Innovative Manufacturing Processes

Award Information
Agency: Department of Defense
Branch: Missile Defense Agency
Contract: DASG6003P0180
Agency Tracking Number: 031-1129
Amount: $70,000.00
Phase: Phase I
Program: SBIR
Awards Year: 2003
Solicitation Year: N/A
Solicitation Topic Code: N/A
Solicitation Number: N/A
Small Business Information
320 Willow Street, New Lenox, IL, 60451
DUNS: 947300208
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Thomas Kaun
 Principal Investigator
 (815) 483-9564
Business Contact
 Thomas Kaun
Title: President
Phone: (815) 483-9564
Research Institution
This SBIR provides an opportunity to reduce unit cost by 25% and improve reliability through production of thermal batteries by a continuous process. This process uses Inventek's ceramic fiber separator CFS to act as a carrier for the fabrication of thinthermal cells through a tunnel kiln. CFS fiber paper exhibits about 20 times greater strength than the standard pressed MgO pellet. Thin separator is required to take advantage of thin electrode. CFS has also demonstrated high power performance that isnot limited by cell size. This process will first be adapted to conventional pellet electrode production. Thin (0.25 mm), flexible, ceramic fiber paper can be a substrate for the application of electrode materials by alternative methods (e.g.tapecasting). The modulus of rupture, MOR, of our typical CFS fiber paper exhibits about 20 times greater strength than the standard pressed MgO pellet. With the high-strength CFS separator, continuous electrode production methods are also enabled. Ourrecent market evaluation found that about 50% of thermal battery costs are a result of slow pellet component production and

* Information listed above is at the time of submission. *

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