Ballistic Missile Defense System Innovative Power Storage Devices

An opportunity exists to lower cost and improve thermal battery performance by applying a unique separator material, ceramic fiber separator (CFS), developed by Inventek Corporation. The paper-like material can also serve as a foundation for thin-electrode fabrication and a continuous method for battery/cell fabrication. Additional InvenTek will apply low-temp nitrate chemistry in development by Millenium Engr. and Integr. (MEI). Cell weight with CFS is reduced by at least 20% and provides greater capacity utilization and 30% lowered internal impedance. Both specific energy and power can be doubled from double cell voltage with metal oxides (up to 4 volts) and reduced cell mass with CFS . The combination of CFS and nitrate electrolyte/metal oxide electrode can approach 100Wh/kg and 7kW/kg. Continuous processing method of cell fabrication with CFS can be 40-fold faster than the conventional pressed powder thermal batteries. Specifically, the CFS serves as a setter for the printing of electrode material that can be conformal in cell/battery shape. Eliminating intensive hydraulic pressing operations can reduce thermal battery production costs by a nominal 25%. Phase I will provide a proof of concept demonstration of the cell technology. In Phase II Inventek will collaborate with a thermal battery manufacturer to demonstrate low-cost continuous processing for the CFS-supported thin cells.