N101-031 TITLE: Non-Flammable Electrolyte for Naval Aviation Lithium Batteries

TECHNOLOGY AREAS: Air Platform

ACQUISITION PROGRAM: Joint Strike Fighter, ACAT I, PMA-276, H-1 Light Attack Helicopter Program

OBJECTIVE: Develop a non-flammable electrolyte to significantly increase the safety and reliability of Lithium batteries used on Navy aircraft.

DESCRIPTION: Increased demand of mission requirements placed on Navy aircraft and other military applications have necessitated high energy and high power storage systems capable of operating over a broad temperature range. High energy Lithium battery systems have proven themselves in many military, commercial and aerospace applications, and present programs are underway to develop high energy Lithium batteries for Navy aircraft. However, present Lithium batteries use electrolytes incorporating a Lithium salt in an organic solvent. When overheated due to overcharging, internal shorting, manufacturing defects, physical damage, or other failure mechanisms, such electrolytes have the disadvantage of high flammability, releasing highly toxic chemicals when combusted. Eliminating all failure mechanisms that lead to overheating would be difficult and expensive due to the complex operational environment of naval aircraft. Although current investigations are underway to develop Lithium battery cathode materials that do not supply oxygen to feed fires, and anode materials that do not generate excessive heat and provide the "spark" that ignites combustion, the flammability of the electrolyte is the one part of the system that has not been addressed. The development of an innovative low-cost non-flammable electrolyte will greatly improve the safety and reliability of Lithium batteries used on Navy aircraft.

The developed non-flammable electrolyte composition is to be incorporated into a complete battery system, maintaining or improving the performance of present Lithium battery technology. These performance parameters include the following: high gravimetric power density (up to 6000 W/kg), quick recharge capability (<10 minutes to recharge fully depleted cell), good cycle life (> 5,000 cycles at 100% depth of discharge), long calendar life (>5 years service and storage life), and functionality and stability over a wide temperature range (-40�C to +80�C). The battery system utilizing the non-flammable electrolyte should also meet the requirements of the cycling test detailed in MIL-PRF-29595A.

PHASE I: Demonstrate feasibility of proposed non-flammable electrolyte replacement for use in Lithium batteries. Proof-of-concept should include benefits of non-flammable electrolyte compositions, manufacturing capabilities, and cost estimates.

PHASE II: Develop, build and demonstrate a prototype non-flammable electrolyte Lithium battery system. Perform functional test and evaluation. A successful prototype demonstration must meet Naval Aviation battery requirements.

PHASE III: Integrate non-flammable electrolyte Lithium battery into Navy aircraft power system including ground and flight demonstrations. Work with weapon system contractor to transition technology across naval platforms.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The results of this work can be directly applied to provide Lithium-ion batteries with non-flammable electrolyte for use on commercial aviation applications.

REFERENCES:
1. "Navy Lithium Fire Fighting Recommendations", D. Fuentevilla, J. Banner, A. Suggs, Proceedings of the 43rd Power Sources Conference, July 7-10, 2008, Philadelphia, Pennsylvania.

2. "Safety Issue and Its Solution of Lithium-ion Batteries", S. Zhang, D. Foster, J. Wolfenstine, J. Read, Proceedings of the 43rd Power Sources Conference, July 7-10, 2008, Philadelphia, Pennsylvania.
Copies of references listed above can be obtained through National Technical Information Service (NTIS), 5285 Port Royal Road, Springfield, VA 22161-0001, http://www.ntis.gov.

3. MIL-B-29595, "Batteries and Cells, Lithium, Aircraft, General Specification For" Military Specification, 29 June 2000.

KEYWORDS: Battery Systems; Lithium; Electrical Systems; Energy Storage; Aviation; Electrolyte

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