Abstract: A coin cell having a hermetic design withstands high performance applications including high temperature missions from a drop in replacement envelope. The coin cell can include a container having a bottom wall and a surrounding wall that form an interior volume, and the surrounding wall can include an inner, upper peripheral edge, at a top of the surrounding wall. The coin cell can include an anode assembly; a cathode assembly; and a header ring including a header ring outer surface and a header ring inner surface that defines an opening. The coin cell can include an insulator ring that includes an insulator ring outer surface that extends along and inside of the header ring inner surface, and an insulator ring inner surface that defines an opening within the insulator ring. A pin can be provided in the opening of the insulator ring. The coin cell can include an electrolyte.

Abstract: Some embodiments are directed to a battery. The battery can include a case having a hollow accommodation cavity formed therein. The case having a material that includes a blend comprising at least one of polysulfone, acrylonitrile butadiene styrene (ABS), Nylon, polyphenylene oxide (PPO), styrene-acrylonitrile (SAN), and polypropylene. The material of the case enables removal of thermal energy generated during operation of the battery.

Abstract: An electrochemical cell that converts chemical energy to electrical energy includes a cathode with an active material of fluorinated carbon on a perforated metal cathode current collector, a lithium anode on a perforated metal anode current collector, a stepped header, a stable electrolyte, and a separator. In various embodiments, an anode current collector design, a cathode current collector design, a stepped header design, a cathode formulation, an electrolyte formulation, a separator, and a battery incorporating the electrochemical cell are provided.

Abstract: Batteries and methods of using and making batteries are provided. A cell can include a housing; a cathode current collector, in the housing, including a cathode tab and a cathode plate. The cathode tab can include a tab area. The cathode plate can include a plate area and a peripheral edge that surrounds at least a portion of the plate area. The peripheral edge can include a plurality of partial perforations. The plate area can include a plurality of interior perforations. The cell can further include an anode current collector, in the housing, including an anode tab; an anode, in the housing, provided adjacent the anode current collector; and a cathode, in the housing, provided adjacent to the cathode current collector.

Abstract: The disclosure provides an electrochemical cell that may comprise a housing; a cathode connection, in the housing, that is associated with a cathode; an anode connection, in the housing, that is associated with an anode; an electrolyte; and a header assembly. The header assembly can include a cathode connection assembly; an anode connection assembly; and a stepped header body that includes (a) a first step portion having a first thickness and first step surface, (b) a second step portion having a second thickness and a second step surface, and the first thickness being thicker than the second thickness. The disclosure may also provide systems and methods of making such a cell.

Abstract: The present disclosure relates to an energy module having a plurality of energy generating cells, and at least one cooling plate having opposing surfaces. The cooling plate is disposed between an adjacent pair of the energy generating cells such that the opposing surfaces of the cooling plate are in contact with surfaces of the adjacent pair of energy generating cells. The cooling plate has at least one coolant flow channel configured to receive a coolant flow therethrough to limit propagation of heat from one to the other of either one of the adjacent pair of energy generating cells when either one of the adjacent pair of energy generating cells fails.

Abstract: An improved electrolyte including a fire-retardant additive suitable for application in wide temperature cell and/or battery operation with safer cell design, a battery including the electrolyte and a separator optionally containing a fire-retardant additive, improved electrical and thermal conductive electrodes are disclosed. The presence of the fire-retardant additive reduces flammability of the electrolyte and improved the overall safety of the battery.

Abstract: The disclosure provides a cell that may comprise (1) a housing; (2) an anode current collector, in the housing, including a first connection, and the anode current collector including a first plate with perforations and a second plate with perforations, the anode current collector further including a tab that connects the first plate and the second plate; (3) a cathode current collector, in the housing, including a second connection; (4) a first anode, in the housing, provided between the cathode current collector and the first plate; (5) a second anode, in the housing, provided between the cathode current collector and the second plate; and (6) a cathode, in the housing, provided adjacent to the cathode current collector. The disclosure may also provide systems and methods of making such a cell.

Abstract: A coin cell having a hermetic design withstands high performance applications including high temperature missions from a drop in replacement envelope. The coin cell can include a container having a bottom wall and a surrounding wall that form an interior volume, and the surrounding wall can include an inner, upper peripheral edge, at a top of the surrounding wall. The coin cell can include an anode assembly; a cathode assembly; and a header ring including a header ring outer surface and a header ring inner surface that defines an opening. The coin cell can include an insulator ring that includes an insulator ring outer surface that extends along and inside of the header ring inner surface, and an insulator ring inner surface that defines an opening within the insulator ring. A pin can be provided in the opening of the insulator ring. The coin cell can include an electrolyte.

Abstract: A method for generating a weld path aligned along a seam between two parts uses a computer having a control unit and a storage medium. The method includes aligning a crosshair line at a plurality of points along the seam and storing a position value for each of the plurality of points in the storage medium; calculating a width and a height of the seam based on the stored position values of each of the plurality of points; and generating the weld path based on the height and the width of the seam.

Abstract: Some embodiments are directed to a dual activation mode thermal battery for powering a load. The thermal battery can include a first power source activable upon receiving mechanical energy. The thermal battery can also include a second power source activable through one of the electrical power produced by the first power source and external electrical stimuli, the second power source is configured to, upon activation provide a voltage for powering the load, wherein the first power source and the second power source are thermally and electrically isolated and the initiator thermal energy output from one initiator is prevented from initiating the other power source directly.

Abstract: A cathode material suitable for use in non-aqueous electrochemical cells that includes copper manganese vanadium oxide and, optionally, fluorinated carbon. A non-aqueous electrochemical cell comprising such a cathode material, and a non-aqueous electrochemical cell that additionally includes a lithium anode.

Abstract: An alloy includes lithium, silicon and tin. An anode may be formed of an anode material containing the alloy of lithium, silicon and tin. The anode material may include an electrolyte. The anode material may be a pressed powder pellet that is solid at ambient temperature. A battery, for example, a thermal battery, can contain an electrolyte-separator, a cathode, and/or an anode with the alloy of lithium, tin and silicon. The anode formed of the alloy consisting of lithium, tin and silicon can have a melting point from about 500° C. to about 600° C. or higher making it suitable for use in a thermal battery.

Abstract: A thermal battery includes 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; and a flexible pyrotechnic heat source, wherein the first conductive layer, the separator layer, and the second conductive layer are rolled together to form the spiral wound configuration. A method of manufacturing a thermal spiral wound battery includes preparing three slurries, each containing one of an anode material, a cathode material, and a separator material, depositing each of the materials from the slurries onto conductive substrates to form three layers, stacking the layers, and winding the layers together into a spiral wound configuration.

Abstract: An electrochemical cell that converts chemical energy to electrical energy includes a cathode with an active material of fluorinated carbon on a perforated metal cathode current collector, a lithium anode on a perforated metal anode current collector, a stepped header, a stable electrolyte, and a separator. In various embodiments, an anode current collector design, a cathode current collector design, a stepped header design, a cathode formulation, an electrolyte formulation, a separator, and a battery incorporating the electrochemical cell are provided.

Abstract: A non-aqueous electrochemical cell including a lithium anode, a solid cathode, a first separator and a second separator disposed between the anode and the cathode, and an electrolyte in fluid communication with the anode, the cathode, and the first and the second separators, the first separator having a higher melting point (or shut-down) temperature than the melting point (or shut-down) temperature of the second separator.

Abstract: Embodiments directed to a method of manufacturing a pyrotechnic article for use with a thermal battery are disclosed. The method includes forming an iron oxide preform from iron oxide powder. The method also includes reducing the iron oxide preform to an iron preform made of metallic iron. The method further includes impregnating the iron preform with an oxidizer to form the pyrotechnic article.

Abstract: An improved alkali metal halide cell including an anode module having at least (i) one planar module including a porous assembly and (ii) that encloses an active anode material in an anode reservoir; and a cathode having active cathode material; where the porous assembly is coated with a thin ion-conducting layer that separates the active anode material enclosed within the anode module from the cathode material, and the anode and cathode are contained in a housing having one or more compartments.

Abstract: An improved electrolyte including a strontium additive suitable for lithium-sulfur batteries, a battery including the electrolyte, and a battery including a separator containing a strontium additive are disclosed. The presence of the strontium additive reduces sulfur-containing deposits on the battery anode, thereby providing a battery with relatively high energy density and good partial discharge performance.

Abstract: At least a portion of the enclosure of a thermal battery is formed of a ceramic material that is non-porous and electrically-non-conductive. The thermal battery includes at least one cell, a squib that when activated causes the at least one cell to become active, and an enclosure that surrounds the at least one cell and the squib. Squib terminals and battery terminals extend through the enclosure and are electrically connected to the squib and to the at least one cell, respectively. At least the portion of the enclosure through which the squib and battery terminals extend is formed of the ceramic material. The enclosure includes a container and a header. At least the header is made from the ceramic material, and preferably both the container and the header are made from the ceramic material.