Electrochemical cell structures.

0001The present invention relates to electrochemical cell structures for use in thermal batteries and materials therefor.

0002Thermal batteries are primary electrical sources which are normally used in a 'one-shot' mode to generate a single continuous energy output once activated. The duration of the output may vary from a few seconds to about an hour depending on the battery design and construction. These batteries are frequently used as power sources for guided missiles and other weapon systems.

0003Thermal batteries are formed from a series construction of electrochemical cells each of which has an inert state and a thermally activated state. The inert state, in which the cell is normally stored, exists when the cell electrolyte between the anode and cathode is in a solid condition, eg at ambient temperature. The thermally activated state exists when the electrolyte is molten. The thermally activated state may be obtained rapidly when required by the ignition of a charge of a pyrotechnic in close proximity to the electrolyte. The temperature of the cell in the thermally activated state is typically 450°C to 600°C.

0004Known thermal batteries of current commercial interest usually employ the following particular cell construction (although other constructions are known). The anode is provided by a layer of lithium either in the form of the pure metal held in a support (since the metal is liquid in the thermally activated state) or in the form of an alloy, eg with boron, silicon, or aluminium. The cathode is a disc of FeS₂. The electrolyte is a pressed powder pellet comprising a eutectic mixture of LiCl and KC1 or of LiF, LiCl, and LiBr. The electrolyte is incorporated within an inert binder such as MgO to immobilise it when molten.

0005The pyrotechnic is a mixture of iron and potassium perchlorate located in the form of a pellet adjacent to the cell.

0006Several cells are arranged as a stack in this way in the battery, each cell having its own pyrotechnic pellet, ie adjacent cells being separated by pyrotechnic pellets. The stack is assembled in a dry atmosphere and is enclosed by material providing a thermal blanket, eg insulating end pads and a jacket moulded from a silica glass. The enclosed stack is then hermetically sealed within a steel case.

0007The conventional cathode material FeS₂ is a widely available and relatively inexpensive material and in conjunction with a lithium based anode and an electrolyte containing one or more lithium salts, provides a reasonable cell output performance.

0008However, it has now been unexpectedly discovered that the cell output performance may be improved by the use of a novel cathode material.

0009According to the present invention in a first aspect an electrochemical cell structure suitable for use in a thermal battery comprises: <ul id="ul0001" list-style="none"><li>an anode; a cathode; and an electrolyte between the anode and the cathode; the cathode comprising a material comprising one or more compounds containing vanadium and oxygen selected from _V6013+x, O≤x≤0.5, _V0_2±z, 0&lt;z&lt;0.05, Li_yV₂O₅, 0.88≤y≤1, V₃0₇ and LiV₃0₈ provided that where V₆0₁₃ is present in the absence of the other specified compounds it forms at least 50% by weight of the said material. The mole fraction 13 + x (of 0) in V6013+_x is preferably from 13 to 13.2.</li></ul>

0010Preferably, the anode comprises a substance providing the displacement of lithium ions into the electrolyte, eg lithium metal or a lithium based alloy, although it could also comprise calcium.

0011Preferably, the electrolyte is one capable of transporting lithium ions from the anode to the cathode, eg a lithium salt, a mixture of salts at least one of which is a lithium salt or a another suitable highly conducting salt or mixture of salts, eg an alkyl pyridinium halide.

0012Where the electrolyte comprises one or more salts it is preferably contained in an inert binder, eg MgO or 8i0₂.

0013It is known to use an oxide of vanadium as a cathode material in conjunction with lithium as an anode material in cells for rechargeable batteries. However, it is surprising that the above compounds are particularly useful in thermal battery cells since the design is usually quite different in the two cases. Cathodes in a rechargeable battery operate in a reversible mode in which metal ions from the electrolyte can pass in and out of the cathode. This is usually achieved by using a cathode showing so-called 'intercalation' in which incoming ions can be readily embedded within the cathode matrix without substantially changing the nature of that matrix. As a consequence a rechargeable battery is normally an expensive power source because it uses expensive material, particularly for the cathode, in order to achieve the special reversible effects required. The oxide V₆0₁₃ for example, is such an expensive material showing the desired intercalation properties.

0014In contrast, a thermal battery being a 'one shot' source is normally spent after activation and is therefore normally designed using material which may be discarded after use.

0015The cathode material FeS₂ which is normally used in thermal batteries is, as noted above, widely available and is much cheaper than V₆0₁₃ (and the other above specified vanadium oxides) for example. In any event the conventional cathodes in thermal batteries which use FeS₂ do not operate in a reversible mode but in a two step reduction process. Thus, it is surprising that the above specified compounds of oxygen and vanadium are of interest for use as cathode materials in a thermal battery in place of FeS₂.

0016It has been proposed to use V₂0₅ as a cathode material in a cell for a thermal battery but the performance of the thermal battery cell is not attractive.

0017However, as noted above, it has now been unexpectedly . discovered that the cell output performance in a thermal battery may be improved using one or more the the above specified oxides of vanadium in the cathode material preferably in conjunction with a lithium based anode and an electrolyte containing one or more lithium salts. In particular, a greater on-load output voltage is possible at high output current densities as compared with conventional thermal batteries containing FeS₂ cathodes or cathodes made of V₂0₅. This provides a higher output power density for a given size of battery and therefore allows batteries of smaller size and weight to be made which give the same output as currently available batteries. Reduced size and weight are highly desirable features of batteries for advanced aerodynamic systems such as guided missiles.

0018According to an important feature of the present invention the material which comprises the cathode of the cell structure according to the first aspect preferably comprises a composition comprising a mixture of VO_2±z and LiyV₂0₅, 0.88≤y≤1, especially where y=l, and where 0&lt;z&lt;0.05, especially where z=l to 0.01.

0019The oxide of vandaium known as VO₂ (alternatively referred to as V₂O₄ in the scientific literature) may in fact have an atomic ratio of V:0 which differs slightly from 1:2.00. This accounts for z specified above. However, for simplicity, V02±_z will hereinafter be referred as as "V0₂".

0020The V0₂ in the above specified composition is preferably (although not necessarily) of the form obtained as one component of the product of Method 2 specified below or a similar form. X-ray diffraction analysis has revealed that this form is similar to that obtained by: (i) the vacuum pyrolysis of anhydrous VOS0₄ at 620°C as described by J Tudo in Revue de Chimie Minerale, 2, (1965) pages 53-117, especially page 84, hereinafter referred to as Reference 1; and to that obtained by (ii) heating equimolar amounts of V₂0₃ and V₂O₅ in a sealed tube at over 650°C for several hours as described by G Andersson in Acta Chemica Scandinavica, 8, (1954), pages 1599-1606 especially page 1600, hereinafter referred to as Reference 2. Thus, the V0₂ may be of the form obtained by one of these methods or a similar form obtained in another known way.

0021In Reference 2 the V0₂ obtained by the method described therein is referred to as monoclinic although it is now known that this form is monoclinic only below 70°C (in contrast to the V0₂(B) from which is another form known to be monoclinic up to higher temperatures).

0022The V0₂ may alternatively be obtained by the further known method involving the fusion of V₂0₅ with oxalic acid or by that involving the reduction of V₂0₅ by a reducing gas such as H₂ or SO₂.

0023Other forms of V0₂, are suitable and in any event, the VO₂ may be obtained commercially.

0024The LiyV₂0₅ in the above specified V0₂/LiyV₂0₅ composition is desirably (although not necessarily) the form of LiyV₂O₅ known as γ-LiV₂O₅ which may be produced by the known method described by Murphy et al in Inorganic Chemistry, 18, (10), 1979, pp 2800-2803, herein referred to as Reference 3, wherein V₂0₅ is reduced at ambient temperature by lithium iodide in acetonitrile.

0025The above specified composition may comprise from 2 to 98%, especially 25 to 75%, by weight of V0₂, from 2 to 98%, especially 25 to 75%, by weight of Li_yV₂O₅ and from 0 to 10% by weight of other oxides of vanadium or vanadates (the overall sum of the percentage adding to 100%).

0026This composition may be made in one of the following ways: Method 1: Separately (i) preparing V0₂, eg by one of the methods described above, or obtaining the compound commercially, and (ii) preparing Li_yV₂O₅, eg by the method of Reference 3 and intimately mixing appropriate amounts of the two products as powders.

0027Method 2: Reducing powdered V₆0_13+x, 0&lt;x&lt;0.5 by the action of heat in the presence of one or more oxidisable salts of lithium, eg one or more lithium halides. The result is typically a fused mass which may be broken into a powder of the required composition. The V₆0_13+x may be obtained in a known way, eg by (i) reducing V₂0₅ by heating V₂0₅ in the presence of V or (ii) by the thermal decomposition of ammonium metavanadate in the presence of a flowing inert gas such as argon.

0028For a composition made by Method 2, or by Method 1 wherein components having a similar microstructure to those obtained by Method 2 are used, the weight ratio of Li_yV₂O₅:VO₂ present in the composition is preferably in the range from 1:3 to 1:1, especially from 1:2 to 1:1.5.

0029Where the composition is made by Method 2 using V₆0₁₃+_x produced by the decomposition of ammonium metavanadate the V₆O_13+x is likely to contain minor amounts (eg a few per cent) of impurities such as V0₂ and V₃0₇. However, it has been found tht these do not seriously affect the performance of the final composition produced by Method 2.

0030In Method 2 the V₆0₁₃+_x may be reduced in the presence of LiBr or a mixture including LiBr, eg of LiBr and LiCl, or of LiBr, LiCl and LiF.

0031Where the mixture is of LiBr and LiCl it preferably contains from 20 to 40% by weight of LiCl, eg 30% by weight of LiCl.

0032Preferably (although not essentially) in Method 2 the lithium salt or salt mixture forms between 12 and 40% of the weight of the overall mixture with V₆013+_x. For perfect stoichiometry using LiBr and V₆0₁₃ approximately 15% by weight LiBr and 85% by weight V₆0₁₃ are required to provide the desired reaction: <chemistry id="chem0001" num="0001"><img file="EP0145261A2_D0001.tif" /></chemistry>

0033However, it has been found that the ratio of LiV₂0₅ to V0₂ in the reaction product may show little variation even if the amount of LiBr in the reactant mixture is increased signifi- _cantly, eg to 30% by weight, especially when V₆0_13+x prepared by the decomposition of ammonium metavanadate is used. In fact, the best results have been obtained using 25 to 30% by weight of LiBr in the reactant mixture with V₆O_13+x (70 to 75% by weight).

0034In the cell structure according to the first aspect of the present invention the said material comprising one or more compounds containing vanadium and oxygen may comprise the body of the cathode or it may form a coating on the body when formed of other material, eg a conventional cathode material.

0035The body of the cathode preferably contains from 20 to 40% by weight, preferably 25 to 35% by weight, of an electrolyte material comprising one or more lithium salts, in addition to the aforementioned electrolyte which is contained between the cathode and the anode. Where the electrolyte between the cathode and the anode comprises one or more lithium salts the electrolyte contained in the cathode preferably is substantially the same electrolyte (excluding any binder).

0036Where the body of the cathode is formed of material comprising one or more compounds containing vanadium and oxygen as specified above and includes also a salt electrolyte material the salt electrolyte material is preferably incorporated in the cathode by intimate admixture of the salt electrolyte material and the cathode body material as powders and forming a pressed pellet from the mixture.

0037If the oxidisable lithium salt(s) which is used to form the product in Method 2 specified above is the same as the salt(s) which may be incorporated within the final cathode structure as electrolyte salt(s), it needs to be replenished after the reduction process in Method 2 since most of the oxidisable lithium salt(s) will be consumed during the reduction process.

0038Preferably, the electrolyte between the anode and the cathode in the cell structure according to the first aspect has a melting point less than 650°C, eg in the range 300°C to 500°C, desirably 345°C to 455°C.

0039This electrolyte may for example comprise the known eutectic mixture of 22 molar % LiF, 31 molar % LiCI and 47 molar % LiBr. This mixture has a melting point of 450°C. This salt, or other electrolyte salt, is preferably mixed with a known binder, preferably MgO or Si0₂, to the extent of 50 to 90%, preferably about 65 to 75%, by weight of binder, per unit weight of the overall mixture.

0040The anode in the cell according to the first aspect of the present invention may be a known lithium based anode, eg comprising pure lithium held in a known container or support, or comprising a suitable known lithium alloy, eg containing one or more of boron, silicon and aluminium.

0041The anode may be any known anode containing lithium. The anode material may optionally be mixed with electrolyte (eg as admixed powders) or contacted by electrolyte contained in a pad, eg of asbestos.

0042The content of lithium im the anode material (excluding any electrolyte present) may be in the range 5 to 85% by weight depending on the manner in which the lithium is contained.

0043If the lithium is contained in an unalloyed state it preferably forms from 5 to 30% of the overall weight of lithium plus support material in which it is contained. The support material is preferably an inert matrix such as an iron mesh or a porous nickel/chromium matrix. Typically, the lithium forms 7 to 8% by weight of such anode materials.

0044If the lithium in the anode material is provided in the form of an alloy it is preferably selected from: <ul id="ul0002" list-style="none"><li>i. lithium/aluminium alloys containing between 20% and 24% of lithium by weight;</li><li>ii. lithium/silicon alloys containing between 44% and 56% of lithium by weight;</li><li>iii. lithium/boron alloys containing between 53% and 80% of lithium by weight.</li></ul>

0045Preferably, the anode, cathode and electrolyte between them are all in the shape of a pellet or disc of similar dimensions to facilitate battery construction.

0046According to the present invention in a second aspect a thermal battery comprises a series of electrochemical cell structures according to the first aspect, adjacent cells in the series being separated by energisable heating layers for heating the cells to convert them from their inert state to their thermally activated state.

0047The heating layers are preferably pyrotechnic layers in the form of pellets stacked between the cathode and anode of adjacent cells.

0048The overall construction of the battery in the second aspect may be similar to that used for the manufacture of conventional thermal batteries having FeS₂ cathodes.

0049According to the present invention in a third aspect a material for use in a cathode structure suitable for a cell structure as defined in the first aspect comprises one or more compounds containing vanadium and oxygen as specified in the first aspect intimately mixed with an electrolyte material, preferably comprising a mixture of salts at least one of which is a lithium halide, the salt mixture preferably having a melting point of 650°C or less, the electrolyte material comprising between 20% and 40%, preferably 25% to 35%, by weight of the overall weight of the cathode structure. Preferably, the electrolyte is the LiF:LiCl;LiBr eutectic mixture specified above.

0050According to the present invention in a fourth aspect there is provided a composition suitable for use in a cathode of a thermal battery which composition comprises a mixture of V0₂ and γ Li_yV₂O₅, where 0.88≤y≤1. Desirable proportions for the components of this composition are as specified above.

0051Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which: <ul id="ul0003" list-style="none"><li>Figure 1 is an exploded front perspective view of a single test cell construction;</li><li>Figure 2 is a circuit diagram of the discharge circuit used for testing the cell shown in Figure 1;</li><li>Figures 3 and 4 are graphs of cell output voltage versus discharge time for the cell construction shown in Figure 1.</li><li>Figure 5 is a partly cut-away front perspective view of a thermal battery incorporating a cell construction embodying the present invention.</li></ul>

0052In-the following Examples the symbols which are used have the following meanings: <ul id="ul0004" list-style="none"><li>rt = room temperature (- 20°C)</li><li>w/o = percentage by weight compared with the overall weight</li><li>TGA = thermal gravimetric analysis.</li></ul>

Example 1

0053Preparation and investigation of a cell using a cathode comprising ^V₆⁰₁₃4 Step la: Preparation of V₆0₁₃

0054Stoichiometric quantities of 47.28g V₂O₅ and 4.08g vanadium powder were intimately mixed and sealed under vacuum in a silica tube. The tube was then heated in a furnace at a rate to give an increase of temperature of 10 C° per minute from rt up to 650°C at which temperature it was held for a further 24 hours. The furnace was cooled to rt over a further 12 hours. The product was a dark blue/black crystalline solid. X-ray diffractometer analysis confirmed that the product was 100X V₆0₁₃ a monoclinic structure with lattice constants:<maths id="math0001" num=""><img file="EP0145261A2_D0002.tif" /></maths><maths id="math0002" num=""><img file="EP0145261A2_D0003.tif" /></maths><maths id="math0003" num=""><img file="EP0145261A2_D0004.tif" /></maths><maths id="math0004" num=""><img file="EP0145261A2_D0005.tif" /></maths>V₆0₁₃ is stable in air at rt and shows no weight loss or gain on TGA in flowing argon up to 700°C.

Step Ib: Preparation of a high temperature cathode material using

V

6

0

1

3

0055A mixture of 70% (w/o) V₆0₁₃ prepared as in Step la and 30% (w/o) of a ternary eutectic lithium halide salt, Salt Mixture A, composed of 68.4% (w/o) LiBr, 22.0% (w/o) LiCl, 9.6% (w/o) LiF, was intimately mixed and pressed into the form of pellets at a pressure of about 3 tonnes cm^-2. Each cathode pellet formed was about 0.3g in weight and 1.6cm in diameter.

Step lc: Preparation of a test cell

0056Electrolyte/binder pellets were formed by intimately mixing and pressing together as a powder 70% (w/o) MgO and 30% (w/o) of Salt Mixture A. These pellets were similar in dimension to the cathode pellets. Anode pellets were formed by pressing the powdered alloy 24% (w/o) Li: 76% (w/o) Al. These pellets were also similar in dimensions to the cathode pellets.

0057A cathode pellet, an electrolyte/binder pellet and an anode pellet were then arranged in an inert atmosphere of argon to provide an electrochemical cell in the construction shown in Figure 1. In that Figure these three pellets are indicated by reference numerals 1, 3 and 5 respectively. Iron current collecting discs 7 and 9 are shown in Figure 1 placed above the cathode pellet 1 and below the anode pellet 5 respectively. The discs 7 and 9 are made of 0.125 mm thick iron and each has a current output lead 11 and a voltage output lead 13. The discs 7 and 9 with the pellets 1, 3 and 5 between them are pressed between boron nitride platens 15, 17 respectively by pneumatic rams 19, 21 respectively at a pressure of about 3 kg _cm-^2. The platens 15, 17 are heated by electrical cartridge heaters 23, 25 respectively.

Step ld: Investigation of the test cell output performance

0058The cell formed in Step 1c was heated to a temperature of between 480°C and 590°C (by heating the platens 15, 17) under the holding pressure of about 3 kg cm-2. The cell comprising the pellets 1, 3 and 5, is indicated by reference number 27 in Figure 2. The cell was tested using the circuit arrangement shown in Figure 2. The cell 27 is shown in Figure 2 contained in an argon atmosphere container 29. The current output leads 11 are shown connected to a discharge unit 31 capable of discharging the cell 27 at any selected constant current between 10mA and 10 amps. The voltage output leads 13 are shown connected across a voltmeter 33 and also a Y-t (output v time) charge recorder 35 in parallel. The readings on the voltmeter 33 may be used to calibrate the chart recorder 35. After heating the cell 27 to its operational temperature (thermally activated state) the open circuit voltage across the -cell 27 was first measured and then the unit 31 was set to give a constant current discharge of 1 amp cm^-2 of cathode pellet cross-sectional area and the output voltage was recorded on the calibrated chart recorder 35. The results are shown as curve A in Figure 3, where the open circuit voltage before discharge is shown as portion Ao of curve A at 2.765 volts.

Example 2

Step 2a: Preparation of V

6

O13+x, x<0.2

0059103.48 g of NR₄V0₃ were equally divided and placed in two silica boats within a stainless steel furnace of inside dimensions 150mm diameter and 200mm depth. The furnace was closed to the atmosphere and high purity argon gas was passed through the furnace at a rate of 1.5 litres per minute. The furnace temperature was raised from rt to 450°C at a rate of 12 C° per minute and the furnace was held at 450°C for 2 hours and then the temperature was raised from 450°C to 550°C at a rate of 5 C° per minute. The furnace was held at 550°C for a further 2 hours and then cooled to rt over 4 hours.

006075.657 g of a dark blue/black crystalline product were obtained. X-ray diffraction analysis showed the product to contain V₆0_13+x, V02 and V307.

0061The decomposition of NH₄VO₃ follows the route outlined in the following reactions: <chemistry id="chem0002" num="0002"><img file="EP0145261A2_D0006.tif" /></chemistry><chemistry id="chem0003" num="0003"><img file="EP0145261A2_D0007.tif" /></chemistry>

Step 2b: Investigation of the product of Step 2a

0062The product of Step 2a was formed into a cathode material as in Step 1b above and a test cell using this cathode material was constructed and investigated as in Steps 1c and ld. The i performance of the cell was similar to that investigated in Step Id.

Example 3

0063Preparation and investigation of a cell using a cathode comprising a mixed vanadium oxide system (V0₂/Y-LiV₂0₅ composition).

Step 3a: Preparation of a mixed vanadium oxide system

006470X (w/o) V₆0₁₃ and 30% (w/o) of the Salt Mixture A specified above were intimately mixed and heated in a silica boat within a furnace under flowing argon (4 litres per min) to ) a temperature of 500°C at a temperature increase rate of 12 C° per minute. The temperature of 500°C was maintained for a further 2 hours. The tube was then cooled to rt over a period of 1 hour. The product was a blue/black friable powder and X-ray diffraction analysis showed it to be a mixture of LiV₂0₅, V0₂ and LiF.

Step 3b: Preparation of a high temperature cathode and cell

0065An admixture of 70% (w/o) of the product of Step 3a, and 30% (w/o) of Salt Mixture A was formed. This mixture was formed into pellets similar to those formed in Step 1b above and such a pellet was then made into a cell as in Step 1c using an alloy anode pellet formed of 24% (w/o) Li : 76% (w/o) Al alloy and a binder/electrolyte pellet comprising MgO 70% (w/o) mixed with Salt Mixture A 30% (w/o).

Step 3c: Investigation of the cell output performance

0066When heated to a working temperature of between 480°C and 590°C in an arrangement similar to that shown in Figure 1 the cell produced in Step 3b gave an open circuit voltage of 2.59 V and, when discharged at a constant current of 1 amp per cm² of cathode pellet cross-sectional area by the arrangement shown in Figure 2, the cell gave the output voltage versus time profile plotted as curve B in Figure 3. The open circuit portion of curve B is labelled as Bo in Figure 3.

0067For comparison purposes a cell having a conventional cathode formed of 70% (w/o) FeS₂ and 30% (w/o) of Salt Mixture A was constructed in an arrangement similar to that shown in Figure 1 (the anode pellet and binder/electrolyte pellet being formed as in Step lb) and this was tested at a working temperature of between 480°C and 590°C in the circuit arrangement shown in Figure 2. This cell gave the output voltage versus time profile plotted as curve C in Figure 3. The open circuit voltage portion of this curve is labelled as Co in Figure 3.

0068As can be seen in Figure 3 the cells embodying the invention formed as in Examples 1 and 3 both show, as in curves A and B respectively, a significantly higher on-load voltage compared with the conventional FeS₂ cathode cell, represented by curve C, over the discharge time of about 30 seconds.

0069In any event the cell formed as in Example 3 (curve B) shows the highest on-load voltage and shows an on-load voltage which is considerably higher than that from the conventional FeS₂ cathode cell (curve C) for about 75 seconds.

Example 4

0070For a cell prepared as in Step 3b the discharge current was increased to 4 amp cm^-2 in the circuit arrangement shown in Figure 2. The output voltage versus time for the cell discharged in this way is as shown in Figure 4 labelled curve B¹. The open circuit portion of the curve before discharge is labelled B¹₀. The comparative curve for this discharge current using the conventional cell incorporating a FeS₂ cathode prepared as described hereinbefore is the curve C¹ shown in Figure 4.

0071Again, there is a considerable improvement in on-load output voltage obtained by using a cell embodying the present invention, as represented by curve B^l, rather than a conventional cell, as represented by curve C¹ even though the overall voltage profile in each case is reduced owing to the greater discharge current. In this example of performance, the percentage improvement in output voltage is greater than in the example described above using a smaller discharge current.

Example 5

Step 5a: Alternative preparation of a mixed vanadium oxide system (VO

2

and γ-LiV

2

O

5

)

0072A composition comprising V0₂ and γ-LiV₂O₅ was prepared by the reaction of a mixture containing (by weight) between 60 to 85% V₆0₁₃+_x prepared as in Step la or 1b and (by weight) 15 to 40% LiBr. The overall mixture was heated in a stainless steel furnace under flowing argon at a flow rate of between 1 and 4 litres per minute from rt to 600°C at a rate of 12 C° per minute and then held at 600°C for a further 30 minutes to 2 hours followed by cooling to rt over a period of 2 to 4 hours. The product has been shown to contain γ-Li_yV₂O₅ where y is between 0.88 and 1.0 and VO₂ and where the overall amount of VO₂ is between 40% and 80% by weight of the product and the overall amount of LiyV₂0₅ is between 20% and 60% by weight of the product.

0073The overall reaction may be represented by Reaction 1 specified above.

0074The product made from about 70 weight per cent V₆0₁₃+_x and 30 weight per cent LiBr was further investigated in Step 5b.

Step 5b: Investigation of the product of Step 5a

0075The product of Step 5a was formed into a cathode material as in Step 3b and the cathode was investigated in a cell as in Step 3c. The cell so produced gave a performance similar to that given by the cell in Step 3c.

Example 6

Step 6a: Further alternative preparation of a mixed vanadium oxide system

0076A similar product to that obtained in Steps 3a and 5a was obtained by reaction of a mixture of 70X (w/o) V₆0_13+x prepared as in Example 1 or Example 2 and 30% (w/o) of a binary lithium halide Salt Mixture B, composed of 70% (w/o) LiBr and 30% (w/o) LiCl. This overall mixture was heated in a silica boat under flowing argon to 550°C and then at 550°C for 2 hours as in Step 3a. The product again showed LiV₂O₅ and VO₂ by X-ray diffraction analysis.

Step 6b: Investigation of the product of Step 6a

0077The product of Step 6a was formed into a cathode material as in Step 3b and the cathode was investigated in a cell as in Step 3c. The cell so produced gave a performance similar to that shown by the cell in Step 3c.

Example7

Step 7a: Further alternative preparation of a mixed vanadium oxide system

0078Step 7a(i) V0₂ was obtained commercially from the Aldrich Chemical Co Ltd. UK (Catalogue No. 21,582.1).

0079Step 7a(ii) γ-Li_yV₂O₅, 0.88≤y≤1, was prepared by the known method described by Murphy et al in Reference 3 specified above.

0080Step 7a(iii) The products of Steps 7a(i) and 7a(ii) were intimately mixed as powders in the following proportions (by weight): <ul id="ul0005" list-style="none"><li>Mixture A: 1:3 VO₂:LiV₂O₅</li><li>Mixture B: 1:1 VO₂:LiV₂O₅</li><li>Mixture C: 3:1 V0₂:LiV₂0₅</li></ul>

Step 7b

0081Each mixture product of Step 7a was separately made into a cathode material in the manner described in Step 3b and each cathode was investigated in a cell as in Step 3a.

0082The cells so produced gave a performance illustrated by the results given in Table 1 below.

Example 8

0083VO₂ obtained as in Step 7a(i) was itself formed into a cathode material in the manner described in Step 3b and investigated in a cell as in Step 3c.

0084The cell so produced gave a performance which is illustrated by the results in Table 1 below.

Example 9

0085γ-Li_yV₂O₅, 0.88≤y≤1, prepared as in Step 7a(ii) was itself formed into a cathode material in the manner described in Step 3b and the cathode was investigated in a cell as in Step 3c.

0086The cell so produced gave a performance which is illustrated by the results given in Table 1 below.

Example 10

0087V₃0₇ is prepared by a known method.

0088This compound is then formed into a cathode material in the manner described in Step 3b and the cathode is investigated in a cell as in Step 3c.

Example 11

0089LiV₃0₈ was prepared by the known method of heating a stoichiometric mixture of V₂0₅ and Li_2C0₃ in air to 680°C and maintaining this temperature for 24 hours followed cooling to rt over 12 hours. This reaction is represented by: <chemistry id="chem0004" num="0004"><img file="EP0145261A2_D0008.tif" /></chemistry>

0090This compound was then formed into a cathode material in the manner described in Step 3b and the cathode was investigated in a cell as in Step 3c.

Example 12

0091VO₂ obtained by the method of Reference 1 specified above is mixed with LiyV₂0_S obtained by the method of Reference 3 specified above in various Li_yV₂O₅:VO₂ weight ratios ranging from 1:9 to 9:1. Each product is separately formed into a cathode material in the manner described in Step 3b and each cathode is investigated in a cell in the manner described in Step 3c.

Example 13

0092VO₂ obtained by the method of Reference 2 specified above is mixed with Li_yV₂O₅ obtained by method of Reference 3 specified above in various Li_yV₂O₅:VO₂ weight ratios ranging from 1:9 to 9:1. Each product is separately formed into a cathode material in the manner described in Step 3b and each cathode is investigated in a cell in the manner described in Step 3c.

Example 14

0093V0₂ obtained by the known method of fusing V₂0₅ with oxalic acid is mixed with Li_yV₂O₅:VO₂ weight ratios ranging from 1:9 to 9:1. Each product is formed into a cathode material as in Step 3b above and each cathode is investigated as in Step 3c above.

Example 15

0094V0₂ obtained by the known method of reducing V₂O₅ by H₂ or S0₂ is mixed with Li_yV₂O₅ obtained by the method of Reference 3 specified above in various Li_yV₂O₅:VO₂ weight ratios ranging from 1:9 to 9:1. Each product is formed into a cathode material as in Step 3b above and each cathode is investigated as in Step 3c above.

0095The cell so produced gave a performance which is illustrated by the results given in Table 1 below.

0096The following Table, Table 1 summarises the comparative discharge performance of a variety of cathode materials discharged at 1 amp cm^-2 of cathode area using a 24 w/o Li/Al alloy anode and Salt Mixture A (specified above) as electrolyte, the cathode being formed of 70% by weight of the material under investigation and 30% by weight of Salt Mixture A. <tables id="tabl0001" num="0001"><img file="EP0145261A2_D0009.tif" /></tables>

0097Table 1 illustrates the superior performance of thermal battery cells embodying the present invention compared with those made in accordance with the prior art.

0098Figure 5 shows a thermal battery of known general construction incorporating a stack of cells embodying the invention. Each cell, indicated by reference numeral 41, comprises a cathode pellet, an anode pellet and an electolyte/binder pellet and is formed as in any one of Examples 1 to 11 described above. Adjacent cells 41 are separated by pyrotechnic pellets 43. A thermally insulating jacket 46 is fitted above and below the stack and final pyrotechnic pellets 43a are placed in between individual layers of the jacket 46 at the top and bottom of the stack. A pyrotechnic ignition strip 47 contacts each of the pellets 43 and 43a and is ignited by an igniter 49 comprising a pyrotechnic flash pellet operated by an electrical heating wire energised by passing a current between ignition terminals 51. A terminal 53a is connected to the cell 41 at the upper end of the stack whilst a terminal 53b a connecting lead 55 insulated from the stack (eg by a layer of mica). The battery comprising the stack and the thermal jacket 46 is hermetically sealed within a steel container 46, the terminals 51, 53a and 53b being insulated from the container 46 where they emerge from the top of the container 46.

0099When an appropriate current is passed between the terminals 51a the electrical heating wire within the igniter 49 is heated causing a flash in the flash pellet of the igniter which propagates alùng the ignition strip 47 and causes the individual pyrotechnic pellets 43 to be ignited rapdily. The cells 41 are all raised to their operating temperature and an output voltage equal to nV, were n is the number of cells in the stack and V is the voltage provided by each for a given load, may be withdrawn from the battery between the terminals 53a and 53b.