying focus areas for improving performance. Battery power was eight times more sensitive to ohmic losses than kinetic and mass transfer losses, regardless of the operating temperature, and the peak power density was simulated to be 18.8 mW cm –2 at 75 °C. Theoretical energy efficiency limits were defined for a series of ammonia concentrations and operating pressures, ranging from 5 – 12%, which is 2–3 times higher than previous experimental estimations. Atmospheric pressure column operation used a larger amount of waste heat compared to sub-atmospheric pressure. It is estimated that the volume of the battery would take up 9.2m 3 for every 1% of the power output of a natural gas turbine, but with realistic improvements to cell conductivity, the size would reduce to 2.5 m 3 . Finally, the results presented in this work will help streamline future development by focusing on minimizing ohmic losses and provide specific data for full system evaluation of future TRABs.

25 ENERGY STORAGE↗
DOE OSTI2019

Efficient Simulation and Abuse Modeling of Mechanical-Electrochemical-Thermal Phenomena in Li-Ion Batteries

This poster covered simultaneous coupling of electrochemical-thermal models with mechanical deformation in lithium ion batteries. Efficiency and stability of mechanical models was significantly enhanced by implementing electrochemical models into LS-DYNA using User-Defined Elements. Six case studies were built and licensed out to participants from Industry for initial testing and their feedback is being incorporated into these tools. Dynamic response of the cells was incorporated by measuring mechanical response of components at strain rates as high as 250 /s. Temperature range for property measurements was expanded (as high as 200 degrees C) to account for property changes at high temperatures experienced by cell components under battery abuse. Multi-cell validation has been expanded to include four different sets of experimental data, with support from various partners. Complex failure modes and fracture response are currently being investigated. These are still very challenging, given the limited amount of prior work available in the literature.

25 ENERGY STORAGE↗
DOE OSTI2022

Power and energy capacity tradeoffs in an all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) can provide energy storage and produce electrical power from low-grade waste heat instead of electricity. The use of all-aqueous copper-based electrolytes has recently produced higher power densities than those achieved using previous TRAB approaches based on reversible metal deposition and dissolution processes, but further gains are possible in power and energy density. We investigated the limitations of power and energy density and how they are impacted by the electrolyte composition and discharge currents. By increasing the ammonia concentration from 1 to 5 M, the power density of the battery increased from 11.2 to 28.5 mW cm –2 , but the energy density decreased from 0.56 to 0.31 Wh L –1 . Increasing discharge current densities from 4 to 12.5 mA cm –2 increased the average power density during discharge from 2.4 to 5.9 mW cm –2 without appreciable losses in energy density. Increasing the copper concentration from 0.1 to 0.5 M increased both energy density to 2.15 Wh L –1 and energy efficiency to 2.2% but did not substantially impact the power density. Furthermore, these results represent the highest performance metrics achieved for a low-grade waste heat to electricity system.

25 ENERGY STORAGE↗
DOE OSTI2025

Thermal management challenges in lithium-ion batteries: understanding heat generation mechanisms

This paper investigates heat generation in commercial 18 650 lithium-ion battery cells and the thermal management challenges from their high energy density and electrochemical processes. Thermal effects can degrade performance, accelerate aging, and increase thermal runaway risk. Using isothermal calorimetry and EIS, the study emphasizes optimizing thermal behavior to improve battery efficiency, safety, and durability.

25 ENERGY STORAGE↗