Abstract: The present invention is a thermal blanketing system used to manage the temperature of individual electrochemical cells within the modules of a single battery system. The present invention uses either a thin walled tube made from either a flexible or rigid material (i.e. plastic, etc.) which is wound in a fashion so at least one side of the tube makes contact with each individual cell, or uses a plurality of individual thermal jackets placed between battery cells such that at least some of the thermal jackets are contacted by at least two of the cells within the battery. In each of the above embodiments, each tube or jacket is filled with a thermal management fluid, chosen for its thermal management characteristics, and which flows throughout the tube or jackets, and acts either as a heat sink absorbing heat from the batteries to cool them, or as a heat source providing heat to the batteries as needed.

Abstract: A separator system for a LiAl/FeS.sub.x electrochemical cell includes microporous sintered metal particle retainer screens fabricated by cold compacting, tape casting or plasma spraying, followed by sintering. The separator may consist of Al.sub.2 O.sub.3 or MgO powder, AlN microporous particles, AlN microporous disk or ceramic standoff sandwiched between two screens or Al.sub.2 O.sub.3 or MgO powder plasma sprayed onto one screen surface. The various separator system combinations are impregnated with 20% to 50% by volume electrolyte salt for ionic conductivity. Pore size is less than 10 .mu.m, excluding electrode particles from reaching the separator.

Abstract: A loosely wrapped multi-layer thermal insulation structure is provided by coextensively winding, a continuous thin metal foil and a superimposed continuous low thermal conductivity porous material spacer about a mandrel, preferably functioning as an inner metallic shell for such loosely wound metal foil and spacer assembly. A plurality of narrow low thermal conductivity porous material strips are interposed between adjacent turns of the spiral wound metal foil and spacer assembly at laterally spaced positions throughout the assembly to form localized, narrow dense wound material areas defining an integral load-bearing system for the thermal insulation structure. Longitudinally extending permanent getter material strips may be bonded to the outer peripheral surface of the inner metallic shell defining gas passages for gas diffusion within the metal foil and spacer assembly. The metal foil may be perforated to facilitate that action.

Abstract: Flanged U-shaped cup members abut the exterior of the negative electrode and positive electrode of a Li alloy/FeS.sub.x multi-cell battery array and function to form a peripherally sealed structural enclosure for these elements, while capturing and maintaining ceramic seal rings between respective flanges. The flanged cup-like members act in conjunction with either back-to-back similarly shaped and sized inverted flanged cup-like members or C-shaped upper and lower spacer rings whose vertical height is double that of the electrodes. At least one of the flanges of the electrode containment structure extends radially outwardly and downwardly oblique from the other flange of the C-shaped support structure, and the periphery thereof is welded to the periphery of a similar diameter juxtaposed cell cover ring to form a complete multi-cell envelope for the battery by welding of two seal assemblies together.

Abstract: A design and process for making hermetically sealed thermocompression feedthrough and peripheral seal for high temperature Li Alloy FeS.sub.x battery cells and battery enclosures. The selected materials and processes parameters are developed to match the high temperature Li Alloy/FeS.sub.x system.

Abstract: A high-temperature bipolar battery consisting of a plurality of stacked individual cells. A first, thermal-sprayed electrode or electrolyte resistant material ceramic layer is sprayed to the exterior of the face-to-face stacked array and onto the peripheral faces of the battery metal end plates remote from the individual cells of a thickness sufficient to virtually eliminate all through pores therein. A second thermal-sprayed ceramic layer is of a thickness sufficient to form a metal support and containment structure of the bipolar battery stack. The thermal-sprayed layers have similar coefficients of thermal expansion (CTE). A metal cup surrounds and encloses at least one of the electrodes of each individual cell tending to form an inter-cell seal between the thermal-sprayed ceramic layer and the metal cup to prevent communication of electrolyte from cell to cell.