N093-197 TITLE: Improved Safety in Large Format Lithium-Ion Cells and Batteries

TECHNOLOGY AREAS: Ground/Sea Vehicles, Electronics

ACQUISITION PROGRAM: PMS399 Special Operations Forces Undersea Mobility Program Office - ASDS

OBJECTIVE: To develop large format lithium-ion cells and batteries that can provide total capacities in excess of 1 Mega-watthour (MWh) while demonstrating improved safety characteristics that reduce the effects of cell failures, eliminate the propagation of cell failures, and thereby reduce the system impact of failure to levels acceptable for use on Navy underwater platforms.

DESCRIPTION: Lithium-Ion systems are more volumetric and gravimetrically efficient than other rechargeable battery systems that can provide cycle life in excess of 200 cycles and 5 years wet life. Unfortunately, energetic failure of a cell normally results in damage to adjacent cells, to battery hardware and to platforms, which can propagate throughout the system. 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.

Although there has been previous work done in methods to improve the safety of small scale Li-Ion batteries, these solutions do not work when scaled up to the sizes and capacities needed to provide primary power for a combatant submersible. This topic seeks innovative methods to improve the inherrent safety of very large scale Li-Ion batteries.

This solicitation seeks innovative improvements in battery and cell technologies that can be incorporated into large-scale Lithium-Ion battery and cell technologies (e.g. possible alternate electrode, electrolyte, or cell component materials) which reduce the energetics of a catastrophic cell failure, and make the cell robust against thermal runaway and against thermal abuse in such a manner as to prevent propagation. These safety modifications must be able to be made while still maintaining cell-level specific energy in the range of 150 to 200 Wh/kg and cell energy density in the range of 300 to 400 Wh/l. The offeror shall target cell sizes ranging from 100 Ah to 500Ah or larger, with cycle life targets in excess of 200 cycles over 5 years.

This solicitation also seeks innovative assembly-level and system-level approaches which reduce the energetics and impact of a catastrophic cell failure and prevent the propagation of a cell failure. Approaches can include mechanical, chemical, thermal methods or otherwise, but should be applicable and effective in addressing the unique needs of high voltage (300 V) and high capacity systems (in excess of 1 MWh), while maintaining system-level specific energy in the range of 140 to 160 Wh/kg and system-level energy density in the range of 250 to 350 Wh/l. Assembly-level and system-level approaches should also consider the need in many situations to break high capacity systems into multiple modular units (e.g. 50 to 100 kWh) which are installed inside pressure vessels for underwater use.

PHASE I: Perform basic R&D to further develop battery and cell technology for safe very large scale Li-ion batteries. Conduct a feasibility demonstration of proposed innovative new material or design concepts, that limit the energetics of lithium-ion cell failure and prevent failure propagation, in a laboratory environment. Demonstrate by engineering analysis that the materials and design concepts are scalable, and will improve the safety of large scale Li-Ion battery applications in high voltage (300 V) and high capacity systems (in excess of 1 MWh), without sacrificing performance significantly. Analyze these designs based on factors listed above, including reliability, efficiency, weight, EMI considerations, size, and predicted cycle life, in addition to the inherent safety of the battery system itself.

PHASE II: Implement and verify the design and concepts from Phase I in full-size cells and full-scale multi-cell modules. Develop prototype battery management system to safely regulate the cells during charge and discharge evolutions. Build prototypes, and conduct proof-of-concept testing in a laboratory environment. This testing should include long term cycle testing and safety testing per reference 1 to assess the safety and performance of the new design. Validate efficiency and energy and power density storage of prototype systems. Develop final Engineering Development Models (EDMs) 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 systems, including shock, vibration, and Scope of Certification testing for Navy Deep Submergence System use. 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: The safety of lithium batteries has long been a concern and use of the technology is limited because of the safety features. If this program is successful more platforms and commercial sectors, including the hybrid and electric car industry, airline industry, and space industry could realize the benefits of the technology.

REFERENCES:
1. NAVSEAINST 9310.1B, Naval Lithium Battery Safety Program

KEYWORDS: lithium-ion; failure; propagation; safety; prevention; mitigation

** TOPIC AUTHOR (TPOC) **

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