Developing NanoFoil-Heated Thin-Film Thermal Battery

Report No. ARL-TR-6664
Authors: Michael S. Ding, Frank C. Krieger, and Jeffrey A. Swank
Date/Pages: September 2013; 32 pages
Abstract: This report describes and discusses a series of experiments in which aluminum-nickel NanoFoil materials were used as the heat source for other thermal battery components, such as cathode, anode, and electrolyte, in the form of coated thin films, to develop a NanoFoil-heated thin-film thermal battery technology. This work culminated in the design, construction, and characterization of a complete, fully functional 12-cell NanoFoil-heated thin-film thermal battery prototype, which demonstrated a much faster rise in working voltage, a much lower internal gas pressure, a much shorter stack height, and a much greater flexibility in form factor, than the traditional pressed-pellet thermal batteries. In the process of screening and optimizing for the NanoFoil-heated thin-film thermal battery prototype, it was found that end-heating was very effective in prolonging the runtime of the battery by reducing the heat-sink from the battery stack into the end insulation, and the effective initiation length of the heat paper fuse strip was a major factor in determining the overall rise time of the battery due to the much lower speed of flame propagation in the heat paper than in the NanoFoil.
Distribution: Approved for public release
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Last Update / Reviewed: September 1, 2013