Jeffrey P. Zagrodnik

Innovative valve-regulated battery designs rekindle excitement inlead/acid battery technology

Abstract Recent innovative approaches to the extension of valve-regulated lead/acid (VRLA) technology have led to thedevelopment of several unique products that possess performance attributes not previously achieved in lead/acid technologies, namely: (i)starting, lighting, ignition (SLI) VRLA batteries; (ii) StackPack™ foil batteries, and (iii) spiral-wound Thin Metal Film (TMF ™) batteries.TheVRLA automotive product has been demonstrated to be capable of improving on the durability of conventional flooded designs in extreme high-temperature climate and extreme drive-cycle operating conditions. In uninterruptible power supply (UPS) applications, the StackPack™ battery, at a 15-min discharge rate has delivered 23.3 Wh kg−1 and 1090 Wh 1−1 as compared with 16.0 Wh kg−1 and 595 Wh 1−1 for traditional designs. TMF™ prototypes have exhibited power capability of an order of magnitude higher than conventional VRLA designs and have been utilized successfully in a vehicle for seven months and over 31 000 km (19 200 miles).

Multiple cell common pressure vessel nickelhydrogen battery

Abstract Johnson Controls Battery Group, Inc. has developed a multiple cell common pressure vessel (CPV) nickelue5f8hydrogen battery that offers significant weight, volume, cost and interfacing advantages over the conventional individual pressure vessel (IPV) nickelue5f8hydrogen configuration that is currently used for aerospace applications. The baseline CPV design was successfully demonstrated through the testing of a 26-cell prototype, which completed over 7000 44% depth-of-discharge LEO cycles at COMSAT Laboratories. Two-cell boilerplate batteries have now exceeded 12 500 LEO cycles in ongoing laboratory tests. CPV batteries using both nominal 12.7 and 25.4 cm diameter vessels are currently available. The flexibility of the design allows these diameters to provide a broad capability for a variety of space applications.

Development Of Common Pressure Vessel Nickeuhydrogen Batteries

The individual pressure vessel (IPV) Nickel/Hydrogen subsystem for commercial communication satellites. The Advanced Battery Engineering Group at Johnson Controls, Inc. (JCI), working with Sandia National Laboratories (SNL) has adapted this technology to terrestrial applications by developing unique design features and Implementing standardized production methods that have resulted in substantial reductions in the battery cost. One of the key design variations of the terrestrial battery is the use of a common pressure vessel (CPV). The battery design cycle has now gone full circle with the ongoing development by JCI and COMSAT of a CPV battery for aerospace applications which provides the potential for significant specific energy and life advantages as compared to the aerospace IPV technology.

Photovoltaic testing of 2 kWh common pressure vessel nickel hydrogen batteries

A common pressure vessel (CPV) nickel-hydrogen battery for terrestrial applications has been developed. A 7 kWh boilerplate battery and four 2 kWh batteries are being tested for a variety of photovoltaic applications. During initial testing, the 7 kWh battery delivered 7.85 kWh. In recent testing, the battery delivered over 9.5 kWh. From the onset of testing, one cell in one 2 kWh battery showed evidence of shorting, resulting in a reduced voltage and capacity. Despite this problem, the series-connected battery pair has consistently delivered more than the nominal 4 kWh energy capacity during characterization cycling.<<ETX>>

Nickel-hydrogen multicell common pressure vessel battery development update

Flight qualification of the multicell common pressure vessel (CPV) nickel-hydrogen (Ni-H/sub 2/) battery is discussed. The battery has completed full flight qualification, including random vibration at 19.5 g for two minutes in each axis, electrical characterization in a thermal vacuum chamber, and mass-spectroscopy vessel leak detection. A first launch is scheduled in 1992. Several design variations, ranging from 9 Ah to 125 Ah and 12 to 32 V, have been developed and prototypes fabricated. Designs for smaller capacity, smaller diameter (6.4-8.9 cm), and higher voltage (up to 100 V) are in progress. The CPV battery offers cost and weight savings of up to 30% as compared to traditional nickel-cadmium (Ni-Cd) and individual pressure vessel (IPV) Ni-H/sub 2/ batteries. The fully qualified design provided a 50% weight savings over its Nd-Cd predecessor for the same application. Its reduced volume also provides a significant advantage over IPV technology. Resistance data show a further advantage.<<ETX>>

Development of advanced battery systems for vehicle applications

The Advanced Battery Business Unit (ABBU) of Johnson Controls, Inc. is developing several promising advanced battery technologies including flow-through lead-acid, zinc/bromine, and nickel hydrogen. The flow-through lead-acid technology, which is being developed under Department of Energy (DOE) sponsorship, is progressing towards the fabrication of a 39 kWh battery system. Recent efforts have focused on achieving the aggressive specific energy goal of 56 Wh/kg in 12 volt module form. Recent DOE sponsored work in the zinc/bromine program has focused on the development of a proof-of concept 50 kWh electric vehicle system for a light van application. Efforts in the nickel hydrogen program have focused on reducing system cost in order to make the life-time premium market and EV market possible targets. The status and future direction of each of these programs are summarized.

Multiple Cell CPV Nickel Hydrogen Battery

Johnson Controls, Inc. has developed a multiple cell CPV nickel hydrogen battery that offers significant weight, volume, and cost advantages for aerospace applications. The baseline design was successfully demonstrated through the testing of a 26-cell prototype, which completed over 7000 44 percent depth-of-discharge low earth orbit cycles. Prototype designs using both nominal 5 and 10 inch diameter vessels are currently being developed for a variety of customers and applications.

THE ZINC/BROMINE BATTERY: RECENT ADVANCES FOR ELECTRIC VEHICLE APPLICATIONS

The advanced Battery Business unit of Johnson Controls, Inc. (JCI) is developing the zinc/bromine battery for elecctric vehicle applications. The batterys potential for good energy density, low manufacturing cost, and long life make itt a particularly attractive candidate. Other advantages include ambient temperature operation, a modular design which facilitates design flexibility, and minimal maintenance.