Research, development and demonstration of nickel-zinc batteries for electric vehicle propulsion. Annual report, 1979. [70 W/lb]

This second annual report under Contract No. 31-109-39-4200 covers the period July 1, 1978 through August 31, 1979. The program demonstrates the feasibility of the nickel-zinc battery for electric vehicle propulsion. The program is divided into seven distinct but highly interactive tasks collectively aimed at the development and commercialization of nickel-zinc technology. These basic technical tasks are separator development, electrode development, product design and analysis, cell/module battery testing, process development, pilot manufacturing, and thermal management. A Quality Assurance Program has also been established. Significant progress has been made in the understanding of separator failure mechanisms, and a generic category of materials has been specified for the 300+ deep discharge (100% DOD) applications. Shape change has been reduced significantly. A methodology has been generated with the resulting hierarchy: cycle life cost, volumetric energy density, peak power at 80% DOD, gravimetric energy density, and sustained power. Generation I design full-sized 400-Ah cells have yielded in excess of 70 W/lb at 80% DOD. Extensive testing of cells, modules, and batteries is done in a minicomputer-based testing facility. The best life attained with electric vehicle-size cell components is 315 cycles at 100% DOD (1.0V cutoff voltage), while four-cell (approx. 6V) module performance has been limited to about 145 deep discharge cycles. The scale-up of processes for production of components and cells has progressed to facilitate component production rates of thousands per month. Progress in the area of thermal management has been significant, with the development of a model that accurately represents heat generation and rejection rates during battery operation. For the balance of the program, cycle life of > 500 has to be demonstrated in modules and full-sized batteries. 40 figures, 19 tables. (RWR