Thermal batteries are primary power sources for military applications requiring high reliability, robustness and long storage life. Conventional electrodes for thermal batteries are prepared by compacting powder mixtures into pellets. Separator is composed of halide mixture, such as LiCl-KC1 eutectic salt, blended with MgO to immobilize the molten salt. In order to increase the power density and energy density, the resistance of electrolyte should be reduced because the resistance of electrolyte is predominant in thermal batteries. In this study, wetting behaviors and impregnation weight of molten salts as well as the micro structures of ceramic felt were investigated to be applicable to thin electrolyte. Discharge performances of single cell with the ceramic separator impregnated by molten salt were evaluated also. Zirconia felt with high porosity and large pore outperformed alumina felt in wetting characteristics and molten salt impregnation as well as discharge performances. Based on the results of this study, ceramic felt separator impregnated with molten salt have revealed as an alternative of conventional thick MgO based separator with no conspicuous sign of thermal runaway by short circuit.
