Safe High Performing Rechargeable Military Battery

TECHNOLOGY AREA(S): Materials OBJECTIVE: To provide a safe high specific energy battery utilizing the BB-2590 form factor and incorporating high performance rechargeable chemistry to enable extended runtime for needed capabilities. DESCRIPTION: Program Executive Office Command Control and Communications-Tactical (PEO C3T) and Communications Electronics Research, Development and Engineering Center (CERDEC) are seeking safe energy dense power sources. Specifically, Program Manager Tactical Radio (PM TR) and Program Manager Mission Command (PM MC), have utilized the BB-2590 form factor battery for dismounted operations. [1,2] The BB-2590 offers the highest energy density (210 Wh/kg) of currently available rechargeable military batteries. However, the current state of the art falls short of meeting mission requirements, 72 hour missions and < 2.2 lbs. (1 kg). An energy dense BB-2590 battery will increase runtime and reduce the weight burden of the dismounted soldier however, increased performance cannot be sacrificed for the safety of the soldier. [3] New chemistries such as Li metal anode, silicon anode, or lithium sulfur show promise to advance the energy density of that currently available (210 Wh/kg). [4,5,6,7] Threshold and objective targets are given here: threshold (T), 300 Wh/kg (~350-400 Wh/kg cell level) and objective (O), 400 Wh/kg (~450-500 Wh/kg cell level). Cell safety tests should include overcharge, short circuit, forced discharge, nail penetration test, and crush test. [8] Also it's important to note that while the particular focus of this topic is the BB-2590 form factor developers may find opportunity in other commercial or military battery form factors, such as the conformal wearable battery (CWB). The performance goals for this topic are shown in Table 1. Table 1: Program End Goals for High Performance BB-2590 [4,5] Voltage range: 20-33 V, two(2) 10-16.5 V section Nominal voltage: 28.8 V, two(2) 14.4 V section Nominal capacity: (T) 9.9 Ah @ 28.8 V, 19.8 Ah @ 14.4 V (O) 11.2 Ah @ 28.8 V, 22.4 Ah @ 14.4 V Nominal energy (new battery): (T) 285 Wh at C/5 (O) 322 Wh at C/5 Battery life: = 224 cycles, = 3 years ; 80% capacity retention Rated power output: = 148 W Continuous load rating: = 10.0 A Pulse load rating: 18 A (5 sec pulse, 25 sec rest) Operating temperature range: -4 to 131oF (-20 to 55oC) Storage temperature range: -4 to 131oF (-20 to 55oC) Overall dimensions: 4.4 in. (l) x 2.4 in. (w) x 5.0 in. (h) Mass: (T) 2.1 lbs (0.95 kg) (O) 1.75 lbs (0.81 kg) PHASE I: Phase I: This phase consists of development and fabrication of prototype pouch or cylindrical cells to demonstrate the targets in Table 1. Deliverables include: o 10x prototype pouch or cylindrical cells, TRL 4, for CERDEC evaluation to ensure cells meet specification, Table 1. o Monthly Progress reports. The reports will include all technical challenges, technical risk, and progress against the schedule. PHASE II: Phase II: Modify design based upon test and evaluation from phase I. Integration of cells into a BB-2590 form factor for demonstration. Testing to safety standards found in MIL-PRF-32383. Phase II deliverables will include: o 10x prototype 2590 form factor batteries, TRL 5. o Monthly Progress reports. The reports will include all technical challenges, technical risk, and progress against the schedule. o Safety Assessment Report o A baseline schedule for phase III. PHASE III: Develop and demonstrate a prototype solution that builds on and matures the Phase II battery development. The battery solution should be qualified and prepared for transition to PEO C3T Program Manager Tactical Radio and/or Program Manager Mission Command. At the performer's discretion, the solution may be productized for sale to other industry markets. Phase III deliverable will include: o 100x prototype 2590 form factor batteries for development and operational testing to bring to a TRL 6/7. o Demonstration of batteries with PM TR Manpack radios and PM MC dismounted operations. o Test reports detailing solution performance o Product documentation detailing operation of the prototype o Monthly Progress Reports. The reports will include all technical challenges, technical risk, and progress against the schedule. REFERENCES: 1: PEO C3T Portfolio Book http://peoc3t.army.mil/c3t/docs/2017-Portfolio-Book.pdf2: PEO C3T Annual Report 2016 http://peoc3t.army.mil/c3t/docs/2016-Annual-Report.pdf3: CERDEC Tactical and Deployed Power https://www.cerdec.army.mil/inside_cerdec/core_technology/tactical_and_deployed_power/4: BB-2590 technical specs http://www.bren-tronics.com/bt-70791ck.html5: High Capacity BB-2590 technical specs http://www.bren-tronics.com/bt-70791jv.htm6: Zuo X., Zhu J., Muller-Buschbaum P., Cheng Y.-J. (2017). Silicon based Lithium-ion battery anodes: A chronicle perspective review. Nano Energy, 31, pp 113-143. http://www.sciencedirect.com/science/article/pii/S22112855163049317: Cheng X.-B., Zhang R., Zhao C.-Z., Zhang Q. (2017). Toward Safe Lithium Metal Anode in Rechargeable Batteries: A Review. Chemical Reviews, 117(15), pp 10403-104 http://pubs.acs.org/doi/abs/10.1021/acs.chemrev.7b0011573.8: MIL-PRF-32383 http://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=277787KEYWORDS: BB-2590, Rechargeable Cells, Electrochemical Energy Storage, Logistics, Dismounted, Manpack Radio, JBCP, Battery