NASA Reference Publication 1353 Primary Battery Design and Safety Guidelines Handbook BobbyJ. Bragg John E. Casey J. Barry Trout Lyndon B. Johnson Space Center Houston, Texas December 1994 This publication is available from the NASA Center for AeroSpace Information, 800 Elkridge Landing Road, Linthicum Heights, MD 21090-2934, (301) 621-0390. Preface This handbook is for use by engineers and safety personnel as a guide to the safe design, selection, and use of the types of primary batteries used in National Aeronautics and Space Administration flight applications. The draft of the handbook was reviewed by members of the NASA Aerospace Flight Battery System Steering Committee and a number of Johnson Space Center Engineering, Quality, and Reliability offices. Most of the suggestions received have been incorporated into the final copy. Questions concerning the contents of this handbook may be directed to Bobby J. Bragg or John E. Casey at code EP52, Lyndon B. Johnson Space Center, Houston, Texas 77058. Mr. Bragg may also be reached at 713-483-9060, Mr. Casey at 713-483-04467. Contents Section Page Acronyms and Abbreviations ........................................................................................ vii 1 Introduction .............................................................................................................. 1-1 1.1 Purpose ................................................................................................................... 1-1 1.2 Definition of Primary Battery ....................................................................................... 1-1 1.3 Approach .................................................................................................................. 1-1 1.3.1 Battery Characteristics & Selection Criteria .................................................................. 1-1 1.3.2 Safety ....................................................................................................................... 1-1 1.3.3 Qualification/Certification ........................................................................................... 1 -1 1.3.4 Acceptance Testing .................................................................................................. 1-1 1.3.5 Discharge Rate Conventions ...................................................................................... 1-2 Design Considerations ............................................................................................. 2.-1 Primary Batteries Flown in Space Flight Programs ........................................................ 3-1 4 Safety_eneral Hazard Sources and Controls ............................................................ 4-1 4.1 Short Circuits ............................................................................................................ 4-1 4.1.1 Sources .................................................................................................................... 4-1 4.1.2 Hazards .................................................................................................................... 4-1 4.1.3 Controls .................................................................................................................... 4-2 4.2 Electrolyte Leakage ................................................................................................... 4-3 4.2.1 Sources .................................................................................................................... 4-3 4.2.2 Hazards .................................................................................................................... 4-3 4.2.3 Controls .................................................................................................................... 4-4 4.3 Battery Gases ............................................................................................................ 4-6 4.3.1 Source ..................................................................................................................... 4-6 4.3.2 Hazards .................................................................................................................... 4-6 4.3.3 Controls .................................................................................................................... 4-7 4.4 High Temperature Exposure ...................................................................................... 4-7 4.4.1 Sources ................................................................................................................... .4-8 4.4.2 Hazards .................................................................................................................... 4-8 4.4.3 Controls .................................................................................................................... 4-9 4.5 Circulating Currents ................................................................................................. 4-10 4.5.1 Sources .................................................................................................................. 4-10 4.5.2 Hazards .................................................................................................................. 4-10 4.5.3 Controls .................................................................................................................. 4-10 4.6 Structural ................................................................................................................ 4-11 4.6.1 Sources ............... ................................................................................................... 4-11 4.6.2 Hazards .................................................................................................................. 4-11 4.6.3 Controls .................................................................................................................. 4-11 5 Descriptions of Individual Primary Battery Types .......................................................... 5-1 5.1 Silver Oxide-Zinc Alkaline ............................................................................................ 5-1 5.1.1 Major Usage ....................................................................................................... 5-1 5.1.2 Typical Applications ................................................................................................... 5-1 ,,o III P_ PJC_Ji P...#.NN _ F1LMED Section Page 5.1.3 Electrochemistry ....................................................................................................... 5-1 5.1.4 Electrodes and Separators ......................................................................................... 5-2 5.1.4.1 Positive Electrodes (Plates) ....................................................................................... 5-2 5.1.4.2 Negative Electrodes (Plates) ..................................................................................... .5-2 5.1.4.3 Separators ............................................................................................................... .5-3 5.1.5 Capacities and Configurations................................................................................... .5-3 5.1.6 Typical Characteristics ............................................................................................... .5-3 5.1.7 Safety ....................................................................................................................... 5 -4 5,1.7,1 General ..................................................................................................................... 5-4 5.1.7.2 Hydrogen Gas ........................................................................................................... 5-4 5.1.8 Activation ................................................................................................................. 5-6 5.1.8.1 Requirements ........................................................................................................... 5-6 5.1.8,2 Activation Instruction Requirements ........................................................................... 5-6 5.2 Carbon-Zinc .............................................................................................................. 5-7 5.2.1 Major Usage .............................................................................................................. 5-7 5.2.2 Typical Applications ................................................................................................... 5-7 5.2.3 Electrochemistry ...................................................................................................... .5-7 5.2.4 Construction ............................................................................................................. 5-8 5.2.4.1 Positive Active Material .............................................................................................. 5-8 5.2.4.2 Negative Active Material ............................................................................................. 5-8 5.2.4.3 Separator .................................................................................................................. 5-8 5.2.4.4 Closure ..................................................................................................................... 5-8 5.2.4.5 Variations .................................................................................................................. 5-8 5.2.5 Capacities and Configurations ...................................................................................