Binder-Free Cathode for Thermal Batteries Fabricated Using FeS₂ Treated Metal Foam

In this study, we fabricated a cathode with lower amounts of additive materials and higher amounts of active materials than those of a conventional cathode. A thermal battery was fabricated using FeS₂ treated foam as the cathode frame, and its feasibility was verified. X-ray diffraction, transmission electron microscopy, and scanning electron microscopy were used to analyze the effects of thermal sulfidation temperature (400 and 500°C) on the structure and surface morphology of the FeS₂ foam. The optimal temperature for the fabrication of the FeS_x treated foam was determined to be 500°C. The FeS₂ treated foam reduced the interfacial resistance and improved the mechanical strength of the cathode. The discharge capacity of the thermal battery using the FeS₂ treated foam was about 1.3 times higher than that of a thermal battery using pure Fe metal foam.