Abstract: Thin cathodes are presented, For example, a cathode includes a substrate; and a layer of a nanostructured pyrite active material deposited on the substrate, wherein the layer of the nanostructured pyrite has a thickness in the range from about 1 to about 1000 microns. The cathodes find particular utility in thermal batteries.

Abstract: A method for making a blended powder mixture, whereby two or more powders are mixed in a container with a liquid selected from nitrogen or short-chain alcohols, where at least one of the powders has an angle of repose greater than approximately 50 degrees. The method is useful in preparing blended powders of Li halides and MgO for use in the preparation of thermal battery separators.

Abstract: An electrochemical cell for a medium-temperature thermal battery includes an electrolyte having a melting point between 75° C. and 200° C., a thermal decomposition temperature above 300° C., and consisting essentially of at least one organic salt. The electrolyte is ionically conductive at temperatures from the melting point to at least the thermal decomposition temperature, generating a voltage across a cathode and an anode of the cell. The electrolyte is ionically non-conductive at temperatures below the melting point.

Abstract: Thin electrodes produced by thermal spray techniques are presented, wherein the thermal spray feedstock comprises an active material and a protective barrier coating. In a particularly advantageous feature, the active material feedstock is a metal sulfide, metal selenide, or metal telluride which ordinarily decomposes at thermal spray temperatures or which transforms to a material unsuitable for use as an electrode at thermal spray temperatures. The electrodes find particular utility in thermal batteries.

Abstract: Thin electrodes produced by thermal spray techniques are presented, wherein the thermal spray feedstock comprises an active material and a protective barrier coating. In a particularly advantageous feature, the active material feedstock is a metal sulfide, metal selenide, or metal telluride which ordinarily decomposes at thermal spray temperatures or which transforms to a material unsuitable for use as an electrode at thermal spray temperatures. The electrodes find particular utility in thermal batteries.

Abstract: A method for the manufacture of an electrode for an energy storage or conversion device comprises thermally spraying a feedstock mixture comprising an effective quantity of a source of a thermally protective salt and an active material or active material precursor onto a substrate to produce a film of the active material and salt. The film can have a thickness of about 1 to about 1000 microns. In a particularly advantageous feature, the active materials which ordinarily decompose or are unavailable at the high temperatures used during thermal spray processes, such as metal chalcogenides such as pyrite, CoS2, WS2, Ni(OH)2, MnO2, and the like may be thermally sprayed to form an electrode when the feedstock mixture employs an effective amount of a source of the thermally protective salt coating. The active material feedstock may comprise microstructured or nanostructured materials, which after thermal spray results in electrodes having microstructured or nanostructured active materials, respectively.

Abstract: Thin electrodes produced by thermal spray techniques are presented, wherein the thermal spray feedstock comprises an active material and a protective barrier coating. In a particularly advantageous feature, the active material feedstock is a metal sulfide, metal selenide, or metal telluride which ordinarily decomposes at thermal spray temperatures or which transforms to a material unsuitable for use as an electrode at thermal spray temperatures. The electrodes find particular utility in thermal batteries.

Abstract: An electrolyte system suitable for a molten salt electrolyte battery is described where the electrolyte system is a molten nitrate compound, an organic compound containing dissolved lithium salts, or a 1-ethyl-3-methlyimidazolium salt with a melting temperature between approximately room temperature and approximately 250° C. With a compatible anode and cathode, the electrolyte system is utilized in a battery as a power source suitable for oil/gas borehole applications and in heat sensors.

Abstract: A method for the manufacture of an electrode for an energy storage or conversion device comprises thermally spraying a feedstock mixture comprising an effective quantity of a source of a thermally protective salt and an active material or active material precursor onto a substrate to produce a film of the active material and salt. The film can have a thickness of about 1 to about 1000 microns.

Abstract: Disordered carbons were synthesized at 700° C. from methacrylonitrile-divinylbenzene precursors. The disorder, even at the free surface, was confirmed with TEM. These powdered carbons were subjected to rapid surface heating by a pulsed infrared laser (59 MW pulses). While the bulk structure remained essentially unchanged, there was substantial “surface reconstruction” to a depth of 0.25 &mgr;m presumably due to ablation, re-deposition, and “recrystallization” of the surface carbon after heating by the laser. The surface ordering appears similar to the bulk microstructure of carbons isothermally annealed at 2,200° C. (i.e., turbostatic). Improvements were observed in first cycle irreversible loss, rate capability, and coulombic efficiencies of the “reconstructed” carbons, relative to the untreated carbon.

Abstract: In a method for preparing lithiated, particulate FeS.sub.2 useful as a catholyte material in a lithium thermal battery, whereby the latter's voltage regulation properties are improved, comprising admixing FeS.sub.2 and an amount of a lithium-containing compound whereby the resultant total composition falls in an invariant region of the metallurgical phase diagram of its constituent components, an improvement comprises admixing said lithium-containing compound and FeS.sub.2 together with a solid electrolyte compatible with said catholyte, and heating the mixture at a temperature above the melting point of said electrolyte and at which said mixture reaches its thermodynamic equilibrium number of phases.

Abstract: A cathode for use in a thermal battery, comprising a chromium (V) compound. The preferred materials for this use are Ca.sub.5 (CrO.sub.4).sub.3 Cl, Ca.sub.5 (CrO.sub.4).sub.3 OH, and Cr.sub.2 O.sub.5. The chromium (V) compound can be employed as a cathode material in ambient temperature batteries when blended with a suitably conductive filler, preferably carbon black.

Abstract: There is disclosed, in a process for separating zirconium and hafnium, an improvement for the removal of sodium sulfate from a sulfate-containing sodium chloride solution. This improvement includes adding a water-miscible organic precipitant such as methanol, ethanol or acetone to the sulfate-containing sodium chloride solution. The precipitant is added in an amount sufficient to cause the removal of sulfate as sodium sulfate. The organic precipitant is removed and the substantially sulfate ion free sodium chloride solution is recycled. Also provided is a process for the recovery of sodium sulfate having a purity greater than 99.9%.