Innovative Manufacturing Processes

This SBIR provides an opportunity to reduce unit cost by 25% and improve reliability through production of thermal batteries by a continuous process. This process uses Inventek's ceramic fiber separator CFS to act as a carrier for the fabrication of thinthermal cells through a tunnel kiln. CFS fiber paper exhibits about 20 times greater strength than the standard pressed MgO pellet. Thin separator is required to take advantage of thin electrode. CFS has also demonstrated high power performance that isnot limited by cell size. This process will first be adapted to conventional pellet electrode production. Thin (0.25 mm), flexible, ceramic fiber paper can be a substrate for the application of electrode materials by alternative methods (e.g.tapecasting). The modulus of rupture, MOR, of our typical CFS fiber paper exhibits about 20 times greater strength than the standard pressed MgO pellet. With the high-strength CFS separator, continuous electrode production methods are also enabled. Ourrecent market evaluation found that about 50% of thermal battery costs are a result of slow pellet component production and