Consumer Product Safety Commission (CPSC) Staff’s Statement on Naval Surface Warfare Center, Carderock Division’s (NSWCCD) Report on “Emerging Energy Storage Technologies” October 2020 The “Report on Emerging Energy Storage Technologies,” presents the results of research conducted by NSWCCD for CPSC, under CPSC Contract No. CPSC-I-17-0002. CPSC funded this research to learn about emerging high-energy-density battery technologies and to identify strategies to mitigate the fire hazards related to battery failures. The research focused on technologies with viability for consumer applications. CPSC staff is using the results to guide future efforts to promote development of safer high- energy-density batteries for consumer applications and possibly to develop recommendations for improvements to standards for batteries and battery-powered products. 1 Naval Surface Warfare Center Carderock Division West Bethesda, MD 20817-5700 NSWCCD-63-TR-2020/39 October 2020 Platform Integrity Department Technical Report Emerging Energy Storage Technologies by Gordon H. Waller, Jonathan K. Ko, Thomas H. Hays, and Daphne A. Fuentevilla Technologies Emerging Energy Storage Emerging Storage Energy 39 2020/ – TR - 63 - DISTRIBUTION A. Distribution unlimited. NSWCCD 2 Naval Surface Warfare Center Carderock Division West Bethesda, MD 20817-5700 NSWCCD-63-TR-2020/39 October 2020 Platform Integrity Department Technical Report Emerging Energy Storage Technologies by Gordon H. Waller, Jonathan K. Ko, Thomas H. Hays, and Daphne A. Fuentevilla DISTRIBUTION A. Distribution unlimited. 3 UNCLASSIFIED Form Approved REPORT DOCUMENTATION PAGE OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Richmond Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. 1. REPORT DATE (01-29-2019) 2. REPORT TYPE 3. DATES COVERED (From - To) 10-09-2020 Technical Report 10/01/18 - 9/30/19 4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER CPSC-I-17-0002 Emerging Energy Storage Technologies 5b. GRANT NUMBER N/A 5c. PROGRAM ELEMENT NUMBER N/A 6. AUTHOR(S) 5d. PROJECT NUMBER N/A 5e. TASK NUMBER Gordon Waller, Jonathan Ko, Thomas Hays, and Daphne N/A Fuentevilla 5f. WORK UNIT NUMBER N/A 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER Expeditionary Power and Energy 9500 MacArthur Blvd, Bldg. 11 Branch, Naval Surface Warfare West Bethesda, MD 20817 Center Carderock Division 9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S) U.S Consumer Product 4330 East West Hwy, CPSC Safety Commission Bethesda, MD 20814 11. SPONSOR/MONITOR’S REPORT NUMBER(S) N/A 12. DISTRIBUTION / AVAILABILITY STATEMENT DISTRIBUTION A. Distribution unlimited. 13. SUPPLEMENTARY NOTES N/A 14. ABSTRACT: This report summarizes various rechargeable battery technologies with a particular emphasis on lithium- ion batteries (LIB), which are commonly used in consumer electronics applications of all sizes. A main limitation of lithium-ion batteries is their relatively poor safety compared to other technologies. Methods to mitigate safety issues are described. Technologies covered in this report include lithium-ion alternatives, modifications to lithium-ion active and passive components, packaging materials, which can prevent cell-to-cell propagation and “early failure detection” technologies, which monitor the state of health of LIB and prevent unsafe scenarios. 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: UNCLASSIFIED 17. LIMITATION 18. NUMBER 19a. RESPONSIBLE PERSON OF ABSTRACT OF PAGES Gordon Waller a. REPORT b. ABSTRACT c. THIS PAGE 19b. TELEPHONE NUMBER UNCLASSIFIED UNCLASSIFIE UNCLASSIFIE N/A 61 301-227-1649 UNCLASSIFIED i Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std. Z39.18 NSWCCD-63-TR-2020/11 CONTENTS Page CONTENTS................................................................................................................................... ii FIGURES ...................................................................................................................................... iv TABLES ..........................................................................................................................................v ADMINISTRATIVE INFORMATION ..................................................................................... vi EXECUTIVE SUMMARY ........................................................................................................ vii ACRONYMS .............................................................................................................................. viii 1. Introduction .........................................................................................................................10 2. Energy Storage Technologies .............................................................................................11 2.1 Lithium-ion batteries ........................................................................................11 2.1.1 Key features ..................................................................................................11 2.1.2 Commercial state-of-the-art..........................................................................14 2.1.3 Literature trends ...........................................................................................18 2.2 Emerging secondary battery technologies .......................................................23 2.2.1 Na+ Ion .........................................................................................................23 2.2.2 Metal air batteries.........................................................................................25 2.2.3 Aqueous systems............................................................................................29 2.2.4 Solid-state .....................................................................................................31 2.3 Battery safety ...................................................................................................34 2.3.1 Safety at the cell level ...................................................................................35 2.3.2 Non-propagating battery design ...................................................................44 3. Early Failure Detection Technologies ...............................................................................48 3.1 Overview ..........................................................................................................48 3.2 1.1 CAMX Power LLC “Blue Demo Box” Description..................................48 3.2.1 Discussion .....................................................................................................50 3.3 Johns Hopkins University Applied Physics Lab (JHUAPL) BITS Prototype Description ..................................................................................................51 3.3.1 Discussion .....................................................................................................52 3.4 Other Prototypes ..............................................................................................53 3.4.1 CAMX Real-time Detection Technology (RDT) ............................................53 3.4.2 INL/Dynexus Prototype (iRIS) ......................................................................54 ii NSWCCD-63-TR-2020/11 3.4.3 NRL Diagnostic Prototype- BatMD ................................................................54 3.4.4 Nexceris Li-ion Tamer ..................................................................................55 3.4.5 Feasible ResoStat ..........................................................................................55 3.4.6 NSWCCD in-house strain gauge sensor .......................................................56 4. Conclusions and Findings ..................................................................................................56 5. References ............................................................................................................................57 iii NSWCCD-63-TR-2020/11 FIGURES Page Figure 1 Schematic depicting a lithium-ion battery during discharge ...........................................11 Figure 2 Voltage and capacity of several LIB electrode materials relative to the voltage stability window of 1M LiPF6 salt in EC/DEC (1:1) solvent ..............................12 Figure 3 The Peled model of the solid electrolyte interphase ........................................................13 Figure 4 Prismatic and pouch cell construction used for LIB .......................................................15 Figure 5 Cylindrical cell construction used for LIB ......................................................................16 Figure 6 Schematic depiction