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Evaluation of ceramic papers and tapes for use as separators in thermal batteries.

Description: Ceramic tapes and papers were evaluated for potential use as separators in high-temperature thermal batteries. The bulk of the tests involved fiberglass tape and borosilicate filter discs. Quartz (SiO{sub 2}) and zirconia (ZrO{sub 2}) materials were also examined to a limited extent. In addition, custom-prepared MgO-coated ceramic discs from Inventek Inc. were evaluated as separators. The tapes and paper discs were impregnated with LiCl-KCl eutectic or LiCl-LiBr-LiF electrolytes using three different techniques. Test discs were punched from the tapes and papers, impregnated with electrolyte and evaluated as separators in Li(Si)/FeS{sub 2} single cells at 400 or 500 C at a steady-state current of 63 or 125 mA/cm{sup 2}. The performance of single cells containing these discs generally improved with increased electrolyte loading for most of the materials in the case of the LiCl-KCl eutectic. Better results were obtained with the paper filter discs than with the tapes. The best results with the paper discs were obtained with Whatman GF/A filter discs. Active lives for cells with these separators were about 85% of standard cells with pressed-powder separators. Good results were obtained in one battery test with the eutectic electrolyte. Mixed results were obtained with the LiCl-LiBr-LiF electrolyte under similar conditions. Higher loadings of electrolyte did not always translate into improved cell performance. Self-discharge reactions are believed responsible. The best overall results were obtained with the Inventek separators. Based on the results of this study, more work in this technology area is merited.
Date: June 1, 2006
Creator: Reinhardt, Frederick William & Guidotti, Ronald Armand
Partner: UNT Libraries Government Documents Department

Thermal conductivity of thermal-battery insulations

Description: The thermal conductivities of a variety of insulating materials used in thermal batteries were measured in atmospheres of argon and helium using several techniques. (Helium was used to simulate the hydrogen atmosphere that results when a Li(Si)/FeS{sub 2} thermal battery ages.) The guarded-hot-plate method was used with the Min-K insulation because of its extremely low thermal conductivity. For comparison purposes, the thermal conductivity of the Min-K insulating board was also measured using the hot-probe method. The thermal-comparator method was used for the rigid Fiberfrax board and Fiberfrax paper. The thermal conductivity of the paper was measured under several levels of compression to simulate the conditions of the insulating wrap used on the stack in a thermal battery. The results of preliminary thermal-characterization tests with several silica aerogel materials are also presented.
Date: August 1, 1995
Creator: Guidotti, R.A. & Moss, M.
Partner: UNT Libraries Government Documents Department

Characterization of semiconductor bridges (SCB) igniters for use in thermal batteries

Description: Semiconductor bridges (SCB) igniters were evaluated as possible replacements for conventional hot-wire igniters for use in thermal batteries. The all-fire and no-fire characteristics were determined using an up-down scheme; the Neyer/SENSIT program was used to analyze the data. The SCB igniters functioned with a higher no-fire level, relative to a hot-wire igniter, for a given all-fire level. This makes the SCB igniter safer and more reliable than its hot-wire counterpart. The SCB is very resistant to electrostatic discharge and does not require a sensitization mixture for ignition of the primary pyrotechnic charge. These factors, along with its amenability to large-scale production, make the SCB igniter ideally suited for use in thermal batteries.
Date: May 1, 1996
Creator: Bickes, R.W.; Guidotti, R.A. & McCampbell, C.B.
Partner: UNT Libraries Government Documents Department

Evaluation of Aerogel Materials for High-Temperature Batteries

Description: Siiica aerogels have 1/3 the thermal conductivity of the best commercial composite insulations, or ~13 mW/m-K at 25°C. However, aerogels are transparent in the near IR region of 4-7 µm, which is where the radiation peak from a thermal-battery stack occurs. Titania and carbon- black powders were examined as thermal opacifiers, to reduce radiation at temperatures between 300°C and 600°C, which spans the range of operating temperature for most thermal batteries. The effectiveness of the various opacifiers depended on the loading, with the best overall results being obtained using aerogels filled with carbon black. Fabrication and strength issues still remain, however.
Date: May 4, 1999
Creator: Ashley, Carol S.; Guidotti, Ronald A.; Reed, Scott T. & Reinhardt, Frederick W.
Partner: UNT Libraries Government Documents Department

Characterization of vacuum-multifoil insulation for long-life thermal batteries

Description: The use of vacuum multifoil (VMF) container for thermal insulation in long-life thermal batteries was investigated in a proof-of-concept demonstration. An InvenTek-designed VMF container 4.9 inches in diameter by 10 inches long was used with an internally heated aluminum block, to simulate a thermal-battery stack. The block was heated to 525 C or 600 C and allowed to cool while monitoring the temperature of the block and the external case at three locations with time. The data indicate that it should be possible to build an equivalent-sized thermal battery that should last up to six hours, which would meet the requirements for a long-life sonobuoy application.
Date: April 17, 2000
Partner: UNT Libraries Government Documents Department

A study of the ignition processes in a center-hole-fired thermal battery

Description: The ignition processes that take place during activation of a 16 cell, center hole fired thermal battery were examined by monitoring the voltage of each cell during activation. The average rise time of each cell to a voltage of 1.125 V was determined for the LiSi/LiCl-LiBr-LiF/FeS{sub 2} electrochemical system. The effects of heat pellet composition, center hole diameter, and the load on the activation parameters were examined for three different igniters. A large variability in individual cell performance was evident along with cell reversal, depending on the location of the cell in the stack. It was not possible to draw detailed statistical information of the relative ignition sequence due to the intrinsic large scatter in the data.
Date: April 1, 1998
Creator: Guidotti, R.A. & Reinhardt, F.W.
Partner: UNT Libraries Government Documents Department

A study of the stack relaxation in thermal batteries on activation

Description: The stack-relaxation processes occurring in a thermal-battery upon activation and discharge were studied dynamically with a special test fixture that incorporated an internal load cell. The factors which were screened initially included stack diameter and height (number of cells), thickness and binder content of the separator, temperature, and closing pressure. A second series of more-detailed experiments included only those factors that were identified by the screening study as being important (as closing force, number of cells, and separator thickness). The resulting experimental data from this second series of experiments were used to generate a surface-response model based on these three factors. This model accounted for 94% of the variation in the response (final stack-relaxation pressure) over the range of conditions studied.
Date: April 17, 2000
Partner: UNT Libraries Government Documents Department

Iron/potassium perchlorate pellet burn rate measurements

Description: A burn rate test having several advantages for low gas-producing pyrotechnic compacts has been developed. The technique involves use of a high speed video motion analysis system that allows immediate turnaround and produces all required data for rate computation on magnetic tape and becomes immediately available on the display screen. The test technique provides a quick method for material qualification along with data for improved reliability and function. Burn rate data has been obtained for both UPI and Eagle Pitcher Iron/Potassium Perchlorate blends. The data obtained for the UPI blends cover a range of composition, pellet density, and ambient (before ignition) pellet temperature. Burn rate data for the E-P blends were extended to include surface conditions or particle size as a variable parameter.
Date: January 25, 1995
Creator: Reed, J.W. & Walters, R.R.
Partner: UNT Libraries Government Documents Department

Engineering process instructions and development summary MC3642 thermal battery

Description: The MC3642 is a dual channel thermal battery used on the DE1010/W85 Command Disable Controller. It utilizes the CalCaCrO{sub 4} electrochemical system. The electrical requirements of this battery are as follows: RISE TIME PEAK VOLTAGE ACTIVE LIFE LOAD Channel 1 - 1.0 Sec. Max. 34 Volts 10 Sec. Min. 40.0 Ohms to 20 Volts above 20 Volts Channel 2 - .350 Sec. Max. 42 Volts 10 MSec. Min. 6.5 Ohms to 23 Volts above 23 Volts The battery consists of 14 cells connected in series (Channel 2) and 12 cells connected in series (Channel 1). Each cell is composed of an anode fabricated from a bimetallic sheet (0.005{double_prime} thick calcium on 0.005{double_prime} thick iron substrate), a depolarizer-electrolyte-binder (DEB) pellet and a heat pellet. Activation is achieved by mechanical primer. Optimum battery performance is achieved with a 35155/10 DEB pellet weighing .80g and a heat pellet, weighing 1.30 grams, of 88/12 heat powder.
Date: June 1, 1981
Creator: Jacobs, D.
Partner: UNT Libraries Government Documents Department

Utilization of sensitivity coefficients to guide the design of a thermal battery

Description: Equations are presented to describe the sensitivity of the temperature field in a heat-conducting body to changes in the volumetric heat source and volumetric heat capacity. These sensitivity equations, along with others not presented, are applied to a thermal battery problem to compute the sensitivity of the temperature field to 19 model input parameters. Sensitivity coefficients, along with assumed standard deviation in these parameters, are used to estimate the uncertainty in the temperature prediction. From the 19 parameters investigated, the battery cell heat source and volumetric heat capacity were clearly identified as being the major contributors to the overall uncertainty in the temperature predictions. The operational life of the thermal battery was shown to be very sensitive to uncertainty in these parameters.
Date: August 1, 1998
Creator: Blackwell, B.F.; Dowding, K.J.; Cochran, R.J. & Dobranich, D.
Partner: UNT Libraries Government Documents Department

Development of a high-power and high-energy thermal battery

Description: The Li(Si)/FeS{sub 2} and Li(Si)/CoS{sub 2} couples were evaluated with a low-melting LiBr-KBr-LiF eutectic and all-Li LiCl-LiBr-LiF electrolyte for a battery application that required both high energy and high power for short duration. Screening studies were carried out with 1.25 inch-dia. triple cells and with 10-cell batteries. The Li(Si)/LiCl-LiBr-LiF/CoS{sub 2} couple performed the best under the power load and the Li(Si)/LiCl-LiBr-LiF/FeS{sub 2} was better under the energy load. The former system was selected as the best overall performer for the wide range of temperatures for both loads, because of the higher thermal stability of CoS{sub 2}.
Date: April 18, 2000
Partner: UNT Libraries Government Documents Department

Evaluation of plasma-sprayed CoS{sub 2} cathodes for thermal batteries

Description: Conventional electroactive stack components in thermal batteries are constructed from pressed-powder parts. These include the anode, separator, and cathode pellets (discs). Pressing parts that are less than 0.010 inch thick is difficult. The use of plasma spray to deposit thin CoS{sub 2} cathode films onto a stainless steel substrate was examined as an alternative to pressed-powder cathodes. The plasma-sprayed electrodes were tested in single cells under isothermal conditions and constant-current discharge over a temperature range of 400 C to 550 C using standard LiSi anodes and separators based on the LiCl-KCl eutectic. Similar tests were conducted with cells built with conventional pressed-powder cathodes, which were tested under the same conditions for comparative purposes. This paper presents the results of those tests.
Date: December 22, 1999
Creator: Guidotti, R.A.
Partner: UNT Libraries Government Documents Department

Characterization of the Li(Si)/CoS(2) couple for a high-voltage, high-power thermal battery

Description: In order to determined the capabilities of a thermal battery with high-voltage and high-power requirements, a detailed characterization of the candidate LiSi/LiCl-LiBr-LiF/CoS{sub 2} electrochemical couple was conducted. The rate capability of this system was investigated using 0.75 inch-dia. and 1.25 inch-dia. single and multiple cells under isothermal conditions, where the cells were regularly pulsed at increasingly higher currents. Limitations of the electronic loads and power supplies necessitated using batteries to obtain the desired maximum current densities possible for this system. Both 1.25 inch-dia. and 3 inch-dia. stacks were used with the number of cells ranging from 5 to 20. Initial tests involved 1.25 inch-dia. cells, where current densities in excess of 15 A/cm{sup 2} (>200 W/cm{sup 2}) were attained with 20-cell batteries during 1-s pulses. In subsequent follow-up tests with 3 inch-dia., 10-cell batteries, ten 400-A 1-s pulses were delivered over an operating period often minutes. These tests formed the foundation for subsequent full-sized battery tests with 125 cells with this chemistry.
Date: February 1, 2000
Partner: UNT Libraries Government Documents Department

Final report on LDRD project: A phenomenological model for multicomponent transport with simultaneous electrochemical reactions in concentrated solutions

Description: A phenomenological model was developed for multicomponent transport of charged species with simultaneous electrochemical reactions in concentrated solutions, and was applied to model processes in a thermal battery cell. A new general framework was formulated and implemented in GOMA (a multidimensional, multiphysics, finite-element computer code developed and being enhanced at Sandia) for modeling multidimensional, multicomponent transport of neutral and charged species in concentrated solutions. The new framework utilizes the Stefan-Maxwell equations that describe multicomponent diffusion of interacting species using composition-insensitive binary diffusion coefficients. The new GOMA capability for modeling multicomponent transport of neutral species was verified and validated using the model problem of ternary gaseous diffusion in a Stefan tube. The new GOMA-based thermal battery computer model was verified using an idealized battery cell in which concentration gradients are absent; the full model was verified by comparing with that of Bernardi and Newman (1987) and validated using limited thermal battery discharge-performance data from the open literature (Dunning 1981) and from Sandia (Guidotti 1996). Moreover, a new Liquid Chemkin Software Package was developed, which allows the user to handle manly aspects of liquid-phase kinetics, thermodynamics, and transport (particularly in terms of computing properties). Lastly, a Lattice-Boltzmann-based capability was developed for modeling pore- or micro-scale phenomena involving convection, diffusion, and simplified chemistry; this capability was demonstrated by modeling phenomena in the cathode region of a thermal battery cell.
Date: January 1, 2000
Partner: UNT Libraries Government Documents Department

Screening study of mixed transition-metal oxides for use as cathodes in thermal batteries

Description: Over 100 candidates were examined, including commercial materials and many that were synthesized in house. The mixed oxides were based on Ti, V, Nb, Cr, Mo, W, Mn, Fe, Co, Ni, and Cu doped with other transition metals. A number of individual (single-metal) oxides were included for comparison. The candidates were tested in single cells with Li(Si) anodes and separators based on LiCl-KCl eutectic. Screening was done under constant-current conditions at current densities of 125 me/cm{sup 2} and, to a lesser extent, 50 me/cm{sup 2} at 500 C. Relative performance and limitations of the oxide cathodes are discussed.
Date: May 1, 1996
Creator: Guidotti, R.A. & Reinhardt, F.W.
Partner: UNT Libraries Government Documents Department

Pyrolysis of epoxies used for thermal-battery headers

Description: Thermally activated batteries use an epoxy for encapsulation of the electrical feedthroughs in the header of the battery. When the thermal battery is thermally abused, the encapsulant can pyrolyze and generate large internal pressures. This causes the battery to vent in extreme cases. The nature of these gases has never been adequately documented. Therefore, a study was undertaken to address this deficiency. The pyrolysis of various encapsulants that have been used, or are being considered for use, in thermally activated batteries was studied over a temperature range of 155 to 455 C. The composition of the pyrolysis decomposition products was determined by gas chromatography/mass spectrometry (GS/MS). This determination is helpful in assessing the potential environmental and health effect for personnel exposed to such gases. In addition, the thermal stability of the various epoxies was measured by thermogravimetric analysis (TGA).
Date: August 1, 1995
Creator: Guidotti, R.A.; Thornberg, S.M. & Campbell-Domme, B.
Partner: UNT Libraries Government Documents Department

Deformation study of separator pellets for thermal batteries

Description: The deformation characteristics of pellets of electrolyte-binder (EB) mixes based on MgO were measured under simulated, thermal-battery conditions. Measurements (using a statistically designed experimental strategy) were made as a function of applied pressure, temperature, and percentage of theoretical density for four molten-salt electrolytes at two levels of MgO. The EB mixes are used as separators in Li-alloy thermal batteries. The electrolytes included LiCl-KCI eutectic, LiCl-LiBr-KBr eutectic, LiBr-KBr-LiF eutectic, and a LiCl-LiBr-LiF electrolyte with a minimum-melting composition. The melting points ranged from 313 C to 436 C. The experimental data were used to develop statistical models that approximate the deformation behavior of pellets of the various EB mixes over the range of experimental conditions we examined. This report, discusses the importance of the deformation response surfaces to thermal-battery design.
Date: May 1, 1995
Creator: Guidotti, R.A.; Reinhardt, F.W. & Thomas, E.V.
Partner: UNT Libraries Government Documents Department

Thermal Batteries for Electric Vehicles

Description: Advanced Research Projects Agency-Energy project sheet summarizing general information about the High Energy Advanced Thermal Storage (HEATS) program including critical needs, innovation and advantages, impacts, and contact information. This sheet discusses modular high-energy, low-cost thermal storage as part of the "Thermal Batteries for Electric Vehicles" project.
Date: May 25, 2012
Creator: University of Texas at Austin
Partner: UNT Libraries Government Documents Department

Evaluation of aqueous cleaners as alternatives to vapor degreasing

Description: As part of the preparation process during assembly of thermally activated batteries, the stainless steel piece parts are normally cleaned by vapor degreasing with trichloroethylene. Severe restrictions on the use of chlorinated and fluorinated hydrocarbons in recent years prompted the evaluation of a number of aqueous cleaners as a replacement technology for this application. A total of seven commercial aqueous degreasers was evaluated in this study at several dilution ratios and temperatures. One organic cleaner was also examined under ambient conditions. The effectiveness of the cleaner was determined by the use of x-ray photoelectron spectroscopy (XPS), which is a surface analytical technique that is very sensitive to low levels of surface contaminants. A quartz-crystal microbalance (QCM) that is immersed in the cleaning bath was evaluated as a tool for monitoring the bath cleanliness. The best overall cleaning results were obtained with Micro, Impro-Clean 3800, and Sonicor cleaners.
Date: May 1, 1996
Creator: Guidotti, R.A.; Schneider, T.W. & Frye, G.C.
Partner: UNT Libraries Government Documents Department

MC4523 Sealed Cap: Component & characteristics development report

Description: The MC4523 Sealed Cap is a WW42C1 Percussion Primer that is pressed into a steel cylinder. Hermaticity of the input end is then provided by welding a thin steel closure disk on the input end of the MC4523. Thus, the user is provided with a component that is prequalified in terms of ignition sensitivity and hermeticity. The first customer is the Thermal Battery Department (1522). The MC4523 will be used on the MC2736A Thermal Battery which in turn will be used on the W78 JTA. Attachment of the MC4523 to the battery is with a laser weld. Combined test results of four production lots at a commercial supplier (PPI, TMS, WR1, and WR2) show an all-fire ignition sensitivity (.999 @ 50%) of approximately 60 millijoules of mechanical energy with a 2.2 gram firing pin. The firing pin had an impact tip with a radius of 0.020 inch. This firing pin is like that to be used in the W78 JTA application. Approximately 112 millijoules of mechanical energy will be supplied in the application, thus the design margin is more than adequate.
Date: March 1, 1997
Creator: Begeal, D.R.
Partner: UNT Libraries Government Documents Department

Combustion of Bulk 84% Fe/16% KCIO{sub 4} heat powder

Description: Fe/KClO{sub 4} pyrotechnic mixtures are used in thermal batteries to provide the heat necessary to bring the battery stack to operating temperatures of 550 to 600 C. This heat source is normally used as discs pressed from bulk powder. To evaluate the consequences associated with unexpected ignition of large amounts of heat powder, combustion of 84% Fe/16% KClO{sub 4} heat powders was conducted for various scenarios under controlled conditions and the response documented. Increasing amounts of heat powder--up to 8 lbs--were ignited in both unconfined and confined (sealed) containers in a remote area. The containers were thermocoupled and the resulting burning filmed with a standard video camera, high-speed (1,000 frames/s) film and video cameras, and an infrared video camera. A 20- minute video of the burning under the various conditions is presented.
Date: May 1, 1996
Creator: Nissen, M.; Guidotti, R.A. & Berry, B.
Partner: UNT Libraries Government Documents Department