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Novel Composite Pressure Vessel Structures With High Heat Transfer and Fire Resistance Properties
Navy SBIR 2010.1 - Topic N101-052 NAVSEA - Mr. Dean Putnam - dean.r.putnam@navy.mil Opens: December 10, 2009 - Closes: January 13, 2010 N101-052 TITLE: Novel Composite Pressure Vessel Structures With High Heat Transfer and Fire Resistance Properties TECHNOLOGY AREAS: Materials/Processes ACQUISITION PROGRAM: PMS399 SOF Undersea Mobility Programs - ASDS and DDS OBJECTIVE: Develop composite pressure vessels to house electronics and batteries (including large format lithium-ion cells) able to efficiently transfer heat, resist external pressures without collapse, and contain heat, pressure and combustion products without failing in the event of thermal runaway in up to three battery cells. DESCRIPTION: Several types of submersibles, including the Advanced SEAL Delivery System (ASDS), house batteries and associated electronics in externally mounted pressure vessels. These pressure vessels are currently fabricated out of Titanium to minimize weight, but at a high fabrication cost. Many of these submersibles use Lithium-Ion systems that are more volumetric and gravimetrically efficient than other rechargeable battery systems, providing cycle life in excess of 200 cycles and 5 years wet life. However, energetic failure of a cell can result in damage to adjacent cells, to battery hardware, and ultimately to the host platform in the event the pressure vessel is breached. The impact and severity of failure propagation increases with the size of the battery, with a corresponding increase in the likelihood and severity of collateral damage to peripheral assets. As batteries are charged or discharged, heat builds up in the cells, increasing the chance of thermal runaway of a given cell. Standard composite materials are not highly efficient at transferring heat. This topic solicits a novel composite material and method of fabricating it into a pressure vessel that would maximize the transfer of any heat developed by the battery and electronics from within a composite pressure vessel to the ambient environment (i.e. seawater). Thermal conductivity shall be as close as possible to that of titanium. The pressure vessel must be able to do this while maintaining sufficient structural strength to withstand external collapse pressures, that is not implode. The external pressure varies, but the composite pressure vessel must be able to withstand pressure differentials (external to internal) of 1,000 PSI (threshold) and 1,100 PSI (objective). The composite vessel must also be able to withstand the heat and pressures resulting from energetic failure of up to three individual Li-Ion cells within the pressure vessel. For these Li-Ion batteries, the cell-level specific energy ranges from 150 to 200 Wh/kg and cell energy density ranges from 300 to 400 Wh/l. The offeror shall target cell sizes up to 500Ah. The pressure vessel must be able to contain all of the heat and pressure produced without failing and venting any products outside of the vessel. PHASE I: Provide feasibility assessment of a composite material and pressure vessel design. Proposals that offer to survey existing composite material in Phase I will not be considered. Show that the material and design is scalable and will improve meet the safety requirements of pressure vessels containing large scale Li-Ion battery applications in high voltage (300 V) and high capacity systems (in excess of 1 MWh), without increasing weight significantly compared to Titanium pressure vessels. Analyze the design based on factors listed above, including pressure cycling resistance, weight, thermal conductivity, and fire resistance. PHASE II: Implement and verify the design and concepts from Phase I in full-size pressure vessels capable of housing complete multi-cell Li-Ion modules and associated battery management system. Build prototype pressure vessels, and conduct proof-of-concept testing in a laboratory environment. This testing should include long term pressure cycle testing, and safety testing per reference 1 to assess the ability of the pressure vessel to withstand failures of up to three individual Li-Ion cells. Validate heat transfer efficiency and fire resistance of prototype systems. Develop one final Engineering Development Models (EDM) capable of being installed shipboard. Vendors shall submit a business plan for the commercialization of the technology developed under this topic. The Small Business Administration’s Web site, www.sba.gov, provides guidance, examples, and contact information for assistance. PHASE III: Conduct shipboard testing and suitability analysis of the EDM system, including shock and vibration testing, and implodable volume testing per reference 2. Validate safety and efficiency of EDM system in a true at-sea environment. Develop commercialization, and transition plans for full-scale shipboard implementation. Develop technical and user manuals, end-user training programs, logistics/ repair support plans, and troubleshooting and repair guides. Conduct initial end-user training and operator certification. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Lightweight composite pressure vessels that simultaneously protect contents from thermal overheating, fire and pressure would be applicable to any undersea submersible system, as well as potentially of interest to the space and airline industries. REFERENCES: 2. Julie Banner, Mark Tisher, and Glen Bowling. "When Batteries Go Bad: ‘9310’ Serious Testing for Serious Batteries," Joint Power Expo, New Orleans LA, 5-7 May 2009. http://www.dtic.mil/ndia/2009power/May6CJulieBanner/banner.pdf 3. Khairul Izman Abdul Rahim. "Wall Architecture of Pressure Hull," http://urrg.eng.usm.my/index.php?option=com_content&view=article&id=47:by-khairul-izman-abdul-rahim&catid=31:articles. (This article contains a number of references.) KEYWORDS: composites; pressure vessel ; thermal conductivity; fire resistance; batteries
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