Cast thermal battery electrodes and separators using a salt binder

Abstract

Cast components can improve the effectiveness of current state-of-the-art in thermal battery processing technology in terms of cost, labor, materials usage, and flexibility. Cast components can include cast cathodes, anodes, and separators.

We claim: 
     
         1 . A non-cylindrical shaped thermal battery comprising:
 an anode comprising a first salt binder;   a cathode comprising a second salt binder; and   a separator disposed between the anode and the cathode, the separator comprising a third salt binder;   wherein the thermal battery is not cylindrical.   
     
     
         2 . The battery of  claim 1 , wherein the anode comprises a lithium-boron alloy. 
     
     
         3 . The battery of  claim 1 , wherein the anode comprises a lithium-aluminum alloy. 
     
     
         4 . The battery of  claim 1 , wherein the first salt binder, the second salt binder, and the third salt binder are inorganic. 
     
     
         5 . The battery of  claim 1 , wherein the first salt binder, the second salt binder, and the third salt binder are not aqueous. 
     
     
         6 . The battery of  claim 1 , wherein the cathode is cast onto a current collector. 
     
     
         7 . The battery of  claim 6 , wherein the separator is cast onto the cathode. 
     
     
         8 . The battery of  claim 7 , wherein the anode is cast onto the separator. 
     
     
         9 . The battery of  claim 1 , wherein the first salt binder, the second salt binder, and the third salt binder comprise KCl. 
     
     
         10 . The battery of  claim 1 , wherein the anode comprises an active material. 
     
     
         11 . The battery of  claim 1 , wherein the separator comprises MgO and LiCL:KCl. 
     
     
         12 . The battery of  claim 1 , wherein the cathode comprises an active material. 
     
     
         13 . The battery of  claim 1 , wherein the separator comprises an active material. 
     
     
         14 . The battery of  claim 1 , wherein the first salt binder comprises KCl. 
     
     
         15 . The battery of  claim 1 , wherein the first salt binder comprises LiCl. 
     
     
         16 . The battery of  claim 1 , wherein the first salt binder, the second salt binder, and the third salt binder comprise LiCl. 
     
     
         17 . The battery of  claim 1 , wherein the first salt binder, the second salt binder, and the third salt binder comprise an alkali halide salt.