ABSL's COTS Li-Ion Cell Suite Development

ABSL’s COTS Li-Ion Cell Suite Development 2007 NASA Battery Workshop Tami Max, Sales Manager 720 300 8817, [email protected]

000074.--.ABSL Presentation Template Proprietary Information 800011.--.ABSL’s COTS Li-Ion Cell Suite Development ©© ABSL ABSL SpaceSpace ProductsProducts 20052007 Objective

z Explain ABSL’s programs for identifying and qualifying Li-Ion COTS cells for space use. z Show some of the benefits this approach to space batteries provides. z Provide a briefing on the current status of ABSL’s next generation COTS cells.

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 2 © ABSL Space Products 2007 ABSL Space Battery Experience 000074.--.ABSL Presentation Template Proprietary Information ©© ABSL ABSL SpaceSpace ProductsProducts 20052007 Launches Powered by ABSL Lithium Batteries Launch Date Program Type Orbit 16 Nov 00 STRV-1c GTO

22 Oct 01 PROBA LEO 02 Jun 03 Beagle I/Planetary 02 Jun 03 Mars Express I/Planetary

02 Mar 04 Rosetta I/Planetary

02 Mar 04 Philae I/Planetary ABSL has the 29most Jun 04 Saudisat2launches of Li-ionLEO batteries with 32 29 Jun 04 Demeter LEO spacecraft powered16 Dec 04 by NSAT ABSL batteriesLEO without ANY failures 16 Dec 04 ESSAIM I, II, III, IV LEO 16 Dec 04 Parasol LEO

08 Oct 05 Cryosat LEO 09 Nov 05 Venus Express I/Planetary 28 Dec 05 GIOVE-A LEO

22 Mar 06 ST5 A, B, C GTO 19 Dec 06 SAR-Lupe 1 LEO 16 Feb 07 THEMIS I, II, III, IV, V LEO 09 Mar 07 CFESat LEO 17 Apr 07 SaudiSat3 LEO 15 Jun 07 TerraSAR-X LEO 03 Jul 07 SAR-Lupe 2 LEO 20 Jul 07 Sumbandila (ZaSat) LEO 14 Sep 07 FOTON-M3 LEO 1 Nov 07 SAR-Lupe 3 LEO 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 4 © ABSL Space Products 2007 Contracts/Launches “at a glance” z 6 space qualified cell (3 launched) – Lithium-ion secondary – Lithium primary z 32 s/c launched – LEO, MEO, GTO, HEO, Interplanetary – Including NASA, AFRL, DOE, ESA missions – Longest serving LEO Li-ion (6+ years, >30k cycles) – Three 10 yr LEOs on orbit z Contracts for 80+ spacecraft and launchers – 2 GEO launches in 2008 – 1st Launch Vehicle flight in 2008 – Many more NASA missions, MDA, AFRL, ESA… 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 5 © ABSL Space Products 2007 U.S. Customers

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 6 © ABSL Space Products 2007 Rest of the World Customers

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 7 © ABSL Space Products 2007 The ABSL COTS Approach 000074.--.ABSL Presentation Template Proprietary Information ©© ABSL ABSL SpaceSpace ProductsProducts 20052007 Contents

z ABSL Space Battery Experience z The ABSL COTS Approach – What is the COTS Approach? – Process Overview – The Details z ABSL’s Next Generation COTS Cells

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 9 © ABSL Space Products 2007 What Is the COTS Approach?

z ABSL’s COTS Approach is a proven process for providing space qualified Li-Ion batteries using commercial off-the-shelf (COTS) Li-Ion Cells. – Encompasses everything from identifying candidate COTS cells, to high fidelity design and qualification testing of space batteries. – Mitigates the risk of using of COTS cells for space applications to provide customer confidence in the end product. – Leverages the immense size of the commercial industry to provide cutting edge performance and security of supply.

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 10 © ABSL Space Products 2007 The ABSL COTS Approach

z Cell Assessment & Qualification – Identify the best COTS cells to meet future space battery needs and qualify them to space industry standards. z The Cell Suite – Readily provide a broad range of battery capabilities and security of supply. z Lot Acceptance Testing (LAT) – Ensuring consistency of cells batch to batch, maximizing the value of comprehensive cell characterization and life test programs. z Life Test Program – Enabling unmatched EOL performance predictions capabilities. z Standardized Battery Design, Build, & Qualification – Leveraging the consistency and predictability of ABSL’s COTS cells to efficiently optimize and qualify battery designs for any mission.

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 11 © ABSL Space Products 2007 COTS Cell Cycle

Space Qualified Cell Suite

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 12 © ABSL Space Products 2007 Cell Assessment

Phase A All cells under investigation in the Technology Watch Reported datasheet, manufacturer, and 3rd party performance Phase B Preliminary in-house testing Measured performance, project needs, R&D budget Phase C Qualification testing

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 13 © ABSL Space Products 2007 Phase A: Technology Watch Database

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 14 © ABSL Space Products 2007 Phase B: In-House Testing z All Phase B cells are screened and assessed for consistency and build quality z Specific test regime depends on the cell, but any test is fair game: performance characterization, temperature sensitivity, safety, etc.

z Lifetesting is initiated as early as possible for promising candidates

z This helps identify the best future mission applications of candidate COTS cells

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 15 © ABSL Space Products 2007 Phase C: Cell Qualification

z Basic Parameters

z Safety

z Environmental

z Characterization

z Endurance

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 16 © ABSL Space Products 2007 ABSL Cell Suite

Energy Space Space Space Cell Attributes Density Qualified Proven Application Excellent and All space ABSL18650HC 130 Wh/kg Characterised programs Cycle Life

Very high current ABSL18650HR 100 Wh/kg 2008 High Power delivery >10 C

High Energy Low temp, ABSL18650LV 174 Wh/kg Density, low temp mass pushed performance

High energy and Primary ABSL33111PR 450 Wh/kg structural integrity batteries

ABSL 26650HC 120 Wh/kg Excellent cycle life Retired

High Energy ABSL 18650LVF 175Wh/kg Retired Density 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 17 © ABSL Space Products 2007 The Cell Suite: ABSL 18650HC z Description: A proven, long-life COTS cell with excellent energy density. z Qualification: The best characterized and understood Li-Ion The HC cell has been employed in batteries cell for space, qualified to a broad ranging from several Ah to more than 100 range of temperatures and vibration Ah. environments to meet the needs of nearly any mission. z Lifetesting: A wide range of varied parameters across both storage and operational conditions have been tested. z Heritage: 30 missions flown, and An unrivaled amount of in- more than 6,000 cell years in space house testing and flight heritage make the HC the without failure most predictable Li-Ion cell available for space. 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 18 © ABSL Space Products 2007 The Cell Suite: ABSL 18650HR

z Description: An extremely robust, high power cell for satellites and launch vehicles. z Qualification: Focus on high rate characterization, qualified to extremely harsh temperature and vibration environments. z Heritage: World’s first space- qualified 270V Li-Ion battery set to fly in 2008. z Characterization: Extensive testing has proven that the HR is an Employment of the HR cell in excellent cell choice for high power ABSL’s 270V TVC battery is applications. crucial to providing the required performance.

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 19 © ABSL Space Products 2007 The Cell Suite: ABSL 33111PR Courtesy of z Description: US manufactured high rate, high energy density (450 Wh/kg) Lithium Sulfuryl Chloride primary COTS cell. z Qualification: Qualified for the rigorous vibration environment of atmospheric re-entry missions. z Heritage: Successfully completed the FOTON-M3 Earth return mission in September, 2007

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 20 © ABSL Space Products 2007 COTS Cell Cycle

Space Qualified Cell Suite & Stock

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 21 © ABSL Space Products 2007 Lot Acceptance Testing (LAT) z Build variability is the key risk for using COTS cells. z LAT = Zero-tolerance mini- qualification program z Ensures predictable performance batch to batch.

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 22 © ABSL Space Products 2007 Life Test Program

Life Test

Initial Qual

Batch 1 + LAT

Batch 2 + LAT

Batch N +Batch LAT 3 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 23 © ABSL Space Products 2007 Life Test Program 8 years of storage data

z A wide range of varied parameters across both storage and operational conditions are tested – Storage Discharged Capacity ¾ Temperature 0 400 800 1200 1600 2000 2400 2800 ¾ SOC Storage Duration (Days) 0 °C 25% Charged 20 °C 25% Charged 40 °C 25% Charged 0 °C 50% Charged – Operational: 20 °C 50%70k+ Charged cycles40 °C 50% Charged of0 operational°C 100% Charged 20 °C 100% data Charged ¾ Orbital profiles ¾ Temperature ¾ DOD ¾ Charge/Discharge rate Retained Capacity ¾ Charge management regimes

0 10000 20000 30000 40000 50000 60000 70000 80000 Cycle Number 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 24 © ABSL Space Products 2007 Stockpiling

z Assured access to cells is critical z Short Term (0 to 3 years) – ABSL buy 10k’s of cells at a time maintain rolling stock – Last-time buy agreements z Long Term (3+ years) – Cell stockpiling – Cell selection – Diverse cell suite – Commitment to qualify new cells

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 25 © ABSL Space Products 2007 COTS Cell Cycle

Space Qualified Cell Suite & Stock

Space Qualified Batteries

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 26 © ABSL Space Products 2007 Cell Screening

Cell Screening Timeline

z In addition to performing a LAT on a sample of each batch, all cells are screened twice. z The first screening is on receipt of the cells from the manufacturer, the second is just before use of the cells. z This approach allows two opportunities to identify cells with abnormally high self-discharge rates.

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 27 © ABSL Space Products 2007 Standardized Battery Design

z Battery performance is highly dependant on the complex interplay of electrical, thermal, and structural design aspects. z For optimal results, all three disciplines must be approached collectively through iteration. z Strong expertise in all aspects is critical for excellence.

Electrical Design

Structural Design Thermal Design

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 28 © ABSL Space Products 2007 Standardized Battery Design

Electrical Design

EOL Capacity & Resistance LIFE BEAST DOD

Comparison against in-orbit telemetry shows a high degree of accuracy for complex mission profiles and long mission durations.

MEX In-Orbit Performance PROBA In-Orbit Battery Performance 06/02/05 26 6

25 5 )

24 4 t (A ) rren

23 3 u

ltage (V 22 2 rge C o 21 1 a sch i

ttery V 20 0 a B 19 -1 arge / D h

18 -2 C 17 -3 0 50 100 150 200 250 300 350 400 Time (mins)

Measured Battery Terminal Voltage BEAST Predicted Battery Voltage Measured Battery Discharge Current Measured Battery Charge Current BEAST Imported Current Data

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 29 © ABSL Space Products 2007 Standardized Battery Design

Electrical Design

EOL Capacity & Resistance LIFE BEAST DOD

on ti ry a te ur at ig B f on C

Structural Design Worst Case CAD Design Loading Max Deflection & Stress Structural Cell Level el Design Vibration ev l L n el tio C a br Vi Random Modes & Vibration Natural Frequencies Frequencies & Mode Shapes Structural Design 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 30 © ABSL Space Products 2007 Standardized Battery Design

Electrical Design

EOL Capacity & Resistance LIFE BEAST DOD

on ti ry a te ur Cell Thermal Dissipation, at ig B f Temperatures Battery Configuration on C

Structural Cell Design Temperatures Worst Case CAD Design BATS Loading Max Deflection Structural Design & Stress 20 Structural 19 Cell Level 18 l 17 e Design 16 Vibration ev L n 15 ll o 14 e ti 18.0°C a Temperature (°C) 13 C r 17.0°C ib 12 V 16.0°C Temperature 15.0°C11 14.0°C Random Modes & 10 13.0°C 0 100 200 300 400 500 600 700 12.0°C Time (minutes) 11.0°C Vibration Natural Frequencies Frequencies 10.0°C Coldest Cell on Failed Block Coldest Cell on Lower Deck Warmest Cell on Lower Deck Warmest Cell on Failed Block Coldest Cell on Upper Deck Average Battery Temperature & Mode Shapes Warmest Cell on Upper Deck BEAST cell Structural Design Thermal Design 000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 31 © ABSL Space Products 2007 Standardized Battery Build

28V Batteries >100Ah Spacecraft

Primary Batteries

270V LV Batteries

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 32 © ABSL Space Products 2007 Space Battery Qualification

z Custom batteries qualified to Design & Analysis, Build different levels at customers’ request. Inspection z ABSL has pre-qualified “build to ICD Verification, Functional print” designs as well, to reduce Checks cost and lead time.

Structural Testing LLS, HLS, Random Vibration, Shock

Thermal Testing Operational & Non-Operational Thermal Cycling in Vacuum

Additional Testing Mission Specific

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 33 © ABSL Space Products 2007 The ABSL COTS Approach

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 34 © ABSL Space Products 2007 ABSL’s Next Generation Cells 000074.--.ABSL Presentation Template Proprietary Information ©© ABSL ABSL SpaceSpace ProductsProducts 20052007 Contents

z ABSL Space Battery Experience z The ABSL COTS Approach z ABSL’s Next Generation COTS Cells – Next Gen Summary – Cells G & F – ABSL 18650LV

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 36 © ABSL Space Products 2007 Next Generation Cells

Current Next-Gen COTS Cell Status: z More than 140 COTS cells currently in Phase A (Technology Watch Database) z Approximately 10 COTS cells currently in Phase B (In-House Testing) z Multiple COTS cell under investigation via cooperative efforts with NASA/ESA z One COTS cell starting Phase C (Cell Qualification) z One COTS cell about to complete Phase C (Cell Qualification)

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 37 © ABSL Space Products 2007 Next Gen Cells: Phase B

z “Cell G”: Lifetesting

20% DOD LEO 100% DOD

Cell G shows improved percent capacity retention performance relative to the HC at both low and high DOD

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 38 © ABSL Space Products 2007 Next Gen Cells: Phase B

z “Cell G”: Additional Completed Characterization – Consistency & Build Quality Testing – Capacity at Temperature, -40° C to 60° C – Rate & Pulse Characterization, up to 3C – Resistance Characterization, -40° C to 60° C – Overcharge Testing z ABSL has assessed prototype rather than production cells z Further testing & characterization planned upon initiation of full-scale production

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 39 © ABSL Space Products 2007 Next Gen Cells: Phase B

z “Cell F”: Lifetesting

20% DOD LEO 100% DOD

Cell F shows improved percent capacity retention performance relative to the HC at low DOD, but not at high DOD

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 40 © ABSL Space Products 2007 Next Gen Cells: Phase B

z “Cell F”: Additional Completed Characterization – Consistency & Build Quality Testing – Capacity at Temperature, -40° C to 60° C – Rate & Pulse Characterization, up to 7C – Resistance Characterization, -40° C to 60° C – Overcharge Testing z More tests are currently underway z A full BEAST cell model will be available Dec. 2007

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 41 © ABSL Space Products 2007 Next Gen Cells: Phase C

z ABSL 18650LV: Lifetesting

20% DOD LEO 100% DOD

The LV shows very similar percent capacity retention to the HC at both high and low DODs

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 42 © ABSL Space Products 2007 Next Gen Cells: Phase C

z ABSL 18650LV: Performance Characterization

4.30 2190 Batch Consistency Rate 4.10 2170 3.90 Characterization

2150 3.70 3.50 2130 3.30 Volatge (V) Volatge Capacity (Ah) Capacity 2110 3.10

2.90 2090 2.70

2070 2.50 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 Capacity (Ah) Discharge Capacity Cell Number Charge Capacity 1.2 A Discharge 2.4 A Discharge 4.8 A Discharge 7.2 A Discharge Average Discharge Capacity Average Charge Capacityl 4.2 EMF vs. SOC

4.0

3.8

3.6 EMF (V) EMF

3.4

3.2

3.0 0 102030405060708090100 SoC (%) Charge Discharge

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 43 © ABSL Space Products 2007 Next Gen Cells: Phase C

z ABSL 18650LV: Safety Testing

1000 PTC 5.2 Overcharge 5.1 100 Characterization 5.0

10 4.9 4.8

1 4.7

PTC Time Trip (s) 4.6 Cell Voltage (V) Voltage Cell 0.1 4.5 0.6 A 4.4 1.2 A 0.01 4.3 2.4 A 10 15 20 25 30 35 40 45 50 55 60 4.8 A Current (A) 4.2 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 100% SoC at 22 deg C 50% SoC at 22 deg C 100% SoC at 70 deg C Overcharge Capacity (Ah) Trendline (22 deg C) Trendline (70 deg C)

4.5 65 4.0 Over Discharge 60 TV & Vibration & 3.5 55 3.0 50 Safety testing is 2.5 45

2.0 40 Voltage (V) 1.5 35 Temperature (°C) Temperature done – the key risk

1.0 30 0.5 25 areas have been 0.0 20 0 1 2 3 4 5 6 7 8 9 10111213141516171819202122 Time (hrs) mitigated Cell Voltage Cell Temperature

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 44 © ABSL Space Products 2007 Next Generation Summary

z Currently ABSL has more than 140 COTS cells under investigation in Phase A. z Approximately 10 COTS cells in are presently under going in-house testing in Phase B z “Cell F” is about to graduate from Phase B to C z The ABSL 18650LV has completed key portions of the qualification testing, and is ready for a mission!

000074.--. ABSL Presentation Template Proprietary Information 800011.--. ABSL’s COTS Li-Ion Cell Suite Development 45 © ABSL Space Products 2007 Questions? 000074.--.ABSL Presentation Template Proprietary Information ©© ABSL ABSL SpaceSpace ProductsProducts 20052007