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<p>Owing to their long shelf life and instantaneous high power, thermal batteries have found various applications. However, thermal batteries face significant challenges in heat management. Also, these challenges are persistent in compact designs and would nucleate subsequent effects such as high heat loss and high skin temperature, which eventually reduce the specified life of batteries, safety, and reliability. To address these challenges, this work proposes a physics-based thermal modelling approach for miniaturized cylindrical thermal batteries that simulates thermal design and ensures efficient heat management. An unsteady-state heat transfer model that combines heat generation from pyrotechnic pellets and convective heat losses through the battery casing and insulation. The predicted skin and electrolyte core temperatures as a function of battery discharge time are investigated and further validated against the prototype. The predicted skin temperature and electrolyte core temperatures are in good agreement with the experimental data, and deviations are ~ 5% and ~ 3%, respectively. Also, the maximum skin temperature of the proposed model is reduced by ~ 35% compared with the uninsulated design. Further, the capacity loss at elevated temperatures is investigated and characterized using a thermal-damage factor. By optimizing insulation and design parameters, the batteries can withstand internal operating temperatures (&gt; 500&#xa0;°C), enhancing safety. The results demonstrate that the proposed thermal model can predict the thermal behavior of miniaturized batteries. Thus, this work not only provides a modelling framework for miniaturized reserve batteries but also enables designers to predict crucial parameters which are pivotal in revalidating the physical designs and reduces the need for iterative prototyping.</p>

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Designing of the heat transfer mechanism and implementing thermal modeling technique to validate the design of the miniaturized thermal battery

  • 期刊论文

  • 发表日期：

    2026年3月6日

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  • Sanjay Biswas,
  • Karuna Kardam,
  • Likhitha P,
  • Manasa M,
  • Neeraja G,
  • Ravi Degala,
  • Vamsi Inturi

摘要

Owing to their long shelf life and instantaneous high power, thermal batteries have found various applications. However, thermal batteries face significant challenges in heat management. Also, these challenges are persistent in compact designs and would nucleate subsequent effects such as high heat loss and high skin temperature, which eventually reduce the specified life of batteries, safety, and reliability. To address these challenges, this work proposes a physics-based thermal modelling approach for miniaturized cylindrical thermal batteries that simulates thermal design and ensures efficient heat management. An unsteady-state heat transfer model that combines heat generation from pyrotechnic pellets and convective heat losses through the battery casing and insulation. The predicted skin and electrolyte core temperatures as a function of battery discharge time are investigated and further validated against the prototype. The predicted skin temperature and electrolyte core temperatures are in good agreement with the experimental data, and deviations are ~ 5% and ~ 3%, respectively. Also, the maximum skin temperature of the proposed model is reduced by ~ 35% compared with the uninsulated design. Further, the capacity loss at elevated temperatures is investigated and characterized using a thermal-damage factor. By optimizing insulation and design parameters, the batteries can withstand internal operating temperatures (> 500 °C), enhancing safety. The results demonstrate that the proposed thermal model can predict the thermal behavior of miniaturized batteries. Thus, this work not only provides a modelling framework for miniaturized reserve batteries but also enables designers to predict crucial parameters which are pivotal in revalidating the physical designs and reduces the need for iterative prototyping.