Thermal batteries use inorganic salt as electrolyte, which is inactive at room temperature. As soon as heat pellets are fired by an igniter, all the solid electrolytes are instantly melted into excellent ionic conductors. However, the abnormal heat generation by the igniter flame or heat pellets causes the thermal decomposition of the electrode and the melting of the anode, eventually leading to a thermal runaway, which results in overheating or explosion. The thermal runaway can be significantly reduced by the adoption of Zr/BaCrO4 heat papers. In this study, the heat papers with various ratios of fuel (Zr) and oxidizer (BaCrO4) were prepared by the paper-making process. We have investigated the calorimetric value, burning rate, and ignition sensitivity. The ignition test of heat pellets and the discharge test of thermal batteries were also carried out. At the composition of 40 wt.% of Zr, the heat papers showed the highest specific calorimetric value and burning rate. As a result, Zr/BaCrO4 heat paper made by the paper-making process has shown the applicability for thermal batteries.

Thermal batteries are primary reserve batteries that use inorganic salt as electrolytes which areinactive at room temperature. The two principal heat sources that have been used in thermal batteries areheat paper and heat pellets. As soon as the heat paper, which is ignited by the initiator, in turn ignites theheat pellets, all the solid electrolytes are melted into excellent ionic conductors. However, the highcombustion temperature by heat papers in thermal batteries causes thermal decomposition at the cathode,eventually leading to a thermal runaway. In this paper, we have attempted to prepare Zr/BaCrO4 heatpapers coated with KCl molten salt. We have also investigated the effect of a molten salt coating on theheat papers through the thermal characteristics such as calorimetric value, combustion temperature andburning rate. The calorimetric value and combustion temperature of heat papers were reduced with anincrease in the molten salt coating. As a result, the molten salt coating on heat papers greatly reducedrisk of a thermal runaway and improved the stability of thermal batteries.