Safer Battery with Switchable Polymer Coating

Physical Sciences Inc. (PSI) proposes to utilize a switchable polymer (SWP) to prevent catastrophic failure due to internal shorting or overdischarge in lithium-ion batteries. The SWP, applied to both the surface of the cathode particles and the cathode current collector, can be reversibly "switched" from an insulator to a conductor upon oxidation permitting normal battery operation. In Phase I, PSI will demonstrate that upon a short or overdischarge the polymer reversibly switches to an insulator reducing the current flow to the cathode material protecting the system and preventing unsafe operation. This reduced current flow will be demonstrated to decrease the localized heat generation by more than two orders of magnitude. PSI will also demonstrate that insulation of the cathode material limits irreversible degradation of the discharge capacity upon overdischarge maintaining cell balance and improving cycle life. In the Phase II program, we will scale up the coating procedure to a production scale, in order to demonstrate the technology in a 5Ah battery. At the conclusion of Phase II, PSI will have demonstrated the technology in full battery systems and be prepared to partner with NASA's industrial partner SAFT America to have cells built for a mock application demonstration.

The initial market for the proposed technology is the military where battery safety is paramount. The increased tolerance to overdischarge and shorting offered by the proposed coating would improve the safety of battery systems. The technology can be further extended to commercial devices such as hybrid and electric vehicles, cordless power tools, remote sensing devices, and portable communications such as cell phones and two-way radios.

The proposed technology could be utilized in all battery applications to improve their safety. In particular application of the technology in human-rated systems could help the system meet NASA's two fault NASA human-rated safety requirement. Incorporation in NASA's high and ultra-high energy cell designs would substantially reduce the potential for catastrophic failure on the development of internal shorts or overdischarge.

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.