Evaluation of new plastic compression (Ziegler) type of seals for long life planetary batteries

A program was initiated to develop improved types of terminal seals for aerospace Ni-Cd batteries. The approach used has not involved attempts, such as employed elsewhere, to improve the ceramic-to-metal seal that is now extensively employed for this application. Rather the approach has been directed toward the development and evaluation of new types of seals. Of prime interest in this initial investigation has been the Ziegler type of compression seal and in particular the injection molded version developed by the Bell Telephone Laboratories (BTL). A number of these units were designed, fabricated, and evaluated on an accelerated life test under a simulated battery environment. Results have shown that there are no major problems involved in scaling up the BTL small-size (5-amp) seal to a larger size (up to 50-amp) seal suitable for most JPL flight batteries. Five out of five such seals successfully completed over 10 months of continuous thermal cycling without developing any leaks greater than 1.8 x to 10 to the minus 9th power atm-cc-He/s.