Defense and Space Power Division Joint Service Power Expo May 2 – 5, 2005 1 Growing to meet the...

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Defense and Space Power Division

Joint Service Power Expo May 2 – 5, 2005

Growing to meet the challenge…

Development of a CFx D Cell for Man Portable Applications

Joint Service Power Expo

May 2 – 5, 2005

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• EPEPC has been a manufacturer of high capacity lithium batteries for over fifteen years

• The first production contracts were for Li/SO2 batteries followed by the development and manufacturing of Li/MnO2

batteries

• The evolution of the chemistries from a liquid to a solid cathode leads the way into the higher performance Li/CFx batteries, very high specific energy and energy density

Introduction

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• Lithium carbon mono-fluoride is the lightest and safest lithium battery, the enhanced safety can lead to simpler battery design

• However, CFx has always been a low rate system, unable to meet the requirements of the US Military

• The goal of the recent program is to develop a CFx D cell which will be close to the same weight as the SO2 D cell with twice the capacity and can be discharged at 2A and perform at -20oF, as required of Military batteries

• If the goal can be achieved the user will be able to dramatically reduce the number of batteries taken to the field. Carry more water, food and ammunition increasing deployment duration if required

Introduction

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• Discharged D cells (LC-3355) at 2A at room temperature (I), at 2A at -20oF (L) and at 2A at 131oF, five minutes on and five minutes rest (H test condition)

• In addition tested the cell at the BA-5347 power protocol at both I and L test conditions

• Finally, EPEPC built and tested the BA-5347 batteries with CFx D cells and compared the results to those obtained from BA-5347 batteries constructed with Li/MnO2 D cells

Li/CFx

Electrical Performance

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Li/CFx

CFx D cell discharged at 2A, Room Temperature

BA-5590 requirement is 3.4 hours

0.0, 3.256

8.086, 2

0

1

2

3

0 2 4 6 8 10

Time (hr)

Vo

ltag

e (

V)

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Li/CFx

Cell

Identification Capacity (Ah) Utilization (mAh/g)

Percentage of Theoretical Capacity (864 mAh/g)

CF129 15.39 720 83.3%

CF140 15.59 721 83.4%

CF149 16.17 708 81.9%

CF152 15.96 713 82.5%

CF170 15.45 720 83.3%

CF171 15.51 720 83.3%

Room Temperature Performance at 2A Three Cell Lots

Under real usage the battery would last even longer

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Li/CFx

Cell

Chemistry Capacity

(Ah) Weight (g) Volume (cc) Specific

Energy (Wh/kg)*

Energy Density (Wh/l)*

Li/SO2 7.5 80 46.74 262.5 449.3 Li/MnO2 10.5 113 46.74 260.2 629.0 Li/CFx 15.5 87 46.74 463.2 862.2

*Li/SO2 and Li/MnO2 based at 2.8V and Li/CFx based at 2.6V

Electrical Performance Comparison of Lithium Battery Chemistries at 20oC and 2A

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Li/CFx

Comparison of Lithium Batteries Discharged at 1A

0

2

4

6

8

10

12

14

16

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Li/SO2 Li/MnO2 Li/CFx

Ru

n T

ime (

hr)

7.5hr

10.5hr

15.5hr

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Li/CFx

CFx D Cell Discharged at 2A, -20oFCF035, Low temp, -20oF

0

1

2

3

8 10 12 14 16

Time (hr)

Vo

ltag

e (

V)

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Li/CFx

Cell Identification

Voltage Delay to 2.0V

(minutes) Capacity (Ah) Utilization (mAh/g)

CF026* 5.6 12.15 595

CF027* 5.6 11.64 575

CF034 7.07 12.15 595

CF035 5.8 11.64 575

* Tested as bare cells, all others tested as two cells in a box.

Low Temperature (-20oF) Performance of CFx D Cells Discharged at 2A

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Li/CFx

CFx D Cell Discharged at BA-5347 Specification, Room Temperature

CF019, RT, 4.5w for 2min; 3.25w to 2v; 2A to 0v

0

1

2

3

14 16 18 20 22 24 26 28

Time (hr)

Vo

ltag

e (V

)

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Li/CFx

CFx D Cell Discharged at BA-5347 Specification, Low Temperature

CF124, L test, 4w for 2min; 2.5w to 2v

0

1

2

3

8 10 12 14 16 18 20

Time (hr)

Vo

ltag

e (V

)

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Li/CFx

Temperature

Voltage Delay (minutes)

Capacity (Ah) Cell

Identification

CF0019 Room Temp. 0 15.35




CF124* -20oF 3.05 11.87

CF141* -20oF 3.15 10.82

* Tested as two cells in a box.

CFx D Cell Discharged at BA-5347 Specification

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• Several BA-5347 batteries were built with CFx D cells

• Batteries were tested according to the L, I and H test protocols, which are constant power and not constant current

• Batteries were also manufactured with EPEPC LiMnO2 D cells and the batteries discharged under identical conditions for comparison

Li/CFx

BA-5347 Batteries built with CFx D cells

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Li/CFx

BA-5347 Batteries built with CFx D cells – L Test (-20oF)

0

1

2

3

4

5

6

8 10 12 14 16 18 20

Time (hr)

Vo

ltag

e (

V)

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Li/CFx

BA-5347 Batteries built with CFx D cells – I Test (70oF)

0

1

2

3

4

5

6

0 2 4 6 8 10 12 14

Time (hr)

Vo

ltag

e (

V)

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Li/CFx

Comparison of BA-5347 Batteries made with CFx or MnO2 D cells

Cell Type

Test

Time to 4V (hr)

Ah Wh Battery

Volume (cc)

Wh/l Battery Weight

(g)

Wh/kg

CFx I 11.55

15.61

74.9

235 318.6

252.6 296.4

CFx L* 6.53 7.95 32.8

235 139.5

251.4 130.4

CFx H 8.35 15.44

74.9

235 318.5

255.7 292.8

MnO2 I 7.31 9.39 47.3

235 201.3

295.8 160.0

MnO2 L 5.31 6.17 21.4

235 90.9 295.7 72.3

MnO2 H 5.49 9.59 49.5

235 210.6

299.8 165.0

* Voltage delay noted

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Li/CFx

Comparison of BA-5347 Batteries made with CFx or MnO2 D cells

0

2

4

6

8

10

12

14

L Test I Test H test

Ru

nn

ing

Tim

e t

o 4

V (

hr)

Li/MnO2 Li/CFx

Li/MnO2 Li/MnO2Li/MnO2

Li/CFxLi/CFxLi/CFx

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• Elevated temperature storage (131oF) shows a self-discharge rate of approximately 1%/year, micro-calorimetry techniques gave a self-discharge value of 0.6%/year

• The self-discharge results prove that all material changes have not resulted in any corrosion issues

• EPEPC has completed all the cell testing for the new Transportation Requirements, T1 to T5, T6 and T8 (forced over discharge)• Forced Over Discharge - Discharged the cells at 2A to a 2.0V

endpoint and then carried out a separate FOD test at 2A for a further 7.82 hours or 15.6-Ah

Li/CFx

Other Electrical Testing – CFx D cell

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Li/CFx

Cell

Identification Build

Number Storage

conditions Equivalent

Time Period

Average Utilization (mAh/g)

Self-discharge/year

CF022, CF023 Third Build

No storage n/a 725 n/a

CF036, CF038 Fourth Build


CF123, CF129, CF138, CF140,

CF143

Sixth Build


CF165, CF166, CF167, CF168,

CF169

Seventh Build


CFx D cell – Storage and Self-Discharge DataBaseline Data

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Li/CFx

Cell

Identification Build

Number Storage

conditions Equivalent

Time Period

Average Utilization (mAh/g)

Self-discharge/year

CF125, CF128,

CF134, CF724

Sixth Build

4 weeks @ 55oC

45.2 weeks 716 (99.4%)

0.7%

CF021, CF029 Third Build

8 weeks @ 55oC

90.4 weeks 709 (97.8%)

1.27%

CF033, CF037, CF039

Fourth Build

8 weeks @ 55oC

90.4 weeks 689 (98.0%)

1.15%

CF148, CF153, CF154,

CF155, CF157

Seventh Build

8 weeks @ 55oC

90.4 weeks 697 (97.9%)

1.21%

CF126, CF130, CF132,

CF135, CF145

Sixth Build

16 weeks @ 55oC

180.8 weeks

696 (96.7%)

1.0%

CF147, CF158, CF161,

CF163, CF164

Seventh Build

12 weeks @ 65oC

270.4 weeks

678 (95.2%)

0.9%

CFx D cell – Storage and Self-Discharge DataStorage Results

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Li/CFx

CF199 and CF200 FOD test

0

10

20

30

40

50

60

70

80

0 5000 10000 15000 20000 25000 30000

Time (sec)

Tem

pera

ture

(C)

-2

-1

0

1

2

3

4

Vol

tage

(V)

(deg C) (deg C) (VOLTS) (VOLTS)

CFx D cell – Temperature and Voltage profile - FOD

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• Capacity of the D cell at 2A at all temperatures superior to Li/SO2 and Li/MnO2

• No voltage delay noted for high temperature or room temperature

• Maximum temperature recorded on the top of the BA-5347 battery was 67oC at end of life under 2A intermittent discharge at 55oC

• Self-discharge results are very good, corrosion is not an issue

Li/CFx

Conclusions – CFx D cell

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• Capacity at -20oF of cells either single or two in a BA-5347 box is higher than room temperature performance for both Li/SO2 and Li/MnO2

• Discharge time under the BA-5347 test protocol of the CFx D cell is approximately 150% of Li/MnO2

• Capacity in a multi-cell battery may be even greater due to self heating

• Limited voltage delay measured at low temperature only, more work on low temperature voltage delay may still be required

Li/CFx

Conclusions – CFx D cell (continued)

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• Since this application is constant power and not constant current the run time is the best measure of performance

• Voltage delay of the BA-5347 at -20oF is excessive but the battery does deliver the required power

• The BA-5347 test results show that the CFx variant exhibits 50% higher energy density (Wh/l) and almost 100% increase in specific energy (Wh/kg) over the MnO2 battery

Li/CFx

Conclusions – CFx BA-5347 Battery

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• Fifty percent longer service life at 20% lower weight

• Therefore, the user can carry two batteries and not three. The same run time with batteries weighing 504g versus three batteries weighing 888g

• The end user can carry less batteries and more other supplies such as water or food

• The reduced battery weight will allow for a longer mission times

Li/CFx

Conclusions – CFx BA-5347 Battery

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• The next goal of the CFx development will be the evaluation of the D cell in the BA-5590 form factor

• Voltage delay issue may not be present due to five cells in a string as opposed to two in the BA-5347

• Thermal issues in this battery must be evaluated

• The CFx battery will be 7.3% heavier but deliver two times the capacity of the SO2 BA-5590. One battery weighing 1030g versus two batteries weighing 1920g

Li/CFx

Conclusions – CFx Battery – Next Steps

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Li/CFx

Comparison of BA-5590 batteries

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2

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8

10

12

14

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Li/SO2 Li/MnO2 Li/CFx

Cap

ac

ity

at

1A

Dis

ch

arg

e (

hrs

)

0

0.5

1

1.5

2

2.5

Batt

ery

We

igh

t (k

g)

Capacity Weight

7.5hr

10.5hr

15.5hr

0.96kg2.11lbs

1.29kg2.84lbs

1.03kg2.27lbs

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• EPEPC could deliver the BA-5590A/U with the CFx D cell

• This battery will be equipped with the SOCI technology

• Will use EPEPC’s experience with the BA-5590A/U, the SO2 variant with a SOCI

Li/CFx

Conclusions – CFx Battery – Next Steps

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Recent Developments - SOCI

EPEPC BA-5590A/U with SOCI

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Author Contact Information

Author Contact Information

Gregg C. BruceDirector of Product

DevelopmentEaglePicher Energy

Products13136 – 82A Avenue

Surrey, BCCanada, V3W 9Y6(604) 543-4354

[email protected]

Defense and Space Power Division Joint Service Power Expo May 2 – 5, 2005 1 Growing to meet the...

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