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Power hungry: Army seeks light, efficient batteries to meet insatiable energy demand.



In an Army that heavily depends on battery-operated devices to do its job, the complaints are well documented: Batteries are too heavy, too bulky and not very user-friendly.

All that could change, if Steve Slane has his way. Slane, chief of the battery branch at Army Communications-Electronics Research, Development and Engineering Center (CERDEC CERDEC Communications-Electronics Research Development and Engineering Center ) at Fort Monmouth Fort Monmouth is a United States Army installation in Eatontown, Tinton Falls and Oceanport, New Jersey, and about one mile from the Atlantic Ocean. The base covers nearly 1,126 acres of land, from the Shrewsbury River west to Route 35, called Main Post. , N.J., is working with several contractors to develop new battlefield batteries--an effort employing 30 Army scientists and engineers and budgeted at around $15 million annually.

One recent innovation championed by CERDEC is a simple charge indicator built into a battery's casing so that soldiers don't have to guess how much juice is left. Such indicators are now standard on all new large batteries. A combination of lighter, longer-lasting batteries and innovations such as the charge indicator, can make a huge difference for soldiers in combat, Slane says.

In today's high-tech Army, where even the smallest patrol counts on a wide range of electronic systems--including radios, network terminals, night-vision goggles goggles,
n the protective eyewear worn by dental personnel and patients during dental procedures.


goggles

see periocular leukotrichia.
, radio jammers and shoulder-fired rockets--batteries are a critical resource. And demand is growing. "Five to 10 years ago, a soldier on soldier on
Verb

to continue one's efforts despite difficulties or pressure
 average would consume three to four watts of [battery] power" on a typical mission, Slane says. "Today ... we're seeing power numbers of around 20 watts."

Watts are a generic unit of power, or work. Wattage wattage

the output or consumption of an electric device expressed in watts.
 is the product of voltage and current; the latter is measured in amperes.

To provide his 20 watts, a soldier might carry as many as eight 2.2-pound BA-5590 lithium sodium dioxide batteries on a mission, in addition to smaller alkaline batteries, for a combined weight of around 20 pounds--a load that outweighs even his rifle ammunition and takes up more space. As a result, battery weight and size have become important factors in mission planning. One way to reduce that load while slaking soldiers' thirst for power is to transition to more efficient chemistries.

"For the last 15 to 20 years, the Years, The

the seven decades of Eleanor Pargiter’s life. [Br. Lit.: Benét, 1109]

See : Time
 majority of applications have been filled with lithium sulfur dioxide sulfur dioxide, chemical compound, SO2, a colorless gas with a pungent, suffocating odor. It is readily soluble in cold water, sparingly soluble in hot water, and soluble in alcohol, acetic acid, and sulfuric acid.  batteries" such as the 5590, says Mark Matthews This article is about Mark Matthews, a Buffalo Soldier in the United States Army. For other uses, see Mark Matthews (disambiguation).
Mark Matthews (August 7, 1894 – September 6, 2005) was the oldest surviving Buffalo Soldier in the United States Army when he died
, director of strategic market development for New York-based firm Ultralife, which alongside French company Saft, manufactures the majority of the million or so soldier batteries the Defense Logistics Agency Noun 1. Defense Logistics Agency - a logistics combat support agency in the Department of Defense; provides worldwide support for military missions
Defense Department, Department of Defense, DoD, United States Department of Defense, Defense - the federal department
 consumes annually at a cost of around $100 million. CERDEC is responsible for administering the agency's orders for Army batteries.

"Lithium sulfur dioxide has been a workhorse for years," says Ben Helminen, Saft's director of sales. "Now we are looking at new chemistries. Lithium carbon monofluoride Carbon monofluoride (CF, CFx, or (CF)x), also called polycarbon monofluoride, polycarbon fluoride, poly(carbon monofluoride), and graphite fluoride  is quite promising."

But that chemistry hasn't yet found widespread acceptance for military applications. In the meantime Adv. 1. in the meantime - during the intervening time; "meanwhile I will not think about the problem"; "meantime he was attentive to his other interests"; "in the meantime the police were notified"
meantime, meanwhile
, both Saft and Ultralife have begun producing a lithium manganese dioxide manganese dioxide
n.
A black crystalline compound, MnO2, used as a depolarizer of dry-cell batteries and in textile dyeing.
 version of the 5590, designated BA-5390.

"The push has been towards lithium manganese dioxide in the same size battery [as the 5590] to get 50- to 80-percent more energy," Matthews says. "With the 5390, we're able to get double the runtime in some applications in the same size box," Matthews reports.

Ultralife's 5390 boasts a capacity of 11.1 ampere-hours of current, compared to 7.2 for its latest 5590, according to according to
prep.
1. As stated or indicated by; on the authority of: according to historians.

2. In keeping with: according to instructions.

3.
 Ultralife spokesman Julius Cirin. "We're on verge of launching a 13-ampere hour version" of the 5390, he adds. "In an environment where [a soldier] might carry six 5590 batteries, he carries only three or four 5390s."

In a parallel effort to better meet soldiers' portable power needs, with CERDEC's encouragement both Salt and Ultralife are investing in improved rechargeable batteries. Greater dependence on rechargeables, versus single-use "primary cell" batteries such as the 5590 and 5390, is one way to cut the number of batteries a unit must haul along on missions.

Historically, soldiers in combat preferred primary cell batteries; the admittedly more cost-effective rechargeable batteries eked out only half the ampere-hours and so were used only in training. But an industry-wide movement towards lithium ion A rechargeable battery technology introduced in 1991 that provides greater charge per pound than nickel metal hydride. In 1993, Toshiba introduced the first notebook in the U.S. with a Li-ion battery.  rechargeables has yielded longer-lasting, more robust batteries that many soldiers now feel confident using in combat. "Rechargeables are being used more and more on the battlefield," Slane says.

"With the latest increases with commercial technology, with laptop computers, we're able to get a higher-capacity, lighter lithium ion battery than in the past," Matthews says. "We are seeing more and more people seeing that as a viable option in the field. At Ultralife, we will always see a need for [both] primary and rechargeable batteries. It's highly unlikely that we'll see reusable batteries approach the capacity of primaries. But for people that are close to base or to a vehicle, it does make sense."

For reusable batteries, chargers are as important as chemistry. Ultralife has developed new multi-bay chargers for vehicles in addition to smaller man-portable chargers. The company's CH0006 Stryker charger can hold three batteries; the infantry carrier variant of the vehicle can fit three chargers for a total of nine bays--one for each dismounted soldier in a Stryker brigade squad.

"There is limited space inside a Stryker," explains Adeeb Saba, Ultralife's director of engineering. "You need to position batteries in different places to take advantage of the space, which is why you'd have three three-bay chargers" instead of one nine-bay charger. "Some Stryker variants fit only one three-bay charger. In this way, we keep things fairly modularized mod·u·lar·ized  
adj.
Having or made up of modules: modularized housing. 
."

Ultralife also has a large 12-bay charger, the CH0017, that fits into most humvee variants. Its tiny CH0008, by contrast, charges just one battery at a time and is tailored for individual soldiers.

"A soldier can put it in his rucksack and use it where he sees fit," Saba says. "He can use it in his bunk or in the field with a generator ... If [he] is going to be around a vehicle, he can run his charger off an AC connection to vehicle."

"He can pretty much use any available power source," Cirin adds.

To diversify those potential power sources, CERDEC has developed what Slane calls a "solar solution to energy scavenging scavenging

of anesthetic. See anesthetic scavenging.
."

Ultralife's work on chargers parallels CERDEC's. The Army command has developed its own vehicle-mounted and individual chargers in addition to introducing commercial chargers to the force.

For both primaries and rechargeable, simply repackaging existing chemistries can result in smaller batteries without a loss in power. While this doesn't necessarily reduce weight very much, the space savings are important to infantrymen struggling to haul around (Naut.) to shift to any point of the compass; - said of the wind.

See also: Haul
 a lot of bulky equipment.

"We do a lot of programs on conformal con·for·mal  
adj.
1. Mathematics Designating or specifying a mapping of a surface or region upon another surface so that all angles between intersecting curves remain unchanged.

2.
 packaging of materials that would allow more body-conformal power sources," Slane says.

Conformal geometries are an especial es·pe·cial  
adj.
1. Of special importance or significance; exceptional: an occasion of especial joy.

2.
 priority for Ultralife, which has been tapped by General Dynamics General Dynamics Corporation (NYSE: GD) is a defense conglomerate formed by mergers and divestitures, and as of 2006 it is the sixth largest defense contractor in the world[1]. The company has changed markedly in the post-Cold War era of defense consolidation.  Land Systems to provide batteries for early incarnations of the Army's $8-billion Land Warrior Land Warrior was a United States Army program, cancelled in 2007,[1][2] that would have used a combination of commercial, off-the-shelf technology (COTS) and current-issue military gear and equipment designed to:
 system. Land Warrior is an integrated suite for the individual soldier featuring a new intra-squad radio, a monocular monocular /mon·oc·u·lar/ (mon-ok´u-ler)
1. pertaining to or having only one eye.

2. having only one eyepiece, as in a microscope.


mo·noc·u·lar
adj.
1.
 display and, for squad leaders, a personal digital assistant--all of which are powered by one pair of rechargeable batteries.

New geometries "may be as simple as going from square to rectangular," Matthews says. "Think of M-16 clips that soldiers put in pouches on their vests. We went through several design iterations and came up with design very similar to that for our current Land Warrior battery. Depending on their mission, soldiers might choose to take additional batteries or additional ammo" and fit either into the same pouches.

For the future, Ultralife is investing in its trademark "thin-cell" technology, which replaces the traditional cylindrical batteries with a sort of pouch. Cylinder batteries waste at least 23 percent of their volume, Cirin reports. "You can utilize more volume" with a pouch.

Salt's Helminen is less bullish about new geometries--and he blames the Army. "It's really quite difficult to create new configurations because they [the Army] want everything to be standardized."

Says Slane, "We do have standard Army battery [configurations]. We try to get more energy into the same package. But some breakthroughs enable smaller packages."

Fuel cells are one potential breakthrough that might spawn entirely new standard batteries--but probably not any time soon, according to Helminen. "It's an old song, that that technology still has quite a lot of development to be done."

"Fuel cells," he adds, "are most likely to come into play in some kind of hybrid system," with the cells perhaps serving as a charging system for reusable batteries.

Slane concurs--but he is more optimistic. Alongside advanced chemistries such as Lithium air, which offers energy density to rival gasoline and should start fielding in around 10 years, fuel cells as part of a hybrid system are the "next step in dismounted soldier power," he says. This year CERDEC conducted tests of fuel cells intended for Land Warrior--the Army's high-tech ensemble that features multiple electronic devices, including a radio, a computer and a GPS receiver.
COPYRIGHT 2007 National Defense Industrial Association
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Title Annotation:UPFRONT
Comment:Power hungry: Army seeks light, efficient batteries to meet insatiable energy demand.(UPFRONT)
Author:Axe, David
Publication:National Defense
Date:Feb 1, 2007
Words:1445
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