Wound thermal batteries and methods of manufacturing the same

1. A thermal battery comprising:

a first conductive layer containing an anode material separated from a second conductive layer containing a cathode material by a separator layer containing a separator material, wherein the separator material comprises an electrolyte and a polymeric binder, wherein the polymeric binder comprises of polymethylmethacrylate present in about 10 wt % to about 30 wt % of the polymeric binder;

a flexible pyrotechnic heat source;

wherein the first conductive layer, the separator layer, and the second conductive layer are rolled together to form a spiral wound configuration, the flexible pyrotechnic heat source being included as a layer spirally wound into the thermal battery to be incorporated within the windings of the first conductive layer, the separator layer, and the second conductive layer;

a battery casing housing the spiral wound configuration; and

a first conductive tab connected to the first conductive layer and a second conductive tab connected to the second conductive layer, wherein the first conductive tab and the second conductive tab protrude from the spiral wound configuration;

wherein the first conductive tab is further joined to an anode current collector, a first external battery terminal and the battery casing, and wherein the second conductive tab is further joined to a cathode current collector, a second external battery terminal and the battery casing;

further, wherein the first conductive layer and the second conductive layer are offset from each other such that the first conductive layer extends beyond the separator layer and the second conductive layer in a first direction, while the second conductive layer extends beyond the separator layer and the first conductive layer in a second direction, which opposes the first direction.

2. The thermal battery of claim 1 , wherein:

the electrolyte is a nonconductive solid at ambient temperatures; and

the electrolyte is molten at operating temperatures of the thermal battery.

3. The thermal battery of claim 2 wherein the operating temperatures are from about 350° C. to about 600° C.

4. The thermal battery of claim 1 , wherein an outermost layer of the spiral wound configuration is the first conductive layer.

5. The thermal battery of claim 1 , wherein an outermost layer of the spiral wound configuration is the second conductive layer.

6. The thermal battery of claim 1 , wherein:

the first conductive layer has a thickness of from about 0.001 inches to about 0.020 inches;

the second conductive layer has a thickness of from about 0.001 inches to about 0.020 inches; and

the separator layer has a thickness of from about 0.001 inches to about 0.020.

7. The thermal battery of claim 1 , wherein the flexible pyrotechnic heat source is located between the cathode current collector and the anode current collector.

8. The thermal battery of claim 1 , wherein the flexible pyrotechnic heat source is circumferentially wrapped around the spiral wound configuration.

9. The thermal battery of claim 5 , wherein:

the flexible pyrotechnic heat source is a non-conductive pyrotechnic material selected from the group consisting of zirconium/barium chromate paper; or

the flexible pyrotechnic heat source is a conductive pyrotechnic material selected from the group consisting of iron/potassium perchlorate/polymer, or mixtures of nickel/zirconium/potassium perchlorate/polymer.

10. The thermal battery of claim 1 , wherein the cathode material comprises:

at least one active material selected from the group consisting of FeS 2 , FeS, NiS 2 , and CoS 2 ;

a catholyte comprising a salt capable of melting at an operating temperature of the thermal battery; and

a polymeric binder that does not generate a deleterious reaction at the operating temperature of the thermal battery, wherein the polymeric binder further comprises polymethylmethacrylate as a releasing agent.

11. The thermal battery of claim 2 , wherein the separator material comprises:

a salt capable of melting at an operating temperature of the thermal battery;

an inorganic material capable of immobilizing the molten salt; and

a polymeric binder that does not generate a deleterious reaction at the operating temperature of the thermal battery.

12. The thermal battery of claim 11 , wherein the inorganic material is selected from the group consisting of magnesium oxide and aluminum oxide.

13. The thermal battery of claim 1 , wherein the anode material comprises:

at least one active material selected from the group consisting of LiSi and LiAl;

an anolyte comprising a salt capable of melting at an operating temperature of the thermal battery; and

a polymeric binder that does not generate a deleterious reaction at the operating temperature of the thermal battery, wherein the polymeric binder further comprises polymethylmethacrylate as a releasing agent.

14. The thermal battery of claim 1 , wherein the separator material further comprises magnesium oxide, polyisobutylene, toluene and silicone-coated biaxially-oriented polyethylene terephthalate.

15. A method of manufacturing a thermal spiral wound battery comprising:

preparing a first slurry comprising an anode material, a first polymeric binder, and a first volatile solvent;

depositing the anode material from the first slurry onto a first conductive substrate to form a first conductive layer;

preparing a second slurry comprising a cathode material, a second polymeric binder, and a second volatile solvent;

depositing the cathode material from the second slurry onto a second conductive substrate to form a second conductive layer;

preparing a third slurry comprising an electrolyte/separator material, a third polymeric binder and a third volatile solvent, wherein the third polymeric binder comprises of polymethylmethacrylate present in about 10 wt % to about 30 wt % of the third polymeric binder;

depositing the electrolyte/separator material from the third slurry onto a third conductive substrate to form a separator layer;

stacking the first conductive layer, the separator layer, and the second conductive layer such that the separator layer separates the first conductive layer and the second conductive layer;

winding the first conductive layer, the separator layer, and the second conductive layer together into a spiral wound configuration, wherein the first conductive layer and the second conductive layer are offset from each other such that the first conductive layer extends beyond the separator layer and the second conductive layer in a first direction, while the second conductive layer extends beyond the separator layer and the first conductive layer in a second direction, which opposes the first direction;

connecting a first conductive tab to the first conductive layer and a second conductive tab connected to the second conductive layer, such that the first conductive tab and the second conductive tab protrude from the spiral wound configuration, wherein the first conductive tab is further joined to an anode current collector, a first external battery terminal and a battery casing, and wherein the second conductive tab is further joined to a cathode current collector, a second external battery terminal and the battery casing;

adding a flexible pyrotechnic heat source before winding the conductive substrate; and

winding the flexible pyrotechnic heat source spirally into the spiral wound configuration.

16. The method of claim 15 , wherein depositing the anode material, the cathode material, or the electrolyte/separator material from the first slurry, the second slurry, or the third slurry onto the first conductive substrate, the second conductive substrate, or the third conductive substrate comprises:

casting the slurry under a doctor blade to deposit a controlled amount of the slurry; and

evaporating the volatile solvent to form the first conductive layer, the second conductive layer, or the separator layer.

17. The method of claim 15 , wherein each of the first conductive tab and the second conductive tab comprises a material selected from a group consisting of iron, stainless steel, nickel, aluminum and copper.

18. The method of claim 15 , wherein the flexible pyrotechnic heat source is located between the first conductive layer and the second conductive layer.