Thermal battery

A pyrotechnic charge for activating a thermal battery that utilizes a solid electrolyte which becomes electrically conductive in a molten state, said pyrotechnic charge comprising a mixture of chemical components which produces an exothermic reaction upon being heated to ignition temperature, said exothermic reaction producing only reaction byproducts which are solids at ambient conditions.

A solid electrolyte composition which becomes electrically conductive in a molten state for activating a thermal battery utilizing a pyrotechnic charge for rapidly generating heat sufficient to melt the electrolyte composition, said electrolyte composition comprising a blended, three-component eutectic salt mixture.

A separator element for separating at least two components of a thermal battery to protect against leakage of molten electrolyte or of other battery components which may become liquid during battery activation, said separator element comprising a material selected from the group of materials consisting of:

• vanadium, tantalum, niobium, platinum-group metals, refractory metals, and alloys thereof.

A method for forming a thermal battery comprising:

• forming an electrolyte to have a first inactive state in which the electrolyte is electrically insulative, and to have a second active state in which the electrolyte is electrically conductive;
• and
• positioning the electrolyte between the anode and cathode, wherein the electrolyte and one of the anode and cathode are formed such that a first interface between the electrolyte and at least one of the anode and cathode is non-planar.