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NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Background
For powering spacesuits,
NASA is considering using a
battery pack consisting of
arrays (16P-5S) of 18650 Li-
ion cells.
These cells are equipped with
a positive temperature
coefficient (PTC) device
proven effective for control of
overcurrent hazards at the Li-
ion cell and small battery level.
However, PTC devices are not
as effective in high-voltage
battery designs.
A fire in a 2004 Memphis
FedEx facility suspected to be
due to a PTC device failure in
a large-capacity (66p-2s)
battery shorted while at 50%
SOC.
*Doljack, F., IEEE Transactions on Components, Hybrids, and Manufacturing Technology, 4, 732, 1981
National Renewable Energy Laboratory 3 Innovation for Our Energy Future
Cell Design Features for Abuse Tolerance
Separator
Electrode
Negative
Positive
0 50 100 150 200 250 300
0 20 40 60 80 Sec
*G.-H. Kim, A. Pesaran, Analysis of heat dissipation in Li-ion cells and modules for modeling of thermal runaway, 3rd International Symposium on Large Lithium Ion Battery Technology and Application, Long Beach,
CA, May 2007. Available: www.nrel.gov/vehiclesandfuels/energystorage/
Chemical Thermal
1
700
2
3
600 4
+
5
Reaction Network
6
500
7
8
400 9
10
Model Model
11
300 12
13
14
200
15
16
100 17
18
19
0
0 10 20 30 40 50 60 70 80 90 100 20
Present Work:
Verify module design tolerant
to external electrical short
Thermal
Electrical
Model + Network
Model
Photo: Symmetry Resources Inc.
National Renewable Energy Laboratory 9 Innovation for Our Energy Future
PTC Resistance versus Temperature;
Moli ICR-18650J
Cell header removed from cell without disturbing closure configuration
Resistance measurements taken from rupture disk surface to positive button
1.0E+06
1.0E+05
1.0E+04
Phase
Resistance (ohms)
1.0E+03
Transition
1.0E+02
1.0E+01
1.0E+00
1.0E-01
1.0E-02
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
Temperature (deg. C)
PTC 71A06 virgin PTC 71A07 virgin PTC 71A08 virgin PTC 71A09 tripped
T2 T3
2
5 4 3 1 T1 T4
5-Node Thermal
Thermal T10 T5 Network
Model Ambient
Model
K5a K4a K3a K1a T9 T6
5.Jelly 4.Jelly 3.Jelly 1.Top
2.PTC
Bottom Middle Top Button
K45 K34 K23 K12 T8 T7
Jellyroll PTC
1
1 = Q = 2.345 A-h
R1C1
d SOC 0 0 SOC 1 / Q
= + I (t )
V
dt 1 0 1 V1 R
1 1
T [oC] MESH
Detailed Cell
Thermal
Model Finite Volume Method
41,250 computational grid
temperature [ oC]
C PTC:2.0W, Jelly:0.0093W
C D PTC:1.0W, Jelly:0.0093W
100
E PTC:1.0W, Jelly:1.0W
80 E
D
60
Top button
PTC
Jelly top
Jelly middle
Jelly bottom
Suitable for multi-cell modeling
2
5 4 3 1
Steady Form
Qi = K ij (Ti T j )
Ambient j
Imeas
Rptc
Data: SRI
Zjr Vmeas Rshort
Jellyroll Resistance V0 +
-
+
-
+
-
1 2 16
as a function of cell temperature
Open-Circuit Voltage
as a function of cell SOC
Rjr = 6.172e-5 exp(2178/T)
Qtransport ,i = Q ,
j =1, j i
ij Qij = Qij ,radiation + Qij ,connector _ conduction + Qij ,convection
D F
d/D
140
m1x
T T Ae m1x
Be 0 x xl
Through Wires 120
T T Ce m2x
x xl
Qi a hAi a (Ti T )
100
T [ C]
o
80
60
40
20
0 5 10 15 20 25 30 35 40 45 50
x [c m ]
Li j
R connector ,i j
k i j Ai j Heat Conduction
Through
g Air-Gapp
1 Peak inrush current readily predicted with knowledge of cell & short resistances.
Max Temperature
Adequate
SOC-limited
PTC-limited
thermal
dissipation
required
small large
Rshort
National Renewable Energy Laboratory 24 Innovation for Our Energy Future
Simulation Results at Various Values of Rshort
Rshort 40 m: PTC-limited
Rshort 50 m: SOC-limited
Jellyroll
Less rejection causes an
increase in jellyroll
temperature.
Post-trip
Post-trip, the PTC device
reduces heat generation rate
as heat rejection decreases.
Max Temperature
SOC-limited
PTC-limited
tolerant to a wide range of external shorts for
the 16p configuration of a spacesuit battery, as
long as
No damage occurs due to the in-rush current
transient Rshort
Nominal tripping of cell PTC devices and steady-
state conditions occur
External short does not excessively heat battery.
conditions.
National Renewable Energy Laboratory 28 Innovation for Our Energy Future
Acknowledgements