Thin Film Thermal Batteries

US Army seeks to develop thermal batteries that are lower in cost, improved in electrochemical performance, and can be made in three-dimensional shapes. Currently, thermal batteries are manufactured in low volume and not cost effective process. The major components, electrodes and electrolytes, are pressed pellets, which need extra thickness to avoid cracking and cannot be used for mass production. US Nanocorp, Inc. (“USN”) proposes a new film fabrication technique to make the sandwich three layer cells to address Army’s request for improvement on thermal battery production. In the new cell production techniques, anode film will be made via porous nickel thermal spray coating and loaded with Li-metal to form a Li-Ni (Fe) composite film with required solidity at thermal battery working temperature. Cathode and electrolyte/separator will be thermal sprayed serially on graphoil sheets and cut into required shape and size. The process is feasible for automation and mass production. Another advantage is that the proposed film/membrane can be cut to any shape and size without dimension limitation. This program is highly feasible with USN’s extensive experience on materials and thin film coatings combined with Advanced Thermal Batteries, Inc (“ATB”) thermal battery manufacture experience.