Performance and Safety Improvement of the Li-ion 6T Battery

OUSD (R&E) MODERNIZATION PRIORITY: General Warfighting Requirements (GWR); Microelectronics TECHNOLOGY AREA(S): Materials / Processes OBJECTIVE: Develop a safer and more sustainable Li-ion 6T battery. DESCRIPTION: The current state of Li-ion 6T batteries is not capable of meeting Marine Corps needs. Transportability and operational safety are limited by current technology. Distributed Maritime Operations (DMO) will present operational challenges that current technology does not meet. Current batteries have not been certified for transportation; have limited (short duration) long-term storage; and has limited capability in austere environments. Weight and cost of the battery need to be reduced. This SBIR topic is intended to mitigate these shortcomings and provide the Marine Corps with a Li-ion 6T battery that can meet operational demands. The system requirements include: Full charge capacity (min at 1 hr. rate): 90 Ah (at 22 C) (T); 100 Ah (at 22 C) (O) at 18 30 VDC. Minimum shelf life of 10 years at 27 C (T); 72 C (O). Shelf life is determined as the ability to provide 80% of its rated capacity after being fully charged, after storage. Shall not degrade to less than 80% of rated capacity in less than 4000 cycles (T=O) to a 90% depth of discharge at the C/2 rate of the battery. Remain at 30% of rated capacity for six months at 21 - 32 C not to exceed 10% loss. The design shall address meeting the requirements of NAVSEA INSTRUCTION 9310.1C, Naval Lithium Battery Safety Program. Total Weight: 56 lbs (T); 44 lbs (O). Survivability: Must survive ballistic testing (i.e., impact of .557 caliber). Must meet SAE J2464 hazard level 6. Rapid Recharge Must be able to go from 0 80% rated charge in 120 min (T); 30 min (O). Cost: $2,000/KWh (T); $1,500/KWh (O). Deliver 5- 10 prototypes for test, evaluation, and experimentation. TRL of 6 (T), 7 (O). PHASE I: Develop concepts for an improved 6T battery that meets the requirements described above. Demonstrate the feasibility of the concepts in meeting Marine Corps needs. Establish that the concepts can be developed into a useful product for the Marine Corps. Feasibility will be established by material testing and analytical modeling, as appropriate. Provide a Phase II development plan with performance goals and key technical milestones, and that addresses technical risk reduction. PHASE II: Develop a full-scale prototype evaluation. Deliver 5 10 prototypes (TRL of 6 (T), 7 (O)) for test, evaluation, and experimentation, to include evaluation to determine their capability in meeting the performance goals defined in the Phase II development plan and the Marine Corps requirements for the Improved 6T Battery. System performance will be demonstrated through prototype evaluation and modeling or analytical methods over the required range of parameters including numerous deployment cycles. Evaluation results will be used to refine the prototype into an initial design that will meet Marine Corps requirements. Provide a detailed plan for meeting NAVSEA Instruction 9310.1C. Prepare a Phase III development plan to transition the technology to Marine Corps use. PHASE III DUAL USE APPLICATIONS: Support the Marine Corps in transitioning the technology for Marine Corps use. Develop an Improved 6T Battery for evaluation to determine its effectiveness in an operationally relevant environment. Support the Marine Corps for test and validation to certify and qualify the system for Marine Corps use. There is no dual-use application for this form factor (6T) battery beyond the DoD. However, the cell technology inside the form factor may be transferable to commercial battery applications and designs, e.g., shelf life, degraded capacity. REFERENCES: Advanced Battery Manufacturing Technologies. Sciligent. BAA Topic Number DLA142-001, 2014, Defense Logistics Agency. https://www.dodsbirsttr.mil/submissions/baa-schedule/broad-agency-announcements MIL-PRF-32565, Compliant Battery Maintenance & Charging System MIL-PRF-32565 BATTERY RECHARGEABLE SEALED 6T (everyspec.com) MIL-STD 1275E, Compliant Vehicle Charging System. MIL-STD-1275 E INTERFACE CHARACTERISTICS 28 VOLT DC (everyspec.com) MIL-PRF-32143B, BATTERIES, STORAGE: AUTOMOTIVE, VALVE REGULATED LEAD ACID (VRLA). http://www.everyspec.com/MIL-PRF/MIL-PRF-030000-79999/download.php?spec=MIL-PRF-32143B.037624.PDF SAE J2464_200911, Hazard Severity Level (R) Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing. f SAE International, November 6, 2009. https://www.sae.org/standards/content/j2464_200911/ NAVSEA INSTRUCTION 9310.1C, Naval Lithium Battery Safety Program. https://nps.edu/documents/111291366/111353854/NAVSEAINST+9310+1C+08.12.15.pdf/0f5b8c13-b5d1-4f28-b9aa-cf607a6ac1f6?t=1450394616000 SG270-BV-SAF-010, High-Energy Storage System Safety Manual. http://everyspec.com/USN/NAVSEA/SG270-BV-SAF-010_27APR2011_50446/ KEYWORDS: Battery; 6T; Lithium; Zero-volt; Rapid Charging; Vehicle; Safety