Army Hardened Aviation Battery (AHAB)

MACRO Industries (Huntsville, AL/Lenexa/KS) will demonstrate the capability of its Macrolite High Temperature (MLHT) family of composite materials in providing a high level of advanced safety for lithium-ion batteries (LiBs) in aviation systems. While aviation platforms seem an ideal candidate for the lightweight and high-energy discharge capabilities offered by LiBs, the potentially catastrophic result of thermal runaway has limited, if not prevented, their use on most military aircraft. For this Phase I effort, MACRO will demonstrate the feasibility of the MLHT material platform for use in aircraft by developing a vendor-agnostic battery test surrogate that can contain high-energy, silicon anode (or equivalent), LiBs during thermal runaway. The surrogate, and ultimately a full battery developed in Phase II, will meet a variety of MIL-STD-810H requirements including operational temperature, altitude, temperature storage, functional shock, vibration, and gunfire vibration. In addition, the surrogate will be characterized against a variety of ballistic threats, per MIL-STD-662F.áMACROĺs approach to demonstrate feasibility will initially focus on developing next-generation (GenX) MLHT materials for use in a reduced footprint battery capable of replacing the current battery on the MH-60 Black Hawk helicopter. Ballistic testing of the MLHT materials will demonstrate that the LiBs will be protected from impacts from various threats, and concurrent testing will show that the materials can withstand the heat and debris generated induced thermal runaway. Development and testing will then turn to the enclosure to ensure it will meet the stringent environmental and air worthiness requirements (AWR) while containing the induced thermal runaway. Phase I efforts will deliver a surrogate container, demonstrating the effectiveness of the GenX MLHT. A subsequent Phase II effort will deliver a functional battery using the Army-approved chemistry, supplier, and architecture, along with the MLHT protective barrier system derived from the Phase I surrogate. MACRO will leverage relationships with existing battery and cell manufacturers to ensure that the functional battery delivered during Phase II will meet the weight, voltage, and energy requirements, while fitting inside of the enclosure developed during Phase I.