Advancements in Thermal Battery Pellet Manufacture

Thermal batteries are a mission-critical component utilized in virtually every weapon system. All thermal batteries require four types of pellets that comprise the cell stack(s), i.e., the energy-producing portion of the battery. Pellet size (diameter and thickness) and the number of pellets required vary by battery type and application. Pellets are manufactured by compaction of their powdered constituents in dies on automated presses. Pellet production is a rate-limiting step in thermal battery manufacture. At present, the pellet production rate (pellets per minute) is highly dependent on the type of powder material being pressed and type of press being used. The powders being utilized for pellet production do not possess ideal properties. The chemical, physical, and mechanical properties of the various powders are vastly different. It is therefore important that any automated powder handling methods developed are applicable to powders having a wide range of properties. This SBIR project focuses on the development of improved powder transfer properties. Accomplishing this will substantially increase thermal battery production rates while ensuring the exacting levels of control necessary to maximize both performance and reliability. The result of this will be a reduced cost to customers and increased production throughput.