Nail Penetration Adapter for Li-Ion Battery Testing

This technology is based upon a 120-watt IR laser is coupled to a fiber optic cable that is routed from the output of the laser into a series of focusing optics which directs energy onto a battery cell mounted to a test stand. When activated, heat from the laser penetrates the metal housing, heating the internals of the cell. At a specific temperature, the separator in the first few layers of the cell melts allowing the anode and cathode to make contact and initiates an internal short circuit. The internal short circuit then propagates throughout the battery eventually causing thermal runaway. The lower the wavelength of the laser used to produce the thermal runaway, the more heat-energy will be absorbed into the cell producing a faster result. The fiber optic cable can be terminated into a series of optics to focus the laser at a specific target, or the fiber optic cable can be stripped bare and placed next to the target to heat an isolated location. This method can also be used on a wide variety of cells, including Li-ion pouch cells, Li-ion cylindrical cells and Li-ion Large format cells. The innovation Triggering Li-ion Cells with Laser Radiation is at TRL 6 (which means a system/subsystem prototype has been demonstrated in a relevant environment) and the related patent application is now available to license and develop into a commercial product. Please note that NASA does not manufacture products itself for commercial sale.

The CFRP sleeve was originally intended for crewed space flight lithium-ion 18650 battery packs rated over 80 Watt-hours (Wh), which are required to be passively propagation-resistant for increased safety. Previous battery designs have addressed SWR propagation by using aluminum or steel interstitial materials to prevent SWRs from directly impacting neighboring cells, but these materials were underperforming. During testing of 18650 battery cells, it was discovered that cells over 2.6Ah in capacity can have an undesirable failure mode in which the cell wall will rupture or breach during a thermal runaway (TR) event sending heat and ejecta into an undesirable direction. TR is typically triggered when heat produced by the battery cell’s exothermic reaction leads to increased and escalating internal cell temperature, pressure, and boiling of the electrolytes. When internal cell pressure exceeds the cell’s safety relief mechanism, rupture or bursting can occur, initiating a cell-to-cell propagation that in turn results in a battery pack fire. By adding a carbon fiber reinforced polymer (CFRP) sleeve to cylindrical battery cells, a sidewall rupture (SWR) can be prevented from occurring or propagating. In initial testing, there were no SWRs of a battery cell using a CFRP sleeve. This result is believed to be due in part to a unique characteristic of CFRP sleeves compared to other materials. Carbon fiber material has a negative coefficient of expansion and accordingly shrinks when heated, while steel and aluminum expand. The shrinking of the CFRP sleeve when heated compresses the cell located within it, significantly aiding in the prevention of SWR. This technology can be implemented into other multi-physics battery safety models to guide the design of the next generation of battery cells and battery packs. This thermal runaway propagation resistant technology has a technology readiness level (TRL) of 6 (System/sub-system model or prototype demonstration in an operational environment) and is now available for patent licensing. Please note that NASA does not manufacture products itself for commercial sale.

Li-ion batteries are an integral part of energy storage systems used in NASA's Exploration program, as well as many modern terrestrial industries. Innovators at the NASA Johnson Space Center wanted a better way to measure total and fractional heat response of specific types of Li-ion cells when driven into a thermal runaway condition. They developed a calorimeter with at least two chambers, one for the battery cell under test and at least one other chamber for receiving the thermal runaway ejecta debris. Both are designed to be structurally strong and thermally insulated. When the test cell is intentionally driven into thermal runaway, ejecta explodes into the ejecta chamber and is decelerated and collected. Thermal sensors are strategically placed throughout the chambers to collect thermal data during the test. Customized software analyzes the thermal data and determines key calorimeter parameters with a high degree of accuracy.

Astronauts' lives depend on the safe performance and reliability of lithium-ion (Li-ion) batteries when they are working and living on the International Space Station. These batteries are used to power everything such as communications systems, laptop computers, and breathing devices. Their reliance on safe use of Li-ion batteries led to the research and development of a new device that can more precisely trigger internal short circuits, predict reactions, and establish safeguards through the design of the battery cells and packs. Commercial applications for this device exist as well, as millions of cell phones, laptops, and electronic drive vehicles use Li-ion batteries every day. In helping manufacturers understand why and how Li-ion batteries overheat, this technology improves testing and quality control processes. The uniqueness of this device can be attributed to its simplicity. In a particular embodiment, it is comprised of a small copper and aluminum disc, a copper puck, polyethylene or polypropylene separator, and a layer of wax as thin as the diameter of one human hair. After implantation of the device in a cell, an internal short circuit is induced by exposing the cell to higher temperatures and melting the wax, which is then wicked away by the separator, cathode, and anode, leaving the remaining metal components to come into contact and induce an internal short. Sensors record the cell's reactions. Testing the battery response to the induced internal short provides a 100% reliable testing method to safely test battery containment designs for thermal runaway. This jointly developed and patented technology is available for your company to license and develop into a commercial product. NASA does not manufacture products for commercial sale.

The technology is comprised of a simple and reliable circuit that detects a single bad cell within a battery pack of hundreds of cells and it can monitor and balance the charge of individual cells in series. NASA's BMS is cost effective and can enhance safety and extend the life of critical battery systems, including high-voltage Li-ion batteries that are used in electric vehicles and other next-generation renewable energy applications. The BMS uses saturating transformers in a matrix arrangement to monitor cell voltage and balance the charge of individual battery cells that are in series within a battery string. The system includes a monitoring array and a voltage sensing and balancing system that integrates simply and efficiently with the battery cell array, limiting the number of pins and the complexity of circuitry in the battery. The arrangement has inherent galvanic isolation, low cell leakage currents, and allows a single bad or imbalanced cell in a series of several hundred to be identified. Cell balancing in multi-cell battery strings compensates for weaker cells by equalizing the charge on all the cells in the chain, thus extending battery life. Voltage sensing helps avoid damage from over-voltage that can occur during charging and from under-voltage that can occur through excessive discharging.