Nail Penetration Adapter for Li-Ion Battery Testing

Johnson Space Center, Houston, TX

Diagram of the nail penetration adapter bridging the battery cell test enclosure (left) with the actuator subassembly (right). The adapter features a quick-disconnect mechanism that facilitates easy separation of the enclosure from the actuator subassembly. (Image: NASA)

Innovators at NASA Johnson Space Center have designed a pneumatic nail penetration trigger system that drives a Li-ion battery cell into thermal runaway using a tungsten nail. By creating a targeted rupture in a battery cell’s outer casing, researchers can initiate an exothermic chain reaction within the battery, much like a short circuit, causing a spike in temperature that can lead to battery failure, fire or explosion.

This research leads to safety advancements in battery design. Novel to the pneumatic nail penetration trigger system is a quick-release barrel adapter that bridges and aligns the nail’s pneumatic actuator subassembly to the battery cell test enclosure while facilitating the precise guidance of a nail when fired through its bore.

This system embodies a fast and consistent nail penetration and retraction tool that tests battery cells within various steel and mylar enclosures. It is operated remotely with electric power and shop air pressure inputs. The trigger system is controlled by a solenoid valve and drives a nail to a set distance at 100 m/s for a precise and repeatable penetration injury to a battery cell.

Contributing to the trigger system’s precision and repeatability is the nail penetration adapter that aligns the battery cell test enclosure with the trigger system and guides the nail by its internal barrel. The tip of the adapter threads into a variety of NASA battery cell test enclosures and provides an internal seating stop to ensure a proper targeting depth.

On the actuator side of the adapter, two quick-release pins connect the adapter to the actuator mount which is bolted to the actuator subassembly. Removal of these pins readily allow for separation of the nail penetration adapter from the actuator mount and subassembly. During a TR event, the adapter is also designed to prevent flames, sparks, and eject from traveling into the actuator subassembly.

While the versatile nail penetration adapter was originally configured to interface with NASA’s Fractional Thermal Runaway Calorimeter (FTRC), a blast plate test platform (BPTP), or cell enclosure for passive propagation resistant (PPR) methods, the adapter could be modified for commercial use with other battery testing systems.

NASA is actively seeking licensees to commercialize this technology. Please contact NASA’s Licensing Concierge at This email address is being protected from spambots. You need JavaScript enabled to view it. or call at 202-358-7432 to initiate licensing discussions. For more information, visit here .