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© ABSL Space Products 2005
000074.--.ABSL Presentation Template
Proprietary Information
© ABSL Space Products 2007
ABSL’s COTS Li-Ion Cell Suite Development2007 NASA Battery Workshop
800011.--.ABSL’s COTS Li-Ion Cell Suite Development
Tami Max, Sales Manager720 300 8817, [email protected]
000074.--. ABSL Presentation Template
Proprietary Information
© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 2
Explain ABSL’s programs for identifying and qualifying Li-Ion COTS cells for space use.
Show some of the benefits this approach to space batteries provides.
Provide a briefing on the current status of ABSL’s next generation COTS cells.
Objective
© ABSL Space Products 2005
000074.--.ABSL Presentation Template
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© ABSL Space Products 2007
ABSL Space Battery Experience
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 4
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
29 Jun 04 Saudisat2 LEO
29 Jun 04 Demeter LEO
16 Dec 04 NSAT LEO
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
Launches Powered by ABSL Lithium Batteries
ABSL has the most launches of Li-ion batteries with 32 spacecraft powered by ABSL batteries without ANY failures
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 5
Contracts/Launches “at a glance”
6 space qualified cell (3 launched)
– Lithium-ion secondary
– Lithium primary
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
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
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 6
U.S. Customers
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 7
Rest of the World Customers
© ABSL Space Products 2005
000074.--.ABSL Presentation Template
Proprietary Information
© ABSL Space Products 2007
The ABSL COTS Approach
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 9
Contents
ABSL Space Battery Experience
The ABSL COTS Approach– What is the COTS Approach?
– Process Overview
– The Details
ABSL’s Next Generation COTS Cells
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 10
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.
What Is the COTS Approach?
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 11
The ABSL COTS Approach
Cell Assessment & Qualification– Identify the best COTS cells to meet future space battery needs and qualify
them to space industry standards.
The Cell Suite– Readily provide a broad range of battery capabilities and security of supply.
Lot Acceptance Testing (LAT)– Ensuring consistency of cells batch to batch, maximizing the value of
comprehensive cell characterization and life test programs.
Life Test Program– Enabling unmatched EOL performance predictions capabilities.
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
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 12
Space Qualified Cell Suite
COTS Cell Cycle
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 13
Cell Assessment
Phase CQualification testing
Measured performance, project needs, R&D budget
Phase BPreliminary in-house testing
Reported datasheet, manufacturer, and 3rd party performance
Phase AAll cells under investigation in the Technology Watch
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 14
Phase A: Technology Watch Database
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 15
All Phase B cells are screened and assessed for consistency and build quality
Specific test regime depends on the cell, but any test is fair game: performance characterization, temperature sensitivity, safety, etc.
Phase B: In-House Testing
Lifetesting is initiated as early as possible for promising candidates
This helps identify the best future mission applications of candidate COTS cells
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 16
Phase C: Cell Qualification
Basic Parameters
Safety
Environmental
Characterization
Endurance
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 17
ABSL Cell Suite
CellEnergy Density
AttributesSpace
QualifiedSpace Proven
Space Application
ABSL18650HC 130 Wh/kgExcellent and Characterised
Cycle Life
All space programs
ABSL18650HR 100 Wh/kgVery high current
delivery >10 C2008 High Power
ABSL18650LV 174 Wh/kgHigh Energy
Density, low temp performance
Low temp, mass pushed
ABSL33111PR 450 Wh/kgHigh energy and
structural integrityPrimary batteries
ABSL 26650HC 120 Wh/kg Excellent cycle life Retired
ABSL 18650LVF 175Wh/kgHigh Energy
DensityRetired
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 18
The Cell Suite: ABSL 18650HC
Description: A proven, long-life COTS cell with excellent energy density.
Qualification: The best characterized and understood Li-Ion cell for space, qualified to a broad range of temperatures and vibration environments to meet the needs of nearly any mission.
Lifetesting: A wide range of varied parameters across both storage and operational conditions have been tested.
Heritage: 30 missions flown, and more than 6,000 cell years in space without failure
The HC cell has been employed in batteries ranging from several Ah to more than 100
Ah.
An unrivaled amount of in-house testing and flight
heritage make the HC the most predictable Li-Ion cell
available for space.
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 19
The Cell Suite: ABSL 18650HR
Description: An extremely robust, high power cell for satellites and launch vehicles.
Qualification: Focus on high rate characterization, qualified to extremely harsh temperature and vibration environments.
Heritage: World’s first space-qualified 270V Li-Ion battery set to fly in 2008.
Characterization: Extensive testing has proven that the HR is an excellent cell choice for high power applications.
Employment of the HR cell in ABSL’s 270V TVC battery is
crucial to providing the required performance.
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 20
The Cell Suite: ABSL 33111PR
Description: US manufactured high rate, high energy density (450 Wh/kg) Lithium Sulfuryl Chloride primary COTS cell.
Qualification: Qualified for the rigorous vibration environment of atmospheric re-entry missions.
Heritage: Successfully completed the FOTON-M3 Earth return mission in September, 2007
Courtesy of
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 21
Space Qualified Cell Suite & Stock
COTS Cell Cycle
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 22
Lot Acceptance Testing (LAT)
Build variability is the key risk for using COTS cells.
LAT = Zero-tolerance mini-qualification program
Ensures predictable performance batch to batch.
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 23
Batch 3
Batch 2
Batch 1
Batch N + LAT
Batch 2 + LAT
Batch 1 + LAT
Life Test Program
Life Test
Initial Qual
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 24
0 400 800 1200 1600 2000 2400 2800Storage Duration (Days)
Dis
char
ged
Cap
acity
0 °C 25% Charged 20 °C 25% Charged 40 °C 25% Charged 0 °C 50% Charged20 °C 50% Charged 40 °C 50% Charged 0 °C 100% Charged 20 °C 100% Charged
0 10000 20000 30000 40000 50000 60000 70000 80000Cycle Number
Ret
aine
d C
apac
ity
Life Test Program
A wide range of varied parameters across both storage and operational conditions are tested
– StorageTemperature
SOC
– Operational:Orbital profiles
Temperature
DOD
Charge/Discharge rate
Charge management regimes
8 years of storage data
70k+ cycles of operational data
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 25
Stockpiling
Assured access to cells is critical
Short Term (0 to 3 years)– ABSL buy 10k’s of cells at a
time maintain rolling stock
– Last-time buy agreements
Long Term (3+ years)– Cell stockpiling
– Cell selection
– Diverse cell suite
– Commitment to qualify new cells
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 26
Space Qualified Batteries
Space Qualified Cell Suite & Stock
COTS Cell Cycle
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 27
Cell Screening
Cell Screening Timeline
In addition to performing a LAT on a sample of each batch, all cells are screened twice.
The first screening is on receipt of the cells from the manufacturer, the second is just before use of the cells.
This approach allows two opportunities to identify cells with abnormally high self-discharge rates.
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 28
Standardized Battery Design
Battery performance is highly dependant on the complex interplay of electrical, thermal, and structural design aspects.
For optimal results, all three disciplines must be approached collectively through iteration.
Strong expertise in all aspects is critical for excellence.
Electrical Design
Thermal DesignStructural Design
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 29
Electrical Design
LIFE BEASTDOD
EOL Capacity & Resistance
Standardized Battery Design
Comparison against in-orbit telemetry shows a high degree of accuracy for complex mission profiles and long
mission durations.
17
18
19
20
21
22
23
24
25
26
0 50 100 150 200 250 300 350 400
Time (mins)
Bat
tery
Vol
tage
(V)
-3
-2
-1
0
1
2
3
4
5
6
Cha
rge
/ Dis
char
ge C
urre
nt (A
)
Measured Battery Terminal Voltage BEAST Predicted Battery VoltageMeasured Battery Discharge Current Measured Battery Charge CurrentBEAST Imported Current Data
PROBA In-Orbit Battery Performance06/02/05
MEX In-Orbit Performance
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 30
Electrical Design
LIFE BEASTDOD
EOL Capacity & Resistance
Structural Design
CAD Design
Battery
Config
uratio
n
Standardized Battery Design
Max Deflection & Stress
Structural Design
Cell Leve
l
Vibration
Worst Case Loading
Cell Level Vibration
Modes & Frequencies
Structural Design
Random Vibration Natural Frequencies
& Mode Shapes
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 31
Electrical Design
LIFE BEASTDOD
EOL Capacity & Resistance
Structural Design
CAD Design
Battery
Config
uratio
n
Standardized Battery Design
Modes & Frequencies
Structural Design
Max Deflection & Stress
Structural Design
Cell Leve
l
Vibration
Worst Case Loading
Cell Level Vibration
Thermal Dissipation, Battery Configuration
Cell Temperatures
Thermal Design
Structural Design
BATS
Cell Temperatures
Random Vibration Natural Frequencies
& Mode Shapes
10
11
12
13
14
15
16
17
18
19
20
0 100 200 300 400 500 600 700
Time (minutes)
Tem
pera
ture
(°C
)
Coldest Cell on Failed Block Coldest Cell on Lower Deck Warmest Cell on Lower DeckWarmest Cell on Failed Block Coldest Cell on Upper Deck Average Battery TemperatureWarmest Cell on Upper Deck BEAST cell
10.0°C11.0°C12.0°C13.0°C14.0°C15.0°C16.0°C17.0°C18.0°C
Temperature
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 32
Standardized Battery Build
28V Batteries
>100Ah Spacecraft
Primary Batteries
270V LV Batteries
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 33
Space Battery Qualification
Custom batteries qualified to different levels at customers’request.ABSL has pre-qualified “build to print” designs as well, to reduce cost and lead time.
Design & Analysis, Build
Thermal TestingOperational & Non-Operational
Thermal Cycling in Vacuum
Structural TestingLLS, HLS, Random Vibration,
Shock
Additional TestingMission Specific
InspectionICD Verification, Functional
Checks
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 34
The ABSL COTS Approach
Cell Assessment & Qualification– Identify the best COTS cells to meet future space battery needs and qualify
them to space industry standards.
The Cell Suite– Readily provide a broad range of battery capabilities and security of supply.
Lot Acceptance Testing (LAT)– Ensuring consistency of cells batch to batch, maximizing the value of
comprehensive cell characterization and life test programs.
Life Test Program– Enabling unmatched EOL performance predictions capabilities.
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.
© ABSL Space Products 2005
000074.--.ABSL Presentation Template
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© ABSL Space Products 2007
ABSL’s Next Generation Cells
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 36
Contents
ABSL Space Battery Experience
The ABSL COTS Approach
ABSL’s Next Generation COTS Cells– Next Gen Summary
– Cells G & F
– ABSL 18650LV
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 37
Current Next-Gen COTS Cell Status:
More than 140 COTS cells currently in Phase A (Technology Watch Database)
Approximately 10 COTS cells currently in Phase B (In-House Testing)
Multiple COTS cell under investigation via cooperative efforts with NASA/ESA
One COTS cell starting Phase C(Cell Qualification)
One COTS cell about to complete Phase C (Cell Qualification)
Next Generation Cells
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 38
“Cell G”: Lifetesting
Next Gen Cells: Phase B
100% DOD 20% DOD LEO
Cell G shows improved percent capacity retention performance relative to the HC at both low and high DOD
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 39
“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
ABSL has assessed prototype rather than production cells
Further testing & characterization planned upon initiation of full-scale production
Next Gen Cells: Phase B
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 40
“Cell F”: Lifetesting
Next Gen Cells: Phase B
100% DOD 20% DOD LEO
Cell F shows improved percent capacity retention performance relative to the HC at low DOD, but not at high DOD
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 41
“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
More tests are currently underway
A full BEAST cell model will be available Dec. 2007
Next Gen Cells: Phase B
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 42
ABSL 18650LV: Lifetesting
Next Gen Cells: Phase C
100% DOD 20% DOD LEO
The LV shows very similar percent capacity retention to the HC at both high and low DODs
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 43
ABSL 18650LV: Performance Characterization
Next Gen Cells: Phase C
2070
2090
2110
2130
2150
2170
2190
0 50 100 150 200 250 300 350 400Cell Number
Cap
acity
(Ah)
Discharge Capacity Charge CapacityAverage Discharge Capacity Average Charge Capacityl
3.0
3.2
3.4
3.6
3.8
4.0
4.2
0 10 20 30 40 50 60 70 80 90 100SoC (%)
EM
F (V
)
Charge Discharge
2.50
2.70
2.90
3.10
3.30
3.50
3.70
3.90
4.10
4.30
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
Capacity (Ah)
Vol
atge
(V)
1.2 A Discharge 2.4 A Discharge 4.8 A Discharge 7.2 A Discharge
Rate Characterization
EMF vs. SOC
Batch Consistency
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 44
ABSL 18650LV: Safety Testing
Next Gen Cells: Phase C
0.01
0.1
1
10
100
1000
10 15 20 25 30 35 40 45 50 55 60
Current (A)
PTC
Trip
Tim
e (s
)
100% SoC at 22 deg C 50% SoC at 22 deg C 100% SoC at 70 deg CTrendline (22 deg C) Trendline (70 deg C)
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
5.1
5.2
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8
Overcharge Capacity (Ah)
Cel
l Vol
tage
(V)
0.6 A1.2 A2.4 A4.8 A
PTC Characterization
Overcharge
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22Time (hrs)
Vol
tage
(V)
20
25
30
35
40
45
50
55
60
65
Tem
pera
ture
(°C
)
Cell Voltage Cell Temperature
Over Discharge TV & Vibration & Safety testing is
done – the key risk areas have been
mitigated
000074.--. ABSL Presentation Template
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© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 45
Currently ABSL has more than 140 COTS cells under investigation in Phase A.
Approximately 10 COTS cells in are presently under going in-house testing in Phase B
“Cell F” is about to graduate from Phase B to C
The ABSL 18650LV has completed key portions of the qualification testing, and is ready for a mission!
Next Generation Summary