ALBERT

Description: Two experimental techniques - equilibrium or reversible cell discharge and measurement of open circuit potential as a function of temperature - are used to determine the thermodynamic data needed to estimate the heat generation characteristics of Li/BCX and Li/SOCl2 cells. The results obtained showed that the reversible cell potential, the temperature dependence of the reversible cell potential, and the thermoneutral potential of the BCX cell were 3.74 V, -0.857 +/- 0.198 mV/K, and 3.994 +/- 0.0603 V, respectively. The respective values obtained for the Li/SOCl2 cell were 3.67 V, -0.776 +/- 0.255 mV/K, and 3.893 +/- 0.0776 V. The difference between the thermoneutral potential of Li/BCX and Li/SCl2 cells is attributable to the difference in their electroactive components.

Description: The bulk heat capacities of Li/BCX and Li/SOClN2 cells were determined at 0 and 100 percent depth-of-discharge for 2.0 V cut-off voltage, in the temperature range 0 to 60 C by a method that did not involve the destruction of the cell nor the contact of cell with a liquid. The heat capacities are found to be dependent on state-of-charge, increasing with depth-of-discharge. The Li/BCX DD-cell has a lower heat capacity than a high rate Li/SOCl2 D-cell. The results obtained by this method compare favorably well with results reported in the literature through other methods. The bulk heat capacities of the cells did not change significantly in the temperature range 0 to 60 C.

Description: Results are presented of the calorimetric determination of the effective thermoneutral potential, Eetp, of Li/BCS and Li/SOCl2 cells in the temperature range 0-60 C through a continuous recording of the cell voltage, heat flow, and current. The average effective thermoneutral potential at 25 C was 4.0 and 3.84 V for BCX and Li/SOCl2 cells, respectively. Based on the classical approach, the reversible cell potential, Er, and temperature dependence of reversible cell potential, dEr/dT, for BCX cell were 3.74 V and -0.952 mV/K, respectively, and for Li/SOCl2, Er = 3.67 V and dEr/dT = 0.567 mV/K. The thermal polarization (Eetp-E1), where E1 is the load voltage, for both cells, showed that they are the most thermally efficient near 40 C. An overall reaction proposed for the BCX chemistry is supported by the calculated thermodynamic parameters.

Description: Aluminum, neopentyl glycol (NPG), and resins FT and KT are evaluated theoretically and experimentally as heat sink materials for lithium battery packs. The thermal performances of the two resins are compared in a thermal vacuum experiment. As solutions to the sublimation property were not immediately apparent, a theoretical comparison of the thermal performance of NPG versus KT, Al, and no material, is presented.

Description: Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Description: A crew emergency return vehicle (CERV) is proposed to perform the lifeboat function for the manned Space Station Freedom. This escape module will be permanently docked to Freedom and, on demand, will be capable of safely returning the crew to earth. The unique requirements that the CERV imposes on its power source are presented, power source options are examined, and a baseline system is selected. It consists of an active Li-BCX DD-cell modular battery system and was chosen for the maturity of its man-rated design and its low development costs.

Description: The Extravehicular Mobility Unit (EMU) suit currently has a silver-zinc battery that is 20.5 V and 45 Ah capacity. The EMU's portable life support system (PLSS) will draw power from the battery during the entire period of an EVA. Due to the disadvantages of using the silver-zinc battery in terms of cost and performance, a new high energy density battery is being developed for future use, The new battery (Lithium-ion battery or LIB) will consist of Li-ion polymer cells that will provide power to the EMU suit. The battery design consists of five 8 Ah cells in parallel to form a single module of 40 Ah and five such modules will be placed in series to give a 20.5 V, 40 Ah battery. Charging will be accomplished on the Shuttle or Station using the new LIB charger or the existing ALPS (Air Lock Power Supply) charger. The LIB delivers a maximum of 3.8 A on the average, for seven continuous hours, at voltages ranging from 20.5 V to 16.0 V and it should be capable of supporting transient pulses during start up and once every hour to support PLSS fan and pump operation. Figure 1 shows the placement of the battery in the backpack area of the EMU suit. The battery and cells will undergo testing under different conditions to understand its performance and safety characteristics.