Next Generation Li-Ion Calorimeter

Among the enhancements reflected in the Next Generation Li-ion Calorimeter is a rigidly wired system that allows direct mounting of thermocouples into key component locations to better capture thermal signature data during testing and improve thermocouple reliability. The ejecta mating chambers have also been modified for better thermal containment and easier system disassembly. Additionally, the system facilitates an easier access, user-friendly Destructive Physical Analysis (DPA) process between uses, and reflects durability improvements in the face of repetitive heat cycling. A clean-sheet redesign was undertaken to create a configurable insula-tion case with an interchangeable “window” section, tailored to the ex-perimental environment. For NASA’s Energy Systems Test Area (ESTA) evaluation, a window with the original foam is installed to maintain ther-mal insulation performance. In contrast, for synchrotron experiments, this section is replaced with an aluminum window that eliminates foam-related X-ray scattering. This modification has substantially improved X-ray radiography resolution, enabling clearer imaging of fine internal battery features during thermal runaway events. Moreover, the insulation case was designed to provide system fire-proofing for both the chamber and pouch cell testing case configurations. Lastly, a control switchbox is also being developed to work with the latest generation calorimeter. It allows users to remotely operate the TR trigger mechanism from a control room, automatically terminate power in a prescribed amount of time to prevent a fire caused by overheating, and provides lit indicators to inform the user of ready or fault states. Innovators at NASA Johnson Space Center have developed a small-fractional thermal runaway calorimeter to support the determination of both total energy yield and fractional energy yield for Li-ion cylindrical format battery cells. This technology comprises updates to the previously disclosed Li-ion Cell Calorimeter (MSC-TOPS-77). By understanding the TR behavior of small format Li-ion cells, engineers can gain insight into improving design safety. This in turn helps prevent cell-to-cell TR propagation in the event of cell short-circuiting leading to battery explosion, and reduces the likelihood of hardware loss or even mission failure. Key industries that may be interested in licensing opportunities are those that provide battery testing services, and battery manufacturers that develop and sell small format Li-ion cells for a multitude of consumer electronics, EV ground transport, commercial aerospace, and the burgeoning Electric Vertical Take-Off and Landing (eVTOL) and related industries. The Next Generation Li-Ion Calorimeter and related components are at technology readiness level (TRL) 6 (System/sub-system model or prototype demonstration in an operational environment) and are now available for patent licensing. Please note that NASA does not manufacture products itself for commercial sale.