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Li-ion Pouch Cell Designs;
Performance and Issues for Crewed
Vehicle Applications
by
Eric Darcy
NASA-JSC
For
Electric Aircraft Symposium
29 April 2011
Santa Rosa, CA
Outline Li-ion Pouch Cells
• Purpose and Motivation
• Cell designs evaluate
• Cell lot uniformity, why that’s important
• Forward plans
– High rate performance
– Cycle life durability
– Seals
– Corrosion susceptibility
– Manufacturing quality
• Conclusions
Purpose Motivation
• Compelling Advantages
– Li-ion pouch cell designs provide the highest specific energy ( 220
Wh/kg), energy density ( 450 Wh/L) of all commercially available designs
– Many high power designs also exist with very impressive performance (
2000 W/kg and 4000 W/L)
– Numerous designs are being produced world wide in high volumes for the
emerging EV/HEV/PHEV market
• As such, calendar life, cycle life, and durability has been improved over the last 5
years
• Many designs have extensive field testing and therefore, maturity
• Our purpose: Are there any performance show stoppers for
spinning them into spacecraft applications?
– Are the seals compatible with extended vacuum operations?
– How uniformly and cleanly are they made?
– How durable are they?
• Why now?
– Electric vehicle market has driven significant improvements
– Many of our applications (VASIMR, R2, etc) could benefit right now
– We have access to several high volume cell suppliers which will soon have
US production lines up and running
Maturity of Pouch Cell/Module Des
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