Patent ID: 8617259

Claim:
A method of making a lithium-FeS 2 battery with at least 4 Wh of capacity on a 1000 mW constant power drain comprising the steps of: a. selecting a container having a size appropriate for FR6 batteries: b. determining an amount of FeS 2 necessary to insure that, when the cell is fully discharged, radial force of expansion is between 50% to 80% of the yield strength of the container when radial expansion forces are at a maximum during discharge of the battery under any conditions; c. providing FeS 2 in the determined amount to a slurry mixture and coating the slurry mixture onto a metallic foil current collector and drying said coated mixture to form a cathode coating, said cathode coating having greater than 95 wt. % of FeS 2 as compared to the total weight of solids in the cathode coating; d. forming a jellyroll electrode assembly by winding the coated current collector with a separator and an anode strip consisting essentially of lithium or a lithium alloy; e. placing the jellyroll electrode assembly within the cylindrical container and closing the container.