Thermal Battery Production Boosted by Title III Project Published April 19, 2011 By Dr. Gregory A. Cazzell Materials and Manufacturing WRIGHT-PATTERSON AIR FORCE BASE, Ohio -- The AFRL has teamed with ENSER Corporation in a Defense Production Act Title III project to advance the domestic production capability for cobalt disulfide (CoS2) thermal batteries, which will be used in a wide variety of air-to-air, air-to-ground, and ground-to-air defense systems. Thermal batteries have a number of unique applications because of their long shelf life and high-power output relative to their size. In thermal batteries that employ CoS2 cathode chemistry, a powder mixture electrolyte is placed between alternating cathode and anode material. As long as the electrolyte is solid, the battery can be stored for 20 years or more without suffering from loss of power. Relative to their alternatives, CoS2 batteries provide longer life and upward of 50 percent more energy output. Additionally, they offer better chemical stability and have a near metallic conductivity. The Thermal Battery Title III program's goal is the establishment of a world-class manufacturer of CoS2 batteries. Working with The ENSER Corporation in Pinellas Park FL, the project team has already installed new production equipment, significantly increasing the manufacturing capacity for high - performance thermal batteries provided to producers of guided munitions. They have automated labor intensive tasks and implemented Lean manufacturing and continuous improvement activities to improve manufacturing process control and lower costs. Further, the project has facilitated the installation of comprehensive on-site environmental testing capabilities, and has improved the in-house production of raw materials to support higher levels of production. Project officials are optimistic that this program will ultimately provide a domestic source of batteries that meets the growing DoD demand for smarter and smaller weapon systems.