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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 OSTI2024

A directional electrode separator improves anodic biofilm current density in a well-mixed single-chamber bioelectrochemical system

In this study, a directional electrode separator (DES) was designed and incorporated into a single-chamber bioelectrochemical system (BES) to reduce migration and reoxidation of hydrogen. This issue arises when H 2 , generated at the cathode, travels to the anode where anodic biofilms use H 2 . To test the feasibility of our design, a 3D-printed BES reactor equipped with a DES was inoculated with anaerobic digestor granules and operated under fed-batch conditions using fermented corn stover effluent. The DES equipped reactor achieved significantly higher current densities (~53 A/m²) compared to a conventional single-chamber BES without a separator (~16 A/m²), showing a 3.3 times improvement. Further, control abiotic electrochemical experiments revealed that the DES exhibited significantly higher proton conductivity (456±127 µS/mm) compared to a proton exchange membrane (67±21 µS/mm) with a statistical significance of P=0.03. The DES also effectively reduced H 2 migration to the anode by 21-fold relative to the control. Overall, incorporating a DES in a single-chamber BES enhanced anodic current density by reducing H 2 migration to the anode.

3D printed BES↗
DOE OSTI2025

Electrode Separation and Froth Flotation for the Recovery of Li-ion Battery Cathode Materials

Increasing use of Li-ion batteries (LIBs) will significantly increase the quantity of LIB waste generated from end-of-life batteries. Spent LiCoO 2 (LCO) battery cathodes contain significant quantities of valuable metals, making them good candidates for recycling. Typical recycling processes rely on high temperatures (pyrometallurgy) and chemical leachants (hydrometallurgy) to completely decompose the cathode and enable material recovery. Direct recycling processes and recovery of active material from electrode scrap do not benefit from such destructive recycling, and an efficient means of separating the cathode active material from the inactive components (e.g., polyvinylidene fluoride (PVDF) binder, conductive carbon) is needed. Here, we explore PVDF removal from LCO cathodes by two separate methods, evaluating their suitability for coupling to subsequent separation by froth flotation (FF). We show that washing electrodes in the solvent PolarClean (PC) dissolves PVDF away from LCO cathodes, enabling separation of the remaining LCO and conductive carbon by FF. The process is suitable for use with both pristine and cycled LCO electrodes, and the pristine recovered material can be used to prepare electrodes capable of cycling at 140 mAh/g. In conclusion, this demonstrates the suitability of coupled PC washing and FF separation for recycling both end-of-life batteries and scrap electrode material.

Batteries↗
DOE OSTI2021

NREL's HydroGEN Photoreactor Platform Design and Characterization

This technical report details the design, fabrication, and construction of a flow-through photoreactor developed at The National Renewable Energy Laboratory (NREL). The photoreactor is designed to facilitate indoor or outdoor testing on photoelectrochemical or integrated solar water splitting devices. The photoreactor design described here is based on a previous demonstration. The photoreactor version described herein contains several advanced design features that include: 1) Chassis-chuck two-part design, 2) Separable counter electrode compartments (here, the counter electrodes are anodes), 3) Reduced electrode separation to reduce electrolyte resistance, 4) Improved flow pattern for bubble removal, 5) Mounting for spectroradiometer receptor, 6) Fresnel lens and collimating tube attachments. The photoreactor presented here was designed primarily to accommodate photocathode materials in an illuminated compartment and a dark anode as the oxygen evolution catalyst. The build materials were thus chosen to for acid electrolyte compatibility. Other embodiments could accommodate a photoanode with dark hydrogen evolution catalyst and other build materials for alkaline compatibility.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1974

Apparatus for conducting flow electrophoresis in the substantial absence of gravity

A zero-g, constant flow electrophoretic separating apparatus is presented. The apparatus is composed a deflecting member to spread carrier fluid across a conduit, and an end wall with a valve located in the conduit past the separation electrodes from which layers of carrier and sample may be extracted. Electrode electrolyte is separated from the carrier and continually circulated and cleaned.

Griffin, R. N.↗
DOE OSTI2021

Molten fluid electrode apparatus

A battery includes negative electrode material and positive electrode material where the materials are in a solid phase except for selected portions that are heated to transform the selected portions into a fluid. The fluid portion of negative electrode material is directed to a negative electrode region of a reaction chamber and the fluid portion of positive electrode material is directed to a positive electrode region of the reaction chamber where a solid electrolyte containing ions of the negative electrode separates the positive electrode region from the negative electrode region.

Vissers, Daniel R.↗
NASA NTRS2009

Low-Pressure, Field-Ionizing Mass Spectrometer

A small mass spectrometer utilizing a miniature field ionization source is now undergoing development. It is designed for use in a variety of applications in which there are requirements for a lightweight, low-power-consumption instrument that can analyze the masses of a wide variety of molecules and ions. The device can operate without need for a high-vacuum, carrier-gas feed radioactive ionizing source, or thermal ionizer. This mass spectrometer can operate either in the natural vacuum of outer space or on Earth at any ambient pressure below 50 torr (below about 6.7 kPa) - a partial vacuum that can easily be reached by use of a small sampling pump. This mass spectrometer also has a large dynamic range - from singly charged small gas ions to deoxyribonucleic acid (DNA) fragments larger than 104 atomic mass units - with sensitivity adequate for detecting some molecules and ions at relative abundances of less than one part per billion. This instrument (see figure) includes a field ionizer integrated with a rotating-field mass spectrometer (RFMS). The field ionizer effects ionization of a type characterized as "soft" in the art because it does not fragment molecules or initiate avalanche arcing. What makes the "soft" ionization mode possible is that the distance between the ionizing electrodes is less than mean free path for ions at the maximum anticipated operating pressure, so that the ionizer always operates on the non-breakdown side of the applicable Paschen curve (a standard plot of breakdown potential on the ordinate and pressure electrode separation on the abscissa). The field ionizer in this instrument is fabricated by micromachining a submicron-thick membrane out of an electrically nonconductive substrate, coating the membrane on both sides to form electrodes, then micromachining small holes through the electrodes and membrane. Because of the submicron electrode separation, even a potential of only 1 V applied between the electrodes gives rise to an electric field with a strength of in excess of a megavolt per meter strong enough to ionize any gas molecules passing through the holes. An accelerator grid and an electrostatic deflector focus the ions from the field ionizer into the rotating-field cell of the RFMS. The potentials applied to the electrodes of the cell to generate the rotating electric field typically range from 1 to 13 V. The ions travel in well-defined helices within this cell, after which they are collected in a Faraday cup. The mass of most of the molecules reaching the Faraday cup decreases with increasing frequency of rotation of the electric field in the cell. Therefore, the frequency of rotation of the electric field is made to vary in order to scan through a desired range of ion masses: For example, lightweight gas molecules are scanned at frequencies in the megahertz range, while DNA and other large organic molecules are scanned at kilohertz frequencies.

Hartley, Frank↗
DOE OSTI2020

Sustainable Direct Recycling of Lithium-Ion Batteries via Solvent Recovery of Electrode Materials

Separation of electrode materials from their current collectors is an enabling step toward recovering critical materials from spent lithium-ion batteries. In this study, a highly efficient, cost-effective, and environmentally sustainable separation process was developed for that purpose. Ethylene glycol, a vital commodity chemical as an antifreeze and polymer precursor, is used to delaminate electrode materials at low temperatures in seconds without altering the crystalline structure and morphology of active electrode materials. The recovered current collectors were intact without any corrosion. The authors also found that the solvent could be continuously reused, leading to the development of a closed-loop ecosystem and lithium-ion battery circular economy. The ultrafast delamination was driven by the competitive inhibition of binding through the weakening of hydrogen bonding. The ethylene glycol-based separation is a sustainable electrode recovery process that paves the way for battery recycling.

25 ENERGY STORAGE↗
NASA NTRS1991

Micromachined silicon tunnel sensor for motion detection

The extreme sensitivity of electron tunneling to variations in electrode separation has been used to construct a novel, compact displacement transducer. Electrostatic forces are used to control the separation between the tunneling electrodes, thereby eliminating the need for piezoelectric actuators. The entire structure is composed of micromachined silicon single crystals, including a folded cantilever spring and a tip. Measurements of displacement sensitivity and noise are reported. This device offers a substantial improvement over conventional technology for applications which require compact, highly sensitive transducers.

Kenny, T. W.↗
NASA NTRS1992

Electron tunnel sensors

We have used the extreme sensitivity of electron tunneling to variations in electrode separation to construct a novel, compact displacement transducer. Electrostatic forces are used to control the separation between the tunneling electrodes, thereby eliminating the need for piezoelectric actuators. The entire structure is composed of micromachined silicon single crystals. Applications of the tunneling displacement transducer to the measurement of acceleration and infrared signals are discussed. Measurements of acceleration and infrared sensitivity are reported.

Kenny, T. W.↗
DOE OSTI2023

Sequential separation of battery electrode materials and metal foils in aqueous media

To recycle high-value lithium-ion battery components, it is imperative to efficiently separate electrode materials from current collector foils and to separate cathodes from anodes. This study investigates the delamination behaviors of cathodes and anodes from their respective current collectors in aqueous media. Whereas anode films can easily detach from copper foils in water, the delamination of cathode films does not exhibit the same behavior in water; instead, the cation exchange reaction results in lithium leaching and aluminum corrosion in the presence of water. Here, a buffer solution with surfactant additives has been designed to prevent aluminum corrosion and to improve solution wetting behavior, thereby facilitating cathode delamination. The delamination difference enables the sequential recovery of electrode materials and metal foils at different separation stages, simplifying the traditionally intricate processes within a one-pot recovery system. The recovered materials retain their crystal structure and morphology, and there are no signs of aluminum corrosion or residues on the metal foils. The sequential separation technique achieves nearly 100% separation efficiency for electrode materials from metal foils and over 98% separation efficiency for cathode and anode materials.

25 ENERGY STORAGE↗
NASA NTRS1975

Development and fabrication of large vented nickel-zinc cells

A preliminary cell design for a 300AH vented nickel-zinc cell was established based on volume requirements and cell component materials selected by NASA Lewis Research Center. A 100AH cell configuration was derived from the 300AH cell design utilizing the same size electrodes, separators, and cell terminal hardware. The first cells fabricated were four groups of three cells each in the 100AH size. These 100AH experimental nickel-zinc cells had as common components the nickel positive electrodes (GFM), flexible inorganic separator (GFM) bags on the negative electrodes, pressed powder zinc oxide electrodes, and cell containers with hardware. The variations introduced were four differing electrolyte absorber (interseparator) systems used to encase the nickel positive electrodes of each cell group. The four groups of 100AH experimental vented nickel-zinc cells were tested to determine, based on cell performance, the best two interseparator systems. Using the two interseparator systems, two groups of experimental 300AH cells were fabricated. Each group of three cells differed only in the interseparator material used. The six cells were filled, formed and tested to evaluate the interseparator materials and investigate the performance characteristics of the 300AH cell configuration and its components.

Donnel, C. P., III↗
NASA NTRS2014

Method and Apparatus for Separating Particles by Dielectrophoresis

Particle separation apparatus separate particles and particle populations using dielectrophoretic (DEP) forces generated by one or more pairs of electrically coupled electrodes separated by a gap. Particles suspended in a fluid are separated by DEP forces generated by the at least one electrode pair at the gap as they travel over a separation zone comprising the electrode pair. Selected particles are deflected relative to the flow of incoming particles by DEP forces that are affected by controlling applied potential, gap width, and the angle linear gaps with respect to fluid flow. The gap between an electrode pair may be a single, linear gap of constant gap, a single linear gap having variable width, or a be in the form of two or more linear gaps having constant or variable gap width having different angles with respect to one another and to the flow.

Pant, Kapil↗
NASA NTRS1974

Long life, rechargeable nickel-zinc battery

A production version of the inorganic separator was evaluated for improving the life of the nickel-zinc system. Nickel-zinc cells (7-10 Ah capacities) of different electrode separator configurations were constructed and tested. The nickel-zinc cells using the inorganic separator encasing the zinc electrode, the nickel electrode, or both electrodes had shorter lives than cells using Visking and cellophane separation. Cells with the inorganic separation all fell below 70% of their theoretical capacity within 30 cycles, but the cells constructed with organic separation required 80 cycles. Failure of the cells using the ceramic separator was irreversible capacity degradation due to zinc loss through cracks developed in the inorganic separator. Zinc loss through the separator was minimized with the use of combinations of the inorganic separator with Visking and cellophane. Cells using the combined separation operated 130 duty cycles before degrading to 70% of their theoretical capacity.

Luksha, E.↗
DOE OSTI2026

Accelerating Laboratory-Based, All-Solid-State Battery Research and Development: Industrially Relevant Small-Batch Dry-Processing, Small and Low-Cost Test Fixtures, and Short-Tolerant Separators

This work presents improvements to mixing (for dry-processed electrodes), separator robustness, and cell testing jigs for all-solid-state batteries (ASSBs). These developments combine synergistically to enable rapid research and development of ASSB catholytes. A mechanical "kneader" is designed and built which emulates the mixing and fibrillation of poly-tetrafluoroethylene binder that occurs in industrially relevant twin-screw extruders. A modest improvement in the mixing and dispersion catholyte materials is observed using micro-resolution X-ray computed tomography (X-ray CT). Catholytes are paired with an In-metal anode and separated by a novel, dual-layer, polyaramid-fiber-supported, sulfide-solid electrolyte (Li6 PS5 Cl) separator. This separator achieves high short tolerance which enabled a 95% success rate across 20 attempted cells and to date over 100 successful cells have been built. ASSBs were tested in a 2032 coin-cell format. Simultaneous cycling of a large number of cells is further enabled by a compact and low cost (~ 38 USD per jig) pressure application jig of which 100 have been constructed to date. The utility of these advances is demonstrated through a brief study on the effect cathode-side conductive carbon and current collector type has on capacity and rate performance.

25 ENERGY STORAGE↗
NASA NTRS1992

High temperature solder device for flat cables

A high temperature solder device for flat cables includes a microwelder, an anvil which acts as a heat sink and supports a flexible flat ribbon cable that is to be connected to a multiple pin connector. The microwelder is made from a modified commercially available resistance welding machine such as the Split Tip Electrode microwelder by Weltek, which consists of two separate electrode halves with a removable dielectric spacer in between. The microwelder is not used to weld the items together, but to provide a controlled compressive force on, and energy pulse to, a solder preform placed between a pin of the connector and a conductor of the flexible flat ribbon cable. When the microwelder is operated, an electric pulse will flow down one electrode, through the solder preform and back up the other electrode. This pulse of electrical energy will cause the solder preform to heat up and melt, joining the pin and conductor.

Haehner, Carl L.↗
DOE OSTI2022

Molten fluid apparatus with solid non-brittle electrolyte

A battery includes a fluid negative electrode and a fluid positive electrode separated by a solid electrolyte at least when the electrodes and electrolyte are at an operating temperature. The solid electrolyte includes ions of the negative electrode material forming the fluid negative electrode and has a softness less than beta-alumina solid electrolyte (BASE) ceramics. In one example, the fluid negative electrode comprises lithium (Li), the fluid positive electrode comprises sulfur (S) and the solid electrolyte comprises lithium iodide (LiI).

Vissers, Daniel R.↗