Structurally embedded intelligent power unit

• US 20030038610A1
• Filed: 03/27/2002
• Published: 02/27/2003
• Est. Priority Date: 03/30/2001
• Status: Active Grant

• Current Assignee: Alfred J. Longhi Jr, Government of the United States of America
• Original Assignee: Lithium Werks Technology BV
• Inventors: Longhi, Alfred J., Munshi, M. Zafar A.
• Granted Patent: US 7,150,938 B2
• Time in Patent Office: Days
• US Class Current: 320/101
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 7/35 with light sensitive cells
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers

Abstract

An electrical power system for a spacecraft or other vehicle or structure comprising a structural member containing an integrated solid-state power source is disclosed. The power source includes a solar cell system and an energy storage system that are combined into a single unit or package, and in certain embodiments, are configured into the shape of a flexible aerobot balloon or a rigid nanosat surface panel. The power components of a preferred lightweight power unit, include thinly layered photovoltaic cells, a rechargeable lithium solid polymer electrolyte battery, a capacitor, electronics and thermal management capability.

Claims

1. An electrical power system for a structure comprising a structural member containing at least one integral solid-state power unit, each said power unit comprising a solar power device and an energy storage device, said power unit including a laminate comprising:

at least one thin film photovoltaic cell,

optionally, at least one thermal management device,

at least one thin film battery,

optionally, at least one high voltage thin film capacitor,

optionally, at least one thin film electrochemical capacitor, and

electronic circuitry in electrical contact with said at least one photovoltaic cell, thermal management device, if present, thin film battery, high voltage thin film capacitor, if present, and thin film electrochemical capacitor, if present.

2. The power system of claim 1 wherein said laminate comprises said at least one photovoltaic cell, thermal management device, thin film battery, high voltage thin film capacitor, and thin film electrochemical capacitor, layered in the order stated.

3. The power system of claim 2 comprising at least one electronic control in electrical contact with said electronic circuitry.

4. The power system of claim 3 wherein at least one said electronic control comprises a preprogrammed microprocessor.

5. The power system of claim 4 wherein at least one said electronic control comprises a dc-dc converter.

6. The power system of claim 1 wherein said electronic circuitry electrically interconnects at least two said photovoltaic cells in series or in parallel.

7. The power system of claim 1 wherein at least two said batteries are connected in series or in parallel and said electronic circuitry electrically interconnects said photovoltaic cells to said batteries.

8. The power system of claim 1 wherein said electronic circuitry electrically interconnects said photovoltaic cells to said batteries, and optionally, interconnects said batteries to said capacitors, to form a single function power module.

9. The power system of claim 1 wherein said electronic circuitry electrically interconnects said photovoltaic cells to said batteries, and optionally, interconnects said batteries to said capacitors, to form a multi-function power module.

10. The power system of claim 1 wherein said electronic circuitry connects said at least one battery and/or said at least one capacitor to a defined electrical load.

11. The power system of claim 1 wherein said thermal management device comprises at least one heating element.

12. The power system of claim 1 wherein each said battery comprises at least one electrochemical cell containing a thin film amorphous carbon anode, a thin film lithium ion polymer electrolyte gel containing a liquid organic solvent, and a thin film lithiated metal oxide cathode.

13. The power system of claim 12 wherein said metal oxide is chosen from the group consisting of the oxides of manganese, cobalt and nickel, and combinations thereof.

14. The power system of claim 12 wherein said thin film lithium ion polymer electrolyte gel contains no more than about 30 wt. % liquid organic solvent.

15. The power system of claim 1 wherein said battery comprises an electrochemical cell containing at least one thin film solid state lithium polymer electrolyte cell.

16. The power system of claim 15 wherein said thin film solid state lithium polymer electrolyte has a conductivity greater than 1×

10⁴ S/cm at 25°

C. or below, and comprises a mixture of;

(a) a base polymer material comprising at least one ionically conductive polymer and having an initial conductivity of at least 1×

10⁵ S/cm at 25°

C. when combined with a metal salt;

(b) a lithium salt;

(c) an inorganic filler having an average particle size less than 0.05 micron in diameter and a surface area of at least about 100 m²/g; and

(d) an ionic conducting material having an average particle size less than 0.1 micron in diameter and an initial ionic conductivity of at least 2×

10³ S/cm at 25°

C.

17. The power system of claim 15 wherein each said cell comprises a thin film lithium metal anode and a thin film lithium insertion cathode.

18. The power system of claim 1 wherein each said film battery has an energy density at least in the range of about 200-250 Wh/kg.

19. The power system of claim 1 wherein each said high voltage film capacitor has an energy density at least in the range of about 5-10 J/cc.

20. The power system of claim 1 wherein said thin film electrochemical capacitor comprises at least one high surface area carbon electrode and an aqueous or non-aqueous electrolyte.

21. The power system of claim 1 wherein said thin film electrochemical capacitor is capable of supplying 1-3 volts.

22. The power system of claim 1 wherein said thin film electrochemical capacitor comprises at least one electrode containing a valve-metal oxide.

23. The power system of claim 22 wherein said valve-metal oxide contains 50-95 wt. % ruthenium oxide and the balance is vanadium oxide.

24. The power system of claim 1 wherein said structural member comprises a solar panel containing electronic circuitry laminated between two power units, each said power unit comprising:

at least one thin film photovoltaic cell,

optionally, a thermal management device,

at least one thin film battery,

optionally, at least one high voltage thin film capacitor, and

optionally, at least one thin film electrochemical capacitor.

25. The power system of claim 24 wherein said laminate comprises, in the order given:

at least one thin film photovoltaic cell,

optionally, a thermal management device,

at least one thin film battery,

optionally, at least one high voltage thin film capacitor,

optionally, at least one thin film electrochemical capacitor,

electronic circuitry,

optionally, at least one high voltage thin film capacitor,

optionally, at least one thin film electrochemical capacitor,

at least one thin film battery,

optionally, a thermal management device, and

at least one thin film photovoltaic cell.

26. The power system of claim 1 wherein said laminate is conformable to a predetermined three-dimensional shape.

27. The power system of claim 1 wherein said laminate is flexible.

28. The power system of claim 1 wherein said laminate is substantially impervious to gaseous species.

29. The power system of claim 1 wherein said laminate is at least semi-rigid.

30. The power system of claim 1 wherein said laminate is resistant to thermal and electromagnetic radiation.

31. The power system of claim 1 wherein said at least one power unit is capable of serving as a structural member for said structure.

32. The power system of claim 1 wherein said solid-state power unit is embedded in said structural member.

33. The power system of claim 1 wherein said structural member comprises an exterior surface of said structure.

34. The power system of claim 1 wherein said structural member is an interior support of said structure and said solid-state power unit is conformable to the shape of said structural member.

35. The power system of claim 1 wherein said solid-state power unit is laminated onto a structural member of said structure.

36. The power system of claim 1 wherein said solid-state power unit provides structural support for said structure.

37. The power system of claim 1 wherein said structural member comprises a panel.

38. The power system of claim 1 comprising at least two electrically interlockable modular panels.

39. The power system of claim 1 wherein said thermal management device comprises a temperature sensor.

40. The power system of claim 39 wherein said thermal management device comprises a heating element and/or a thermoelectric cooling element.

41. The power system of claim 1 wherein said thin film capacitor also serves as a radiation shield.

42. The power system of claim 1 wherein said solid-state power unit comprises at least one thermally insulating material.

43. The power system of claim 1 wherein said battery and said capacitor are operational at a temperature of about −

20°

C. to about +150°

C.

44. A vehicle comprising the solid-state power system of claim 1 wherein said solid-state power unit is integral with a structural member of said vehicle.

45. The vehicle of claim 44 chosen from the group consisting of spacecrafts, satellites, nanosats, aerobots, balloons, high altitude or space platforms, terrestrial vehicles and boats.

46. The vehicle of claim 44 wherein said solid-state power unit comprises at least one operationally interconnected laminate containing:

at least one thin film photovoltaic cell layer,

optionally, at least one layer containing a thermal management device,

at least one thin film battery layer, each said battery being capable of a multiplicity of discharge/recharge cycles,

optionally, at least one high voltage thin film capacitor layer,

optionally, at least one thin film electrochemical capacitor layer, and

electronic circuitry.

47. The vehicle of claim 44 wherein said power unit comprises at least one heating element and said power unit is capable of operating under cryogenic conditions.

48. The vehicle of claim 47 wherein said solid state power system is capable of electrolyzing, compressing, liquefying or freezing a vehicle-transported gas or of electrolyzing, compressing, liquefying, freezing, sublimating or boiling a frozen or liquid phase of an atmospheric gas comes into contact with said vehicle when said vehicle is used for its intended purpose.

49. The vehicle of claim 44 wherein said power unit is capable of operating for up to about 15 years.

50. A structure comprising the power system of claim 1 wherein said at least one power unit is integral with a structural member of said structure.

51. The structure of claim 50 wherein said structural member is flexible.

52. The structure of claim 50 wherein said structural member is at least semi-rigid.