Satellite Battery Manufacturer

Satellite Batteries

As long as space flight has existed, satellites and other space vehicles have carried rechargeable batteries to store electrical energy. While this reality remains constant, the space industry has undergone tremendous change and now demands significant performance improvements from battery systems. Today, spacecraft range in scope from small, cost-effective pico- and microsatellites that orbit Earth in a relatively low orbit to massive geostationary communications satellite systems. Since the primary role of batteries in these craft is to provide power when the Earth’s shadow blocks the satellite’s exposure to the Sun, the performance demands vary significantly depending on the orbit and power needs of the satellite.

Satellites are employed by three key segments of the space industry. Civil space programs (of which NASA is the world’s largest) employ spacecraft to advance space science, pursue exploration and scientific sensing, and improve communications. Military missions pursue such strategic objectives as surveillance, reconnaissance, mapping, weather, and missile defense. Lastly, the commercial sector depends upon satellites to provide communications and allow distribution of television, radio, and other media. All of these sectors have significantly different needs and priorities regarding batteries.

Space exploration includes both manned and un-manned platforms and range from interplanetary surface operations to deep space missions and near earth operations. All of these missions are utilizing batteries with a solar combination or as auxiliary unit in conjunction with an alternative power generating device. This varying environment and generating power sources puts unique demands on the battery system.

The EnerSys Advanced Solution

As part of EnerSys Advanced Solutions, we can offer lithium-ion satellite battery solutions through our ABSL facilities. For these designs, EnerSys Advanced Solutions will evaluate Quallion lithium-ion cell designs (ranging from cylindrical 18650 to large prismatic form factors) for mission suitability.

Quallion is uniquely positioned to offer battery solutions to the satellite and space exploration market. Our lithium ion technology delivers unsurpassed energy density, a critical factor for any customer seeking a power solution for small spacecraft or needing to shift more of the satellite mass from battery to payload. On a large communications or military satellite, the decision to go with Li-ion could reduce mass by hundreds of pounds and allow more strategic or revenue-producing payload. In addition, Quallion is uniquely positioned to satisfy aerospace and military customers with high reliability requirements thanks to our rigorous materials control, which eliminates even the subtlest variations in future cell builds.

Quallion has achieved significant breakthroughs in Li ion battery technology that now deliver critical performance for space satellite systems:

The industry’s lowest demonstrated self discharge and calendar fade, ideal for GEO applications
The industry’s longest demonstrated cycle life for a large satellite cell based on capacity removed in each cycle, ideal for LEO applications requiring > 60,000 cycles and 15 year battery life
Wide operating temperature chemistry for unique missions
A comprehensive understanding of the thermal characteristics of our cell and battery designs through real time testing and modeling
A unique custom first principles model specifically geared to Quallion’s proprietary chemistry and cell design. This modeling effort was based upon first principles analysis of Quallion’s chemistry and empirical testing of Quallion’s aerospace cells and battery design.
A vertically integrated production line offering unique process control from the production control of the cell raw materials (e.g., cathode, anode and electrolyte) to cell and battery design.
Extensive cell testing and characterization

Late in 2006, Quallion was awarded a Title III program from the U.S. government to domestically produce the cathode and anode materials used in large satellite cells. Quallion  set up a large cell manufacturing line in 2013 under the Title III contract. No other space satellite battery manufacturer is able to offer its customers a cradle-to-grave battery solution, in which cell and battery production is controlled in one US based facility. Quallion is able to ensure its customers a fully qualified product for the next 20-30 years.

Quallion can deliver satellite cells and/or batteries with key technological advantages. 1. Quallion can create a battery with its own design and materials, which enables fully customizable solutions for any specifications and takes full advantage of our specialized materials control. This option also enables customers to leverage Quallion’s patented Zero-Volt™ technology, which allows long storage periods in a deep discharged state with no permanent capacity loss.