Nonrechargeable Battery Manufacturing Improvements

The U.S. military is seeking improved methods of battery manufacturing which will enhance the ability of DoD-interest in battery manufacturers to produce nonrechargeable (primary) batteries. The current dough-batch teflonated process for making MnO2 cathodes is quite labor intensive and time consuming. Twin screw extrusion technology is an alternative method of manufacture which offers faster production times, reliability, reduced labor, and higher efficiency. Twin screw extrusion technology is inherently scalable for "right-sizing" production capacity leading to lower production costs and labor time. Building upon previous success in the extrusion of rechargeable Li-Ion (LiCoO2 and LiNi0.8Co0.2O2) PVdF cathodes, MaxPower proposes to adapt the twin screw extrusion process to Li/MnO2 primary cell technology. The main objective of Phase I is to demonstrate that the twin screw extrusion process is compatible with these primary battery systems. Phase II will incur further optimization of the cathode compositions and the introduction of CFx as an alternative candidate system to be selected for the production of BA-5390 batteries for the U.S military. With successful implementation of Phase I and Phase II, the twin screw extrusion processing method should readily transfer to the market scale for both military and commercial applications of primary Li/MnO2 battery systems.