Battery assembly, method of manufacture and thermal control thereof

Abstract

The present disclosure relates to a bipolar battery comprising one or more channels formed in the bipolar battery and cooperating with one or more slots, the slots being adapted to channel flow of electrolyte to provide faster and more uniform flow of electrolyte. The present disclosure relates to a bipolar battery assembly comprising: a) a plurality of electrode plates stacked together to form an electrode plate stack; b) one or more electrochemical cells, wherein each electrochemical cell is formed between a pair of electrode plates; c) one or more separators disposed within the one or more electrochemical cells; and d) one or more slots formed in each of the one or more electrochemical cells and adapted to channel electrolyte flow into the one or more electrochemical cells. The present disclosure also relates to a method for making a battery assembly. The method can circulate one or more fluids through the battery assembly during manufacture. The circulating fluid can be part of a thermal control circulation.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] Applicants claim priority to U.S. Provisional Application No. 62 / 990,073, filed on March 16, 2020, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates generally to bipolar battery assemblies, and more particularly to one or more tanks within a battery assembly. The present disclosure is particularly useful for temperature control of a bipolar battery from within during pickling, forming, charging, discharging, or even during operation. Background Art

[0004] Traditionally, bipolar battery assemblies, such as those taught in U.S. Publication No. US 2009 / 0042099, incorporated herein by reference, include an electrolyte within a stack of electrode plates. The electrolyte allows electrons and ions to flow between the cathode and anode materials of the electrode plates. The bipolar battery assembly is held together by bolts extending through aligned through-holes in the electrode plates and separators. To provide an electrolyte that does not leak from the electrode stack or into the channels of the stack, a solid electrolyte is generally used rather than a liquid electrolyte, reducing the need for separate sealing components within the battery assembly. A solid electrolyte or a semi-solid electrolyte can be part of a sealed lead acid (SLA) battery assembly. An exemplary SLA battery assembly is a gel cell, in which the electrolyte solution formed is a jelly-like solution that dries to a solid electrolyte. While these battery assemblies based on solid or semi-solid electrolytes are generally effective in addressing leakage issues, they can be expensive to manufacture, can be more susceptible to damage when overcharged, and can even have a shorter service life (3 to 5 years for SLA batteries, compared to up to 20 years for wet cell batteries). An ingenious solution that provides an integrated seal via alignment and interlocking of channels and frames provides a way to use liquid electrolytes while overcoming the obstacles of some of these solutions. Suitable integrated seals are disclosed in PCT Publication WO 2013 / 062623 and U.S. Patent No. 10,141,598, which are incorporated herein by reference in their entirety for all purposes.

[0005] In addition to the risk of leakage, a challenge posed by liquid electrolytes can be the duration of the pickling (also known as "soaking") process. The pickling process typically involves filling the electrochemical cells of the battery assembly with liquid electrolyte and allowing the electrolyte to soak into the active materials of the electrode plates. This can be a time-consuming part of the battery assembly process, which may limit large-scale commercialization capabilities. Generally speaking, during pickling, the electrolyte wicks through the pores or paths of the separator to fill the electrochemical cells and is absorbed by the active materials adjacent to each side of the separator, such as taught in PCT publication WO2013 / 062623.

[0006] Not only does pickling add a time challenge, but curing and drying may also present the following challenges: the total time to assemble the battery, the total facility space required for the equipment, and the need for multiple workstations to assemble, cure, dry, pickle, and form before charging for operation. The curing and drying of the active material applied to one or more electrode plates are generally completed with the assistance of a curing oven. Therefore, the electrode plate on which the active material in the form of a paste is prepared can transition from an assembly area for applying the active material to a curing area with a curing oven, and then be able to withstand stacking, pickling, forming, or charging of the electrode plates. One such slurrying process is disclosed in PCT Publication WO2018 / 213730, which is incorporated herein by reference in its entirety for all purposes.

[0007] Another challenge faced by typical bipolar battery assemblies is that the battery can generate excess heat while being acid washed, formed, charged, or discharged. The acid wash process is typically an exothermic process, resulting in an increase in the internal battery temperature. Generally, after acid washing, the battery assembly undergoes a formation process. To begin the formation process, the battery assembly is attached to a power source for charging. The formation process, while endothermic, generates more acid. This generated acid generally sustains the acid wash process, resulting in a subsequent exothermic reaction. Thus, although the formation is endothermic and absorbs heat, the exothermic reaction that generally results often generates the same or even more heat than is absorbed, resulting in the internal temperature of the battery assembly remaining elevated or even further increasing. Power dissipation while current flows through the internal resistance of the battery during charging or discharging (also known as Joule heating) can also result in excess heat. Exothermic reactions within the electrochemical cells during charging or discharging can also generate excess heat. Excess generated heat in the battery assembly can result in a number of problems, including: active chemicals can swell, causing the electrochemical cells to swell; pressure can build up inside the electrochemical cells; increased swelling and pressure can cause mechanical deformation of the components (such as deformation outward, e.g., bulging); mechanical deformation can cause shorting as components move away from each other and create leak paths or lose contact; components can crack due to prolonged operation at excessive temperatures; thermal runaway during chemical reactions; emission of gases; and / or one or more of the cells can rupture or explode due to elevated temperatures. Because of these potential problems, the rate at which the battery assembly can be acid washed, formed, charged, or discharged is therefore dependent on the rate at which excess generated heat can be removed. Another challenge presented by bipolar battery assemblies is their ability to charge at low or high temperatures. At low temperatures, such as below 5°C, some batteries can build up pressure within the battery, resulting in venting. Poor charge acceptance at low temperatures can manifest as a fully charged battery due to pressure build-up.

[0008] Today, there are many different processes used to control the temperature of the battery during formation, acid wash, charging, and discharging, and to maintain the battery assembly below a threshold temperature. To control the heat generated during acid wash and formation and to maintain the battery assembly below a threshold temperature, an initial fill of chilled electrolyte can be used to obtain a lower overall internal temperature of the battery assembly after exothermic reactions occur. The battery assembly can be submerged in a temperature-controlled (e.g., chilled) water bath during formation to provide heat removal. Because the internal temperature of the battery assembly must be maintained below the threshold, the rate of heat removal is often controlled and thus limits the rate of acid wash and formation. In addition to excessive processing time (i.e., increased lead times), these additional processes result in additional costs in terms of work-in-process (i.e., batteries being assembled) inventory, cooling and heating equipment, storage space, power for charging, and labor for assembly.

[0009] What is needed is a battery assembly that is compatible with liquid electrolytes while maintaining a seal around the electrochemical cell and one or more channels extending through the assembly. What is needed is a battery assembly that can more quickly receive electrolyte into the electrochemical cell and allow the electrolyte to soak into the active material. What is needed is an electrode plate and / or battery assembly that can be cured and dried without the use of a curing oven. What is needed is a battery assembly that can be temperature controlled from the inside. What is needed is a battery assembly that can control its temperature to allow for faster pickling, forming, charging and / or discharging. Summary of the Invention

[0010] The present teachings generally relate to troughs suitable for incorporation into battery assemblies. The troughs can assist in distributing one or more fluids into electrochemical cells, thereby helping to distribute the fluids away from channels and into the cells. The troughs can also be used in the reverse situation, collecting fluids from the cells and directing them into channels. The troughs can be advantageous during steps in the battery assembly preparation process, including during curing, draining, filling, pickling, forming, drying, and the like. The troughs can even facilitate thermal management cycles by allowing one or more fluids to flow through the battery assembly.

[0011] The present disclosure relates to a bipolar battery assembly, comprising: a) a plurality of electrode plates stacked together to form an electrode plate stack; b) one or more electrochemical cells, wherein each electrochemical cell is formed between a pair of electrode plates; c) one or more separators disposed within the one or more electrochemical cells; and d) one or more slots formed in each of the one or more electrochemical cells and adapted to direct electrolyte flow into the one or more electrochemical cells.

[0012] The present disclosure relates to a separator for a bipolar battery, comprising: a) one or more thin sheets, the one or more thin sheets being porous and non-conductive and configured to allow electrolyte, ions, electrons, or a combination thereof to pass therethrough; b) one or more openings in the thin sheets, the one or more openings being adapted to align with one or more other openings of an adjacent electrode plate to form one or more channels; and c) one or more grooves formed in the thin sheets as one or more channels of reduced thickness of the thin sheets and adapted to direct the flow of electrolyte of a bipolar battery.

[0013] The present disclosure relates to a bipolar battery assembly comprising: a) a plurality of electrode plates stacked together to form one or more electrochemical cells between the electrode plates; b) one or more separators having one or more grooves formed therein, wherein the one or more separators are positioned between the one or more electrochemical cells; and c) an electrolyte positioned in the one or more electrochemical cells.

[0014] The present teachings generally relate to methods for preparing battery components. Preparing a battery component may include multiple steps, such as assembling, curing, emptying, filling, pickling, forming, drying, thermal control cycling, etc., or a combination thereof. Some of these steps may be completed sequentially, simultaneously, or both. For example, a thermal control cycle may occur during curing, pickling, forming, drying, etc., or a combination thereof. As an example, a thermal control cycle may include emptying, filling, or both. A thermal control cycle may include causing one or more fluids to flow through the battery component (e.g., fluid circulation, thereby circulating one or more fluids). These fluids may flow through one or more electrochemical cells, channels, grooves, ports, vents, valves, holes, openings, etc., or a combination thereof. These fluids may circulate through the battery component. Fluid circulation may include causing the same fluid to flow into and out of the battery component, or vice versa. Fluid circulation may include removing one fluid and filling it with another fluid. A thermal control cycle may be advantageous in introducing a fluid having a different temperature from the interior of the battery component into the battery component. This temperature difference may allow one or more steps of preparing the battery component to occur faster, more cost-effectively, maintain assembly (e.g., stacking), etc., or a combination thereof.

[0015] Preparation of the battery assembly may include or not use one or more grooves as described herein.In addition to channels, the use of one or more grooves may even further increase the benefits of the battery preparation process disclosed herein, such as thermal control cycling.

[0016] The present disclosure relates to a method for preparing a battery assembly, comprising: a) filling the battery assembly with a liquid electrolyte having one or more reactants therein; b) forming the battery assembly by applying an electrical charge; and thermally controlling cycling to maintain an internal temperature of the battery assembly below a threshold temperature.

[0017] The present disclosure relates to a method for preparing a battery assembly, comprising: a) filling the battery assembly with a liquid electrolyte having one or more reactants therein; b) optionally, acid washing the battery assembly; c) forming the battery assembly by applying an electrical charge; and d) thermally controlling cycling to maintain the internal temperature of the battery assembly below a threshold temperature.

[0018] The present disclosure relates to a method for preparing a battery assembly in a single workstation, comprising: a) providing a formed battery stack having a plurality of electrochemical cells at a single workstation; b) optionally, pickling the battery assembly while flowing one or more pickling fluids through the battery assembly; and c) forming the battery assembly by applying an electrical charge while simultaneously flowing one or more forming fluids through the battery assembly.

[0019] The present teachings provide a battery assembly having one or more channels passing through it. One or more of the channels may include one or more fill channels suitable for distributing electrolyte to the electrochemical cells. The one or more fill channels may be connected to one or more grooves. The one or more grooves may include a plurality of grooves distributed around each electrochemical cell. The one or more grooves may guide the flow of the electrolyte so that the electrolyte is wicked through the separator with a faster and more uniform flow. The one or more fill channels may also be used to drain the electrolyte. The draining may be complete or partial during the thermal control cycling process. The thermal control cycling process may be advantageous in allowing a cooler electrolyte to replace the heated electrolyte, and thus provide a means of heat removal and internal heat dissipation. The one or more channels and grooves may provide a more efficient means of curing the battery assembly while avoiding the need for a curing oven. One or more fluids, such as air at a high temperature, may be circulated through the one or more channels and grooves to cure the active materials of the battery assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A cross section of the battery assembly is depicted with the separator exposed.

[0021] Figure 2 is a perspective view of the electrode plate.

[0022] Figure 3 is a perspective view of the electrode plate.

[0023] Figure 4 A partial cross-sectional view of a battery assembly is shown.

[0024] Figure 5 A partial cross-sectional view of a battery assembly is shown.

[0025] Figure 6 A partially exploded stack of electrode plates and separators of a battery assembly is shown.

[0026] Figure 7 A partially exploded stack of electrode plates and separators of a battery assembly is shown.

[0027] Figure 8 is a perspective view of a cross section of one or more channels through a battery assembly.

[0028] Figure 9A separator formed from a stack of sheets and having a plurality of slots is depicted.

[0029] Figure 10 A cross section of a battery assembly is depicted exposing a separator having grooves and electrolyte flowing through the separator.

[0030] Figure 11 A cross section of a battery assembly is depicted exposing the separator with electrolyte flowing therethrough.

[0031] Figure 12 is a line graph showing a comparison of the duration of filling of battery components with electrolyte.

[0032] Figure 13 A flow chart of a method for preparing a battery assembly is depicted. DETAILED DESCRIPTION

[0033] The explanations and illustrations presented herein are intended to familiarize other persons skilled in the art with this teaching, its principles, and its practical applications. The specific embodiments of this teaching as set forth are not intended to be exhaustive or limitative of this teaching. The scope of this teaching should be determined with reference to the full range of equivalents to which the appended claims and these claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations, such as will be gathered from the appended claims, are also possible and are hereby incorporated by reference into this written description.

[0034] Battery components

[0035] The battery assembly disclosed herein generally relates to battery assemblies and can be particularly useful as a bipolar battery assembly. The bipolar battery assembly can be a lead-acid battery. The bipolar battery assembly can be a valve regulated lead acid battery (VRLA). The battery assembly includes one or more stacks of multiple electrode plates. The multiple electrode plates can include one or more bipolar plates, unipolar plates, bipolar plates, end plates, or any combination thereof. One or more bipolar plates include a substrate having an anode on one surface and a cathode on an opposite surface. A unipolar plate can include an anode or cathode deposited on a surface. A first unipolar plate and a second unipolar plate can be positioned at opposite ends of the one or more stacks, with the bipolar plate, bipolar plate, or both positioned between the opposite ends of the one or more stacks. The battery assembly can include one or more end plates, such as a first end plate and a second plate. The one or more end plates are attached to one or more ends of the stack. The one or more end plates can be one or more unipolar plates or separate from the unipolar plates. For example, the first end plate can be attached to the opposite end of the stack as the second end plate. The one or more end plates may be particularly useful for reinforcing one or more electrode plates during evacuation within the battery assembly, during filling of the battery assembly, during charge and / or discharge cycle operation of the battery assembly, or any combination thereof. The stack includes a separator and an electrolyte positioned between each pair of adjacent electrode plates. Each pair of adjacent electrode plates (including the anode and cathode thereon) and the separator and electrolyte therebetween may form an electrochemical cell. One or more electrochemical cells may include one or more grooves therein. The grooves may be positioned within the active area of ​​each electrochemical cell or in direct fluid communication with the active area. The one or more grooves may help accelerate the outflow (e.g., wicking, flow) of the electrolyte within each electrochemical cell. The battery assembly may include one or more channels. The one or more channels may extend transversely through one or more electrode plates, the electrolyte, the separator, the active area, or a combination thereof. The one or more channels may be referred to as transverse channels. The one or more channels may be transverse to the one or more grooves, in fluid communication with the one or more grooves, or both. The one or more channels may be formed by openings, inserts, or both. The one or more openings, inserts, or both may be part of (e.g., attached to, integral with) one or more electrode plates, the separator, or both. The one or more channels may pass through the active area of ​​each electrochemical cell. The one or more channels may be sealed relative to the liquid electrolyte passing therethrough. One or more fluids may circulate through the one or more channels, the grooves, or both. The one or more fluids may assist in faster electrolyte flow; control the temperature of the battery components during pickling, forming, charging and / or discharging; or any combination thereof.

[0036] The battery assembly may include one or more end plates. The one or more end plates may be used to reinforce one or more electrode plates; resist or prevent one or more electrode plates from deforming outwardly and inwardly due to a pressure differential within the battery assembly compared to the external environment; prevent semi-permanent or permanent damage to one or more electrode plates; ensure that interlocking components forming a seal remain sealed; or any combination thereof. The one or more end plates may have any size, shape, and / or configuration that achieves the following effects: reinforce one or more electrode plates; resist or prevent one or more electrode plates from deforming outwardly and inwardly due to a pressure differential within the battery assembly compared to the external environment; prevent semi-permanent or permanent damage to one or more electrode plates; ensure that interlocking components forming a seal remain sealed; or any combination thereof. The one or more end plates may or may not be electrode plates. The one or more end plates may be one or more unipolar plates. For example, each unipolar plate may be an end plate at opposite ends of a stack of electrode plates. The one or more end plates may be adjacent to the one or more electrode plates. For example, an end plate may be attached to each unipolar plate at opposite ends of a stack of electrode plates comprising opposing unipolar plates. The one or more end plates may be attached to the one or more electrode plates at opposite ends of the stack. For example, the stack may include a first end plate at an opposite end of the stack as a second end plate. The one or more end plates may have sufficient rigidity to resist outward bulging caused by the temperature and pressure within the battery assembly during operation, resist inward bending during evacuation of the battery assembly, or both. The end plate may include a base, an internal reinforcement structure, one or more openings, one or more raised inserts, one or more attachment mechanisms, or any combination thereof. Teachings related to end plates acting as electrode plates or being separate from electrode plates and including internal reinforcement structures can be found in U.S. Patent No. 10,141,598.

[0037] The battery assembly may include one or more electrochemical cells. The electrochemical cells may also be referred to as cells. Each electrochemical cell may be formed between a pair of electrode plates. The electrochemical cell may be formed by a pair of opposing electrode plates having opposing anode and cathode pairs between the pair of opposing electrode plates. The space in the electrochemical cell (i.e., between the opposing anode and cathode pairs) may contain one or more separators, transfer sheets, electrolytes, or a combination thereof. One or more electrochemical cells may be sealed. The electrochemical cell may be sealed by one or more seals formed around the periphery of the stack of electrode plates, such as by a diaphragm and / or interlocking of a frame, one or more channels, or a combination thereof, to form a closed electrochemical cell. The closed electrochemical cell may be sealed relative to the environment to prevent leakage and cell shorting.

[0038] A battery assembly may include multiple electrode plates. The electrode plates may serve as one or more electrodes, include one or more electroactive materials, be part of an electrochemical cell, form part of one or more sealed structures, or any combination thereof. The multiple electrode plates may be used to conduct electrical current (i.e., the flow of ions and electrons) within the battery assembly. The multiple electrode plates may form one or more electrochemical cells. For example, a pair of electrode plates may have a separator and / or electrolyte between them, and the pair of electrode plates may form an electrochemical cell. The number of electrode plates present may be selected to provide the desired voltage of the battery. The battery assembly design provides flexibility in the voltage that can be generated. The multiple electrode plates may have any desired cross-sectional shape, and the cross-sectional shape may be designed to accommodate the available packaging space in the environment of use. The cross-sectional shape may refer to the shape of the plate as viewed from the face of the sheet. The flexible cross-sectional shape and size allow the disclosed assembly to be manufactured to suit the voltage and size requirements of the system utilizing the battery. Opposing end plates and / or unipolar plates may sandwich the multiple electrode plates. The multiple electrode plates may include one or more bipolar plates, unipolar plates, dual polar plates, etc., or any combination thereof. Suitable electrode plates are disclosed in PCT Publications WO 2013 / 062623, WO 2018 / 213730, WO 2018 / 237381, and WO 2020 / 102677; U.S. Patent Nos. 8,357,469, 10,141,598, 10,615,393; and U.S. Patent Publication No. 2019 / 03790361, which are incorporated herein by reference in their entirety for all purposes.

[0039] A plurality of electrode plates stacked together may form an electrode plate stack. An electrode plate stack may be referred to simply as a stack or a stack of electrode plates. An electrode plate stack may generally include a plurality of bipolar electrode plates between opposing unipolar plates. An electrode plate stack may include one or more bipolar plates located between a plurality of bipolar electrode plates. An electrode plate stack may include a separator, a transfer sheet, or both located between adjacent electrode plates (e.g., within an electrochemical cell). An electrode plate stack may or may not include an electrolyte. An electrode plate stack may refer to a battery assembly before operation, a stack of components of a battery assembly, an assembly during pickling, an assembly during formation, an assembly after stacking electrode plates, an assembly when a separator is located between adjacent electrode plates, or any combination thereof.

[0040] One or more electrode plates may include one or more substrates. The one or more substrates may be used to provide structural support for the cathode and / or anode; act as cell separators to prevent electrolyte flow between adjacent electrochemical cells; cooperate with other battery components to form an electrolyte seal around the edges of the bipolar plates, which may be located on the outer surfaces of the battery; and, in some embodiments, transfer electrons from one surface to another. Depending on the function or battery chemistry, the substrate may be formed from a variety of materials. The substrate may be formed from a material that is structurally robust enough to provide the desired bipolar electrode plate skeleton, thereby withstanding temperatures exceeding the melting point of any conductive materials used in the battery construction, and has high chemical stability during contact with the electrolyte (e.g., sulfuric acid solution) so that the substrate does not decompose after contact with the electrolyte. The substrate may be formed from a suitable material and / or configured to allow electricity to be transferred from one surface of the substrate to an opposing substrate surface. The substrate may be formed from one or more conductive materials, non-conductive materials, or both. A substrate formed from one or more non-conductive materials may include one or more conductive features constructed therein or thereon. The one or more conductive materials may include one or more metallic materials. The one or more non-conductive materials may include polymeric materials, such as thermosetting polymers, elastomeric polymers, thermoplastic polymers, or any combination thereof. One or more of the polymeric materials that may be employed include polyamides, polyesters, polystyrenes, polyethylenes (including polyethylene terephthalate, high-density polyethylene, and low-density polyethylene), polycarbonates (PC), polypropylene, polyvinyl chloride, bio-based plastics / biopolymers (such as polylactic acid), silicones, acrylonitrile butadiene styrene (ABS), or any combination thereof, such as PC / ABS (a blend of polycarbonate and acrylonitrile butadiene styrene). The substrate may include a composite material. The composite material may include: a reinforcing material, such as fibers or fillers, as known in the art; two different polymeric materials, such as a thermosetting core and a thermoplastic shell; a thermoplastic edge surrounding the perimeter of the thermosetting polymer; a conductive material disposed within the non-conductive polymer; or any combination thereof. The substrate may include or have a bondable (e.g., melt-bondable) thermoplastic material at the edges of the plate. The substrate may include one or more openings, frames, inserts, slots, or a combination thereof.

[0041] One or more electrode plates may include one or more frames. The one or more frames may facilitate stacking of the electrode plates, forming of the electrochemical cells, sealing of the electrolyte within the electrochemical cells, accommodating one or more tanks, or the like, or a combination thereof. The one or more frames may be positioned at least partially or completely around the periphery of one or more substrates. A separate frame may form the outer periphery of a separate electrode plate. The one or more frames may be separate from or integral with the one or more substrates. For example, the frame may be integral with the substrate and positioned around the periphery of the substrate. The one or more frames may be flanges. A protruding edge may facilitate stacking. A protruding edge may be a flange that protrudes from at least one of two opposing surfaces of an electrode plate (e.g., a substrate). One or more sides of the flange may include one or more notches. One or more notches of one frame may interact with a frame from an adjacent electrode plate. One or more notches may be used to nest with a frame from an adjacent electrode plate or even a separator. The battery assembly may include multiple frames. The frames of adjacent electrode plates may align and interlock to form a seal therebetween around the electrochemical cell. The frame may function as a separator. The frame may include one or more inward-facing surfaces. The inward-facing surface can be one or more surfaces of a protruding edge, which faces inward toward, adjacent to, or exposed to the active area, electrochemical cell, separator, or any combination thereof. The frame may include or be free of one or more grooves. The frame may be made of a non-conductive material, such as a thermoplastic material. The use of a non-conductive material can enhance the seal around the outside of the battery stack. The frame can be made of the same or different thermoplastic material as the substrate. The frame of the electrode plate, the end plate, or both may have similar properties to the frame of the separator. One or more suitable frames and edge seals may be disclosed in PCT Publication No. WO 2020 / 243093, which is incorporated herein by reference in its entirety.

[0042] One or more of the electrode plates may include one or more active materials. The one or more active materials may serve as the cathode, anode, or both of the electrode plates. The one or more active materials may be in any form commonly used in batteries for use as the anode, cathode, or both. A bipolar plate may have one or more active materials on a surface serving as the cathode, and one or more active materials on an opposing surface serving as the anode. A unipolar plate may have one or more active materials on a surface serving as the cathode or anode, while the opposing surface has neither an anode nor a cathode. A bipolar plate may have one or more active materials on a surface serving as the cathode or anode, and one or more similar active materials on an opposing surface also serving as the cathode or anode. The cathode of one electrode plate may be opposite the anode of another electrode plate. The cathode may be referred to as one or more positive active materials (PAM). The anode may be referred to as one or more negative active materials (NAM). The one or more active materials may include any suitable active material that promotes electrochemical reactions with the electrolyte of the same electrochemical cell, the opposing one or more active materials, or both. The one or more active materials may be selected to undergo reduction and / or oxidation reactions with the electrolyte.

[0043] The one or more active materials can include one or more materials typically used in secondary batteries, including lead-acid batteries, lithium-ion batteries, and / or nickel-hydrogen batteries. The one or more active materials can include a lithium, lead, carbon, or transition metal complex oxide, sulfate compound, or phosphate compound. Examples of complex oxides include Li / Co-based complex oxides such as LiCoO2; Li / Ni-based complex oxides such as LiNiO2; Li / Mn-based complex oxides such as spinel LiMn2O4, and Li / Fe-based complex materials such as LiFeO2. Exemplary phosphate and sulfide compounds of transition metals and lithium include LiFePO4, V2O5, MnO2, TiS2, MoS2, MoO3, PbO2, AgO, NiOOH, and the like. The one or more active materials can include lead dioxide, lead oxide, lead sulfate, or combinations thereof. For example, in a lead-acid battery, the one or more active materials can be or include lead dioxide (PbO2), ternary lead oxide (3PbO), ternary lead sulfate (3PbO-3PbSO4), quaternary lead oxide (4PbO), quaternary lead sulfate (4PbO-4PbSO4), or any combination thereof. The one or more active materials or sources thereof can perform better when acid washing as part of a method of making a battery component, while others can not require acid washing. For example, lead yellow as a source of lead oxide can not require acid washing as part of a method of making a battery component. The one or more active materials can be in any form that allows the one or more active materials to be used as a cathode, an anode, or both, of an electrochemical cell. Exemplary forms include shaped parts, in a paste form, preformed sheets or films, sponges, or any combination thereof. For example, the one or more active materials can include sponge lead. Sponge lead can be useful due to its porosity. One or more suitable active materials and / or forms thereof can be described in PCT publications WO 2018 / 213730 and WO 2020 / 102677, which are incorporated by reference in their entirety herein for all purposes.

[0044] A battery assembly may include one or more fluids. The one or more fluids may be used to generate one or more electrochemical reactions; provide for pickling, forming, curing, drying, charging, discharging, thermal control cycles, etc.; provide cooling and / or heating; or any combination thereof. During preparation, the one or more fluids may be only a temporary part of the battery assembly, part of the battery assembly for operation, or both. The one or more fluids may flow into the battery, out of the battery, circulate through the battery, or any combination thereof. The one or more fluids may be located within one or more electrochemical cells, channels, tanks, headspace, or any combination thereof. The one or more fluids may circulate through one or more openings, ports, valves, vents, channels, tanks, electrochemical cells, headspace, or any combination thereof. The one or more fluids may be configured to add heat to the battery assembly, remove heat from the battery assembly, or both. The one or more fluids may be configured to cure one or more materials of the electrochemical cells, dry one or more materials, or both. The one or more fluids may include one or more liquids, gases, or both. The one or more fluids may include electrolytes, air, drying fluids, lead collection fluids, reactive materials, electrolyte removal fluids, or the like, or any combination thereof.

[0045] The one or more fluids may include air. The air may be humid air, dry air, or both. The relative humidity of the humid air may be higher than the relative humidity of the dry air. The humid air may have a relative humidity of approximately 50% or greater, 60% or greater, or even 75% or greater. The humid air may have a relative humidity of approximately 100% or less, 90% or less, or even 80% or less. The dry air may have a relative humidity of approximately 0% or greater, 5% or greater, or even 10% or greater. The dry air may have a relative humidity of approximately 50% or less, approximately 40% or less, approximately 30% or less, or even approximately 20% or less. The air may be used for evacuation, curing, drying, or a combination thereof. The humid air, the dry air, or both may be used for evacuation, curing, and / or drying. The dry air may follow the humid air. The humid air may follow the dry air. The humid air and the dry air may be present within the battery assembly simultaneously.

[0046] The one or more fluids may include one or more drying fluids. The one or more drying fluids may assist in curing and / or drying one or more materials. The one or more materials may include one or more active materials. The one or more active materials may be dried by removing one or more fluids therefrom. The one or more fluids may include electrolytes, water, other reactive materials, or the like, or a combination thereof. For example, the active materials may need to be cured after the slurry coating process. As another example, the active materials may need to be dried after draining the electrolyte. As another example, the interior of the battery assembly may need to be dried after flushing with water, other fluids, or both. A battery assembly without electrolyte may be used as a dry-charged battery assembly. The one or more drying fluids may be used to dry one or more active materials, separators, substrates, etc., from liquid electrolytes or other fluids within the battery assembly. The one or more drying fluids may include one or more drying gases, water-chelating liquids, critical point drying fluids, or a combination thereof. The one or more drying gases may include air. The air may include dry air to avoid excessive humidity.

[0047] The one or more fluids may include one or more lead collection fluids. The one or more lead collection fluids may be used to collect and / or remove one or more lead species. The lead collection fluids may be used to extend the life of the battery assembly, drain the battery assembly, recycle and / or dispose of the battery assembly or its parts, or any combination thereof. An exemplary lead species may include lead sulfate. Removing lead species, such as lead sulfate, may help extend the service life of spent batteries. The one or more lead collection fluids may include acetic acid, methanesulfonic acid, or the like, or a combination thereof.

[0048] The one or more fluids may include one or more reactive materials. The one or more reactive materials may include one or more oxidizing agents, passivating agents, solvating agents, etc., or combinations thereof. The one or more reactive materials may include hydrogen peroxide, methanesulfonic acid, phosphoric acid, lead ions in solution, sodium sulfate, organo-ringosulfonates, etc., or combinations thereof. The one or more oxidizing agents may be used to reduce free lead from the one or more active materials. For example, the one or more oxidizing agents may reduce free lead in an unformed paste of the one or more active materials. Unforming may involve a forming step in preparing a battery component. The one or more passivating agents may reduce, prevent, and / or stop lead corrosion. Corrosion may be lead corrosion that tends to occur within an electrochemical cell. Lead corrosion may occur in the cell after forming. Forming may involve a forming step in preparing a battery component.

[0049] The one or more fluids may include an electrolyte. The electrolyte may allow electrons and ions to flow between the anode and the cathode. The electrolyte may be located within the electrochemical cell. The electrolyte may be a liquid, a gel, and / or a solid. Since one or more electrochemical cells may be sealed, the electrolyte may be a liquid electrolyte. The electrolyte may be any liquid electrolyte that promotes an electrochemical reaction with the anode and cathode utilized. The electrolyte may be able to pass through the separator of the electrochemical cell. The electrolyte may be aqueous or organic. One or more suitable electrolytes may be disclosed in U.S. patent application Ser. No. 15 / 359,289, which is incorporated herein by reference in its entirety.

[0050] The aqueous electrolyte may contain one or more reactants. The one or more reactants may be an acid, a salt, or both in water, which may enhance the functioning of the battery cell. The one or more reactants may include sulfuric acid, sodium sulfate, potassium sulfate, or the like, or a combination thereof. The one or more reactants may be present in an amount sufficient to facilitate the operation, pickling process, formation process, or any combination thereof of the battery cell. The concentration of the reactants in the electrolyte may be about 0.5 weight percent or greater, about 5.0 or greater, or even about 30 weight percent or greater, based on the weight of the electrolyte. A useful electrolyte in a lead-acid battery may be sulfuric acid in water.

[0051] During pickling, forming, or operation (e.g., charging, discharging) of the battery cell, the concentration of reactants in the electrolyte may be the same or different. Reactants may be provided at lower concentrations during pickling and forming than during operation. The lower concentration may be referred to as a diluted electrolyte. The diluted electrolyte may be referred to as one or more pickling fluids, forming fluids, or both. Because lead is more soluble in lower concentrations of reactants, the concentration may be lower, allowing pickling and forming reactions to occur faster at lower concentrations. Higher concentrations of reactants allow more energy to be generated from the battery assembly during operation (e.g., charging and discharging). Typical AGM batteries may be flooded with reactant concentrations, which compromises the performance and speed of pickling, forming, and operation. An advantage of the present teachings is that the electrolyte can be removed and replaced, allowing concentrations to be varied to achieve desired performance. The electrolyte can be replaced during thermal control cycles. During preparation and prior to operation, a diluted electrolyte (e.g., a lower concentration) may be passed through the battery assembly. For example, the diluted electrolyte may be one or more fluids passed through the battery assembly during pickling and / or forming. The diluted electrolyte may be replaced with an electrolyte of higher concentration.

[0052] A lower concentration of reactants may be associated with an electrolyte of lower specific gravity, while a higher concentration of reactants may be associated with an electrolyte of higher specific gravity. The specific gravity of the electrolyte may be about 1.05 or greater, about 1.1 or greater, or even about 1.15 or greater. The specific gravity of the electrolyte may be about 1.4 or less, about 1.35 or less, about 1.3 or less, about 1.275 or less, about 1.25 or less, or even about 1.2 or less. The specific gravity during pickling and / or forming may be lower than during operation of the battery assembly. The specific gravity during pickling may be about 1.05 or greater to about 1.15 or less. For example, the specific gravity during pickling may be about 1.100. The specific gravity during operation may be about 1.20 or greater to about 1.35 or less. The lower concentration and specific gravity of the electrolyte during pickling and forming may allow for rapid consumption of reactants and rapid generation of heat within the battery through exothermic reactions.

[0053] One or more slots may allow for rapid and uniform filling, draining, or both of one or more electrochemical cells with electrolyte. One or more fill channels may allow for replacement of hot, spent electrolyte with cool, fresh electrolyte to continue the pickling reaction while controlling the temperature of the battery assembly. The replacement allows for faster pickling and / or forming reactions. One or more fill channels may allow for replacement of hot, lower specific gravity electrolyte used for pickling and / or forming with cooler, higher specific gravity electrolyte used for operation of the battery assembly. Spent electrolyte may be drained from the same and / or different ports than those used to fill the assembly with fresh electrolyte.

[0054] The battery assembly may include one or more separators. The one or more separators may be used to separate the electrochemical cells (i.e., to separate the cathode of the electrochemical cell from the anode of the electrochemical cell); to prevent the cells from shorting due to dendrite formation; to allow liquid electrolyte, ions, electrons, or any combination of these elements to pass through it; or any combination thereof. Any known battery separator that performs one or more of the functions described may be used in the battery assembly. The one or more separators may be disposed within the one or more electrochemical cells. The one or more separators may be positioned between the anode and cathode of the electrochemical cell. The one or more separators may be positioned between a pair of adjacent electrode plates, which may include between bipolar plates or between a bipolar plate and a monopolar plate. The separator may be attached to

[0055] The battery assembly may include one or more separators. The one or more separators may be used to separate the electrochemical cells (i.e., to separate the cathode of the electrochemical cell from the anode of the electrochemical cell); to prevent the cells from shorting due to dendrite formation; to allow liquid electrolyte, ions, electrons, or any combination of these elements to pass through it; or any combination thereof. The one or more separators may be positioned between the anode and cathode of the electrochemical cell. The one or more separators may be positioned between a pair of adjacent electrode plates, which may include between bipolar plates or between a bipolar plate and a unipolar plate. The separators may be attached to one or more end plates, electrode plates, other separators, active materials, or any combination thereof around their perimeter, interior, or surface. The separators may be separated from and not in contact with one or more substrates, frames, other separators, or a combination thereof. The separators may extend toward one or more frames of one or more electrode plates, but may be positioned within the inner perimeter of one or more frames. The separators may have a cross-sectional area that is less than or equal to the cross-sectional area of ​​the interior of the frame. A cross-sectional area that is less than the interior of the frame allows peripheral notches to be positioned around the perimeter of the separator. The separator may have a cross-sectional area that is the same as or greater than the area of ​​the adjacent cathode and anode. The separator may completely separate the cathode portion of the battery cell from the anode portion of the battery cell. The separator may absorb and retain at least some electrolyte. The edge of the separator may or may not contact the peripheral edge of the adjacent electrode plate. The peripheral edge may be the inward-facing surface of the frame. The separator may alternatively include a frame, similar to the frame of the electrode plate. The frame of the separator may be aligned and stacked with the adjacent frames of the electrode plate. The separator may be formed as one or more sheets. The separator may include one or more transfer sheets or be separate from one or more transfer sheets. One or more transfer sheets may be used instead of one or more separators or in combination with one or more separators. The separator may include a transfer sheet or be synonymous with a transfer sheet. Exemplary transfer sheets suitable for use with or as a separator are described in PCT publications WO2018 / 213730 and WO2020 / 0102677, which are incorporated herein by reference in their entirety for all purposes.

[0056] One or more peripheral gaps may be positioned within one or more electrochemical cells. The peripheral gap may provide a transfer gap, one or more slots, or a combination thereof. The transfer gap may be between one or more separators and the inward-facing surface of one or more frames. The transfer gap may be a gap used to position the separator and active material on a substrate within the frame while avoiding contact with the frame. The avoided contact may be contact with the inward-facing surface of the frame. The peripheral gap may be the distance between the outer peripheral surface of the one or more separators and the inward-facing surface of the one or more frames. Such a transfer gap may be used in a coating process, such as disclosed in PCT Publication WO2018 / 0213730.

[0057] The one or more separators may include one or more thin sheets. The one or more thin sheets may serve as part of a separator to: separate opposing active materials of an electrochemical cell; prevent short circuits; allow passage of electrolytes, ions, electrons, or a combination thereof; or any combination thereof. The one or more thin sheets may include a single sheet or multiple sheets. Multiple sheets may be stacked to form a separator. The one or more thin sheets may include one or more thin sheets, two or more thin sheets, or even three or more thin sheets. The one or more thin sheets may include ten or fewer thin sheets, seven or fewer thin sheets, or even five or fewer thin sheets. For example, a separator may be composed of three or more thin sheets. For example, when a single port is used for filling and venting, three to five thin sheets may be stacked to form a separator. As another example, when two separate ports are used for filling and venting, five to seven thin sheets may be stacked to form a separator. If multiple thin sheets are used, the thin sheets may be stacked, coplanar with each other, or both. One or more of the thin sheets may or may not include one or more slots. For example, one or more grooves may be formed in one or more sheets within the interior of the stack of sheets, while one or more sheets on the exterior of the stack lack the one or more grooves. As another example, one or more grooves may be formed through some of the one or more sheets, while others remain without the one or more grooves. As another example, one or more grooves may be formed partially through the thickness of one sheet. And as another example, one or more grooves may be formed only by peripheral notches or within the frame, while all separator sheets lack the one or more grooves, or one or more sheets include the one or more grooves.

[0058] One or more sheets may be non-conductive. Being non-conductive facilitates separation between active materials. The one or more non-conductive materials may be inorganic, organic, or both. Organic materials may include cotton, rubber, asbestos, wood, or any combination thereof. The one or more inorganic materials may include one or more polymers, glass, ceramics, or any combination thereof. The one or more polymers may include one or more polyesters, polyethylene, polypropylene, polyvinyl chloride, polytetrafluoroethylene, nylon, ion gels, or any combination thereof. The one or more sheets may be formed from non-woven fibers, woven fibers, membranes, or any combination thereof. For example, the one or more sheets may be absorbent glass mats (AGMs). The one or more sheets may be absorbent, capable of retaining at least some electrolyte, or both. As another example, the sheet may be a porous, ultra-high molecular weight polyolefin separator. The sheet may be porous. The pores may allow electrolytes, ions, electrons, or a combination thereof to pass through the separator. The pores may be substantially straight, tortuous, or a combination thereof, extending through the thickness of the sheet. As an example, the one or more separators may be formed from one or more sheets that are porous and non-conductive.

[0059] The sheet has a thickness. The thickness can be measured as the distance between the outer faces of the sheet. The outer face can be the face facing the adjacent anode, cathode, or both, substantially parallel to the face of the adjacent anode, cathode, or both, or both. The thickness can be suitable for promoting the energy and power density of the battery assembly. A suitable thickness can be selected based on the overall size of the battery assembly. The thickness of the sheet can be about 10 μm or greater, about 25 μm or greater, about 100 μm or greater, or even about 500 μm or greater. The thickness of the sheet can be about 1 cm (10,000 μm) or less, about 0.5 cm (5,000 μm) or less, about 0.3 cm (3,000 μm) or less, or even about 0.1 cm (1,000 μm) or less. For example, the thickness of the sheet can be about 500 μm to about 0.3 cm. The thickness of the sheet can be uniform or variable over all or a portion of the sheet. The variable thickness may be due to one or more grooves formed in the separator.

[0060] One or more electrochemical cells may include one or more slots. The one or more slots may be used to: direct the flow of electrolyte into the one or more electrochemical cells; direct the flow of electrolyte wicking through the separator; provide faster flow of electrolyte wicking through the one or more separators; provide a more uniform distribution of electrolyte along the separator and / or within each electrochemical cell; speed up the filling and / or emptying of the electrochemical cell with electrolyte; improve the efficiency of the pickling process and / or the forming process; collect one or more gases generated within the battery; or any combination thereof. The one or more slots may have any size, shape and / or configuration to distribute the electrolyte. The one or more slots may be formed within the one or more electrochemical cells.

[0061] The one or more slots may be exposed to the interior of one or more electrochemical cells; face the interior; be in fluid communication with the interior; or a combination thereof. The interior of the electrochemical cell may be the active area of ​​the cell. The active area may be the area of ​​the cell that houses one or more active materials, one or more separators, an electrolyte, or a combination thereof. The active area may be the area of ​​the cell where electrochemical reactions occur.

[0062] One or more slots may be in fluid communication with one or more openings, channels, vents, ports, valves, etc., or combinations thereof. One or more slots may be in fluid communication with one or more fill openings. One or more fill openings may include fill openings for a separator, an electrode plate, or both. One or more slots may be in fluid communication with one or more fill channels. One or more slots may be in fluid communication with one or more fill channels via one or more vents, fill openings, or both. One or more slots may include a plurality of slots radiating from one or more fill openings. Radiating may refer to extending from, forming an array around, being distributed from, flowing entirely from, etc., or combinations thereof.

[0063] One or more grooves may be formed in one or more separators, peripheral notches, one or more electrode plates, or any combination thereof. One or more grooves may be formed in one or more frames, substrates, or both of the one or more electrode plates. One or more grooves may be formed in one or more inward-facing surfaces of one or more frames. One or more grooves may be formed on one or more surfaces of one or more substrates (e.g., surfaces facing inwardly in the battery cell). One or more grooves may be formed in one or more sheets of one or more separators. One or more grooves may be formed, at least in part, by one or more peripheral notches. One or more grooves may be gaps in one or more sheets, one or more frames, or both. One or more grooves may protrude inwardly from one or more exterior surfaces of a sheet. One or more grooves may be one or more recesses in one or more inward-facing surfaces of one or more frames. Exemplary grooves may include one or more channels, tunnels, pipes, grooves, passages, notches, etc., or any combination thereof.

[0064] The one or more grooves can be substantially straight, non-linear, uneven, curved, varied, etc., or any combination thereof. For example, the sheet can include a plurality of substantially straight grooves. As another example, the peripheral notch can form a groove that is the opposite of the peripheral shape of the partition. The one or more grooves can have one or more surfaces that are planar, non-planar, or a combination thereof. The one or more grooves can be voids in the sheet material, the frame, or both, shaped like one or more cuboids, cubes, cylinders, spheres, cones, etc., or any combination thereof. For example, the one or more grooves can have substantially flat surfaces such that the void is substantially cubic. As another example, the grooves can have substantially curved surfaces such that the void in the sheet material resembles half a cylinder (e.g., a "C-shape"). As another example, the grooves can have substantially flat surfaces and curved surfaces such that the void in the sheet material resembles a combination of half a cylinder and a cube (e.g., a "D-shape").

[0065] The one or more slots may include a single slot or multiple slots. Multiple slots may allow liquid electrolyte to flow through the separator more quickly than a single slot. Multiple slots may be in fluid communication with each other. A linear segment, a continuous segment, or both may be referred to as a single slot. One or more slots may intersect, abut, be separated from, or a combination thereof, one or more other slots. One or more slots may be substantially parallel to, separated from, or both of the peripheral edges of one or more sheets. One or more slots may be positioned around one or more separators. One or more slots may be positioned within the inner surface of one or more frames. One or more slots may be in fluid communication with the active area of ​​one or more electrochemical cells; facing the active area; and / or within the active area. One or more slots may be positioned between one or more openings and one or more peripheral edges. One or more slots may be positioned between multiple openings. For example, one or more slots may be positioned between adjacent arrays of openings; parallel to the arrays; or both. Multiple slots may form a repeating pattern, be staggered, or be offset across the sheets of the separator.

[0066] The plurality of slots may include one or more main slots, branch slots, or a combination thereof. A main slot may be the slot closest to the incoming fluid, the slot wetted first by the electrolyte, or both. One or more branch slots may be slots in fluid communication with the main slot; wetted by the electrolyte after the main slot; or both. One or more branch slots may be downstream of one or more main slots, channels, or both. One or more branch slots may be separated by one or more openings. A main slot may be used to distribute one or more fluids to one or more branch slots. A main slot may be used to collect one or more fluids from one or more branch slots. A main slot may be adjacent to, directly adjacent to, or in fluid communication with multiple branch slots; or a combination thereof. A main slot may comprise only a single slot on the separator sheet, a slot formed by a peripheral notch, a slot formed in a frame, or a combination thereof. A branch slot may comprise one or more slots, two or more slots, three or more slots, or even four or more slots on the separator sheet. A branch slot may comprise ten or fewer slots, six or fewer slots, or even five or fewer slots on the separator sheet. The main groove, the branch groove or the above two can be directly connected to one or more filling openings, filling channels, inlet grooves or their combinations. For example, the main groove can be in direct fluid communication with one or more channel openings, and then the fluid flow is directed to one or more branch grooves. As an example, a plurality of branch grooves can all be in direct fluid communication with the filling opening. As another example, the main groove can be positioned between one or more inlet grooves and one or more branch grooves. And even as another example, the main groove can be in fluid communication with the inlet groove without the presence of a branch groove. A plurality of grooves can be free of one or more main grooves, branch grooves or the above two.

[0067] One or more slots may include one or more inlet slots. The one or more inlet slots may be in fluid communication with one or more openings, channels, or both for receiving one or more fluids. The one or more inlet slots may be in fluid communication with one or more filling openings, filling channels, vents, or a combination thereof. The one or more inlet slots may allow electrolyte or other fluids to be received from one or more filling openings, filling channels, or vents. The one or more inlet slots may be in fluid communication with, in direct contact with, adjacent to, abutting, intersecting, or a combination thereof, one or more other slots. Other slots may include one or more main slots, branch slots, or both. The one or more inlet slots may distribute one or more fluids to one or more main slots, branch slots, or both. The one or more inlet slots may be in direct contact with, adjacent to, abutting, intersecting, or a combination thereof, one or more main branches, openings, vents, channels, or a combination thereof. The one or more inlet slots may be in fluid communication with one or more filling channels. The one or more slots may not have one or more inlet slots.

[0068] One or more grooves may have a thickness, a width, and a length. The thickness of the groove may be considered to be the depth of the gap through the thickness of the sheet or frame; the distance between two opposing surfaces of adjacent substrates at a peripheral notch; may be measured parallel to the thickness of the sheet (in the case of a portion of the sheet or peripheral notch); may be measured parallel to the surface of the sheet having the active material thereon (in the case of a portion of the frame); or any combination thereof. The width of the groove may be considered to be the distance between the surfaces of the sheet or frame forming the gap; the distance between the inward-facing surface of the frame and the peripheral surface of the separator (if formed in a peripheral notch); the smaller of the width and length; may be perpendicular to the depth; or any combination thereof. The length of the groove may be considered to be the distance between the surfaces of the sheet forming the gap; the larger of the width and length; may be perpendicular to the depth and width; may be parallel to the inward-facing surface; may be parallel to the peripheral edge of the separator; or any combination thereof. One or more grooves may have a depth that partially or completely passes through the thickness of the sheet. One or more grooves may have a depth that only partially passes through the frame. The partial depth in the frame may allow the frame to still provide a seal around the electrochemical cell. The depth of the one or more grooves may be equal to or less than the distance between the two substrate surfaces facing each other to form the electrochemical cell. The one or more grooves may not completely extend through the thickness of the sheet, as doing so would eliminate the separation between the pair of active materials (anode and cathode) of the electrochemical cell. If multiple sheets are used, the one or more grooves may completely extend through the thickness of the one or more sheets. The one or more grooves may have a depth that is about 5% or more, about 10% or more, about 25% or more, or even about 50% or more of the total thickness of the separator, the width of the frame, or both. The one or more grooves may have a depth that is about 100% or less, about 90% or less, about 80% or less, or even about 75% or less of the total thickness of the separator. The one or more grooves may have a depth that is about 80% or less, 70% or less, or even 60% or less of the width of the frame. The width of the frame can be considered the distance between the inward-facing surface and the opposing outward-facing surface (e.g., not spanning the active area). The depth of one or more grooves may be about 10 μm or greater, about 25 μm or greater, about 100 μm or greater, or even about 500 μm or greater. The depth of one or more grooves may be about 1 cm (10,000 μm) or less, about 0.5 cm (5,000 μm) or less, about 0.3 cm (3,000 μm) or less, or even about 0.1 cm (1,000 μm) or less. For example, the depth of one or more grooves may be about 0.5 mm to about 2 mm. The depth of the groove may be measured as the depth through a single or multiple slices. One or more widths may have a width suitable for one or more grooves to be located between one or more openings, as a peripheral notch, or within the inwardly facing surface of the frame. One or more grooves may have an aspect ratio between depth and width.The aspect ratio promotes rapid wicking of electrolyte through one or more thin sheets of separator. The aspect ratio of depth to width can be 1:10 or greater, about 1:5 or greater, or even about 1:3 or greater. The aspect ratio of depth to width can be about 10:1 or less, about 5:1 or less, about 3:1 or less, or even about 1:1 or less. For example, the aspect ratio of depth to width can be about 1:5 to about 1:1 (e.g., 1:3). One or more grooves may have a width, and the width is about 0.01% or greater, about 0.05% or greater, about 1% or greater, about 3% or greater, or even about 5% or greater of the width of the separator sheet or the height of the frame (e.g., substrate surface to edge). One or more grooves may have a width, and the width is about 30% or less, 15% or less, about 12% or less, or even about 10% or less of the width of the separator sheet or the height of the frame. One or more grooves may have a length. The length can be adapted to help speed up the flow of electrolyte through as many separator sheets as possible. The length can allow one or more slots to pass through one or more openings, or even multiple openings. The one or more slots can have a length of about 5% or more, about 10% or more, about 25% or more, about 50% or more, or even about 75% or more of the length of the separator sheet or the length of the inward-facing surface of the frame. The one or more slots can have a length of about 100% or less, 95% or less, about 90% or less, or even about 85% or less of the length of the separator sheet or the length of the frame.

[0069] The one or more grooves may comprise one or more compressed portions in one or more separators, one or more areas of removed material in one or more separators, or both. Material may be compressed and / or removed to achieve a thickness that is less than that of other areas of the separator. The one or more grooves may be formed by material removal, compression, molding, absence of material, or a combination thereof. For example, the one or more grooves may be formed by removing a thin sheet of material. As an example, the one or more grooves may be formed by embossing a thin sheet of material. The one or more grooves may be embossed portions of one or more sheets to form the one or more compressed portions. As another example, the one or more grooves may be formed by molding into one or more frames. And as another example, the one or more grooves may be formed by the absence of material (e.g., active material, conductive material, separator, etc.) in the peripheral notch.

[0070] The one or more grooves can be temporary, semi-permanent, permanent, or a combination thereof. If the grooves are formed by compression, the one or more grooves can be permanent, re-expandable, or both. If the grooves are formed by removal, a molding process, or the like, the grooves can remain in place permanently.

[0071] Re-expansion of one or more troughs may occur after a pickling process, a forming process, a curing process, a drying process, or a combination thereof. Re-expansion may occur due to: reaching a specific temperature within the interior of the battery assembly; a period of time; contact with one or more fluids; or a combination thereof. Re-expansion may occur after a minimum duration of contact with the electrolyte. The minimum duration may be at least the time it takes to fill the electrochemical cell with electrolyte during the filling process. The minimum duration may be the time it takes to fill the electrochemical cell, optionally including the minimum duration through the pickling process, through the forming process, and / or through thermal cycling. Re-expansion may occur after completing the pickling and / or forming process. Re-expansion may occur after thermal control cycling. Re-expansion may be considered rebound. One or more troughs may be temporary and / or semi-permanent and configured to at least partially expand. Partial expansion may refer to an increase in thickness. The thickness may be the thickness of the separator at the trough. Re-expansion may be partial or complete. For example, after re-expansion, the thickness of one or more troughs may expand but still be less than the thickness of the rest of the sheet. Partial re-expansion may be considered a semi-permanent trough. As another example, after re-expansion, the thickness of one or more troughs may expand so that the sheet has a substantially uniform thickness. A complete re-expansion may be considered a temporary trough.

[0072] One or more slots may be formed by gaps in the material of one or more sheets, while other sheets remain free of the one or more gaps. The sheets may be stacked to form a separator. One or more inner sheets may include one or more gaps that extend through a portion, all, or both of the thickness of the individual sheets. For example, one or more inner sheets of a separator may include one or more slots, while the stacked opposing outer sheets may not have any slots. One or more inner sheets may include one or more slots, while one or more other inner sheets may not have one or more slots. For example, two or more adjacent inner sheets may each include one or more slots aligned with one another. As another example, three or more adjacent inner sheets may have alternating slots, such that two inner sheets have one or more slots, while one inner sheet does not have any slots. The outer sheets, one or more inner sheets, or both may cooperate with the inner sheets so that the slots are closed (e.g., having four walls) and formed as one or more conduits through the separator. Leaving the outer sheets free of one or more slots allows the separator to have a consistent and continuous surface area exposed within the electrochemical cell during operation of the battery assembly.

[0073] One or more grooves may be in fluid communication with an electrolyte source. By being in fluid communication with the electrolyte source, one or more grooves may absorb electrolyte and allow the electrolyte to pass through them more quickly, flowing to one or more other grooves, or both. The fluid communication may be direct, indirect, or both. For example, one or more grooves may be in fluid communication with one or more vents, openings, ports, channels, valves, etc., or a combination thereof. One or more grooves may be adjacent to one or more openings, one or more vents of an opening, or both. One or more openings may include an opening that forms a channel. The channel may be a filling channel, an exhaust channel, or both. For example, an inlet groove may be in direct fluid communication with an opening of a separator that is part of a filling channel, and may be adjacent to and in fluid communication with the main groove.

[0074] One or more slots can significantly reduce the amount of time it takes to fill a battery assembly with electrolyte. To achieve a battery assembly in which the electrochemical cells are approximately 90% to 100% filled with electrolyte, one or more slots can significantly reduce the filling time. The time to fill to 90% full can be reduced by about 25% or more, about 35% or more, about 45% or more, or even about 50% or more. The time to fill to 90% full can be reduced by 95% or less, about 90% or less, about 85% or less, or even about 75% or less. The reduction in filling time can be compared to the same battery assembly without slots. As an example, with no slots, the time to fill a battery assembly to 90% full may take about 14.5 minutes, while with 5 slots (1 main slot and 4 branch slots), the time to fill the battery assembly to 90% full may take about 1 minute, achieving an improvement of about 90% in time. The time to fill to 100% full can be reduced by about 25% or more, about 40% or more, about 50% or more, or even about 60% or more. The time to fill to 100% full can be reduced by about 95% or more, about 85% or more, about 75% or more, or even 70% or more. As an example, with no tanks, the time to fill a battery assembly to 100% full may take about 45 minutes, while with 5 tanks (1 main tank and 4 branch tanks), the time to fill a battery assembly to 100% full may take about 14.5 minutes, achieving an improvement in time of about 68%. The time to reach 100% full may include circulating about 5% to 50% of the electrolyte volume and replacing it with cooled electrolyte from the battery assembly to help assist in controlling temperature.

[0075] One or more electrode plates, end plates, separators, or a combination thereof may include one or more openings. The one or more openings may be used to provide an opening for a connection mechanism to pass therethrough; to cooperate with one or more electrode plates, separators, end plates, and / or inserts to form part of one or more channels; to accommodate or form part of one or more seals; to allow for evacuation, filling, and / or venting of the battery assembly; to provide for the circulation of fluid through one or more channels; to retain one or more conductive materials; or any combination thereof. The one or more openings may have any size, shape, and / or configuration to provide any combination of desired functions. The one or more openings may have any combination of features as described for the openings and / or holes in one or more electrode plates, end plates, and / or substrates. The one or more openings of one or more electrode plates, end plates, and / or separators may be aligned (i.e., concentric) with one or more openings of one or more other electrode plates, end plates, and / or separators to form one or more channels. The alignment may be in a lateral direction. Transverse may refer to being substantially perpendicular to a face of the substrate and / or separator, spanning the length of the battery assembly, parallel to the longitudinal axis of the battery assembly, or a combination thereof. The lateral direction may be substantially perpendicular to the opposing surface of the substrate on which the cathode and / or anode may be deposited. Lateral can refer to the overall width, diameter or both of the cross section of one or more openings that are substantially parallel to the face of the substrate and / or separator. The one or more openings of an electrode plate, end plate and / or substrate may have a shape and / or size similar to one or more openings of another electrode plate, end plate and / or separator that may be adjacent. The one or more openings may have a cross-sectional shape for accommodating any combination of an attachment mechanism, a receiving column, cooperation with an insert or the desired function of the opening, and may be substantially rectangular, circular, triangular, elliptical, oval or any combination thereof. The one or more openings may have a cross-sectional width sufficient to accommodate one or more attachment mechanisms, one or more columns, one or more valves or any combination thereof. The opening may be machined (e.g., milled), formed during manufacture of the substrate (e.g., by molding or shaping operations), or otherwise manufactured. The opening may have a straight and / or smooth inner wall or surface.

[0076] One or more openings may extend partially or completely through the insert, base, substrate, separator, reinforcement structure, rib structure, or any combination thereof. One or more openings may be positioned around or near the periphery of the end plate, electrode plate, separator, or combination thereof, within the interior thereof, or both. One or more openings may be distributed around the periphery of the end plate, electrode plate, separator, or combination thereof, within the interior defined within the periphery, or both. One or more openings may be located near one or more rib structures, between two or more rib structures, within the battery cell, near one or more inserts, within one or more inserts, or any combination thereof. One or more openings may form a repeating pattern, may be aligned with one or more other openings, may be staggered or offset from one or more other openings, or any combination thereof.

[0077] The size and frequency of the openings formed in the substrate may affect the resistivity of the battery. One or more openings may have a cross-sectional width that is less than, equal to, or greater than the diameter of one or more openings formed in the same end plate and / or adjacent electrode plate. The cross-sectional width of one or more openings may be continuous, gradually narrowing, or expanding along the length of the opening. The cross-sectional width of one or more openings may be suitable for receiving one or more columns, rods, fluids, electrolytes, or a combination thereof passing therethrough. One or more openings may have a cross-sectional width of about 0.2 mm or greater, 1 mm or greater, about 3 mm or greater, or even about 5 mm or greater. One or more openings may have a cross-sectional width of about 30 mm or less, about 25 mm or less, or even about 20 mm or less. The cross-sectional width of an opening may be considered to be the same as the diameter of the opening. One or more openings in an electrode plate, end plate, and / or substrate may have a larger diameter than one or more other openings in the same electrode plate, end plate, and / or substrate. An opening may be at least about 1.5 times, at least about 2 times, or even at least about 2.5 times larger than another opening. The openings may be about 4 times smaller, about 3.5 times smaller, or even about 3 times smaller than another opening. The openings may be formed to have at least about 0.02 openings / cm 2 The openings may be formed to have a density of less than about 4 openings / cm 2 The openings may be formed to have a density from about 2.0 openings / cm 2 To approximately 2.8 openings / cm 2 The one or more openings may include one or more peripheral openings, one or more internal openings, one or more channel openings, one or more conductive openings, etc., or any combination thereof. Exemplary openings may be discussed in U.S. Patent No. 10,141,598, which is incorporated herein by reference in its entirety.

[0078] The one or more openings may include one or more channel openings. The one or more channel openings may be used to align with one or more openings of one or more electrode plates to form one or more channels; provide openings for venting, filling and / or exhausting the battery assembly; provide openings for circulating one or more fluids within the interior of the battery assembly; cooperate with one or more valves and / or ports; receive one or more columns to compress the stack of electrode plates; receive one or more inserts; or any combination thereof. The one or more channel openings may be aligned (i.e., concentrically aligned) with one or more openings and / or holes of one or more electrode plates, end plates and / or separators in the transverse direction to form one or more channels through the stack. Multiple openings may be aligned to form one or more channels. Multiple may refer to multiple openings in a single component, or multiple openings among multiple components (e.g., electrode plates, separators, active materials, inserts, etc.). The one or more channel openings may have a size substantially equal to one or more holes of one or more other electrode plates, end plates and / or separators. The channel opening of one or more separators may be equal to or larger than the channel opening of one or more electrode plates. The one or more channel openings of one or more separators may allow one or more inserts, such as from adjacent electrode plates, to extend through the opening. One or more channel openings may have any size through which one or more columns, fluids, inserts or combinations may pass. One or more channel openings may have a cross-sectional width or area that is less than, equal to or greater than one or more other channel openings. For example, one channel opening may have a larger diameter than one or more other channel openings to allow filling, venting, cooling and / or heating of the battery. One or more channel openings may be connected or communicated with one or more valves and / or ports. For example, a channel opening with a larger diameter than other channel openings may be connected to a valve or port. One or more channel opening portions of a filling channel or one or more channel openings having a filling channel passing therethrough may be referred to as one or more filling openings. One or more filling openings of one or more separators may be portions of a filling channel or having a filling channel passing therethrough. One or more filling openings of one or more electrode plates may be portions of a filling channel. One or more channel opening portions of a support channel, column or both or having a support channel, column or both passing therethrough may be referred to as one or more support openings. The surface of the base near and / or adjacent to the one or more channel openings may be a sealing surface.

[0079] The one or more openings may include one or more conductive openings. The one or more conductive openings may be filled with a conductive material, such as a metal-containing material. The one or more conductive openings may be formed in one or more electrode plates, end plates, substrates, or a combination thereof. The conductive material may be a material that undergoes a phase transition at a temperature below the thermal degradation temperature of the substrate, such that at an operating temperature of the battery assembly below the phase transition temperature, the dielectric substrate has a conductive path through the material blend between the first and second surfaces of the substrate. In addition, at a temperature above the phase transition temperature, the conductive material blend undergoes a phase transition that disables conductivity through the conductive path. For example, the conductive material may be or include a solder material, such as one containing at least one of lead, tin, nickel, zinc, lithium, antimony, copper, bismuth, indium, or silver, or a mixture of any two or more thereof. The conductive material may be substantially free of any lead (i.e., it contains at most trace amounts of lead) or it may include a functionally effective amount of lead. The material may include a mixture of lead and tin. For example, it may include a major portion of tin and a minor portion of lead (e.g., about 55 to about 65 parts by weight of tin and about 35 to about 45 parts by weight of lead). The material may exhibit a melting temperature of less than about 240°C, less than about 230°C, less than about 220°C, less than 210°C, or even less than about 200°C (e.g., in the range of about 180°C to about 190°C). The material may include a eutectic mixture. A feature of using solder as the conductive material for filling the opening is that the solder has a defined melting temperature that can be adjusted, depending on the type of solder used, to melt at a temperature that may be unsafe for continued battery operation. Once the solder melts, the substrate opening containing the molten solder is no longer conductive, and an open circuit is created within the electrode plate. The open circuit can operate to significantly increase the resistance within the bipolar battery, thereby stopping further current flow and terminating unsafe reactions within the battery. Thus, the type of conductive material selected to fill the openings may vary depending on whether it is desired to include such an internal termination mechanism within the battery, and if so, at what temperature such internal termination is desired. The substrate will be configured such that, in the event of operating conditions exceeding predetermined conditions, the substrate will function to disable operation of the battery by disrupting conductivity through the substrate. For example, the conductive material filling the pores in the dielectric substrate will undergo a phase change (e.g., it will melt) such that conductivity across the substrate is disrupted. The extent of the disruption may be such that the function of conducting electricity through the substrate is partially or even completely disabled. The size (e.g., diameter) of one or more conductive openings may be smaller than or equal to one or more other openings of the end plate, electrode plate, substrate, or combination thereof. The one or more conductive openings may have a diameter that is about 1% or greater, 5% or greater, 10% or greater, or even about 25% or greater compared to the diameter of one or more other openings (e.g., channel openings, peripheral openings, internal openings).One or more conductive openings may have a diameter that is about 75% or less, about 50% or less, or even about 40% or less compared to a diameter of one or more other openings.

[0080] One or more electrode plates, end plates, separators, or any combination thereof may include one or more inserts. The one or more inserts may be used to interlock with one or more inserts of another electrode plate, end plate, separator, or combination thereof; define a portion of one or more channels through the stack; form a leak-proof seal along one or more channels; cooperate with one or more valves and / or ports; provide a housing for one or more columns; allow fluid to pass therethrough; or any combination thereof. The one or more inserts may have any size and / or shape for the following functions: interlock with one or more inserts of an electrode plate, end plate, and / or separator; form a portion of a channel; form a leak-proof seal along one or more channels; cooperate with one or more valves and / or columns; or any combination thereof. The one or more inserts may be integral with or attached to an electrode plate, end plate, separator, or combination thereof. The one or more inserts may be integral with or attached to a substrate, a base, or both. The one or more inserts may be formed as one or more bosses. Inserts that are integral with the surface of an end plate (e.g., base), an electrode plate (e.g., substrate) and / or a separator and protrude from that surface may be defined as bosses. One or more inserts may be integrally formed by compression forming, stretch forming, molding, or the like, or any combination thereof. Compression forming may include mold forming, extrusion, indentation, or the like, or any combination thereof. Molding may include injection molding. In the case where the electrode plate, end plate and / or separator have an insert and a frame, flange and / or recessed portion, these parts may be molded in one step, for example, by injection molding. One or more inserts may protrude from the surface of the end plate, electrode plate and / or separator, thereby forming one or more raised inserts. One or more inserts may protrude from the base of the end plate, the substrate of the electrode plate, the surface of the separator, or any combination thereof. One or more inserts may protrude substantially orthogonally or obliquely from the surface of the base, substrate, separator, or a combination thereof. One or more inserts may have one or more openings therethrough. One or more inserts may have one or more peripheral openings, internal openings, channel openings, or a combination thereof therethrough. One or more inserts can be concentric and formed around one or more openings. One or more inserts can extend the length of the opening (e.g., the opening can completely pass through the insert). A sealing surface can be formed between the outer diameter of the one or more openings and the interior of the one or more inserts. For example, a surface of the base and / or substrate that is substantially perpendicular to the longitudinal axis of the battery between the insert and the opening can be a sealing surface. One or more inserts can be matched with one or more other inserts. Matching can refer to alignment, nesting, interlocking, or a combination thereof. After matching, one or more inserts can form a seal. The seal can seal one or more channels relative to an electrolyte such as a liquid electrolyte. The seal can be a channel seal.One or more inserts can be capable of interlocking with one or more inserts of an adjacent electrode plate, separator, and / or end plate to form a leak-proof seal around the channel. For example, one or more end plates and / or electrode plates can be machined or formed to include a matching indentation on a surface opposite the insert for an insert, sleeve, or bushing of an adjacent electrode plate and / or separator.

[0081] One or more inserts can include one or more vents. A vent can allow fluid communication between an opening through the insert and an external environment located around the insert. A vent can allow communication between one or more electrochemical cells and one or more channels. One or more vents can allow the transport of gases from one or more electrochemical cells to one or more channels and prevent the transport of one or more liquids (i.e., electrolyte) from one or more electrochemical cells to one or more channels. One or more vents can place one or more channels in fluid communication with a headspace of a battery assembly. An insert forming a channel in close proximity to a battery assembly and / or in a headspace of a battery assembly can include one or more vents. One or more vents can be formed as a notch or cut. A notch can extend from an opening to an exterior of an insert. One, some, or all of the inserts of an electrode plate can include a vent. An insert forming a fill channel, a vent channel, or both can include one or more vents. An insert that intentionally needs to distribute fluids from an electrochemical cell, collect fluids, or both can include one or more vents. An insert forming one or more support channels can not have one or more vents. An insert that should not have fluids flowing through it that are exposed to an electrochemical cell can not have one or more vents. A portion of an insert of a vent channel can have one or more vents positioned above, spaced apart from, or both an electrolyte of an electrochemical cell. A vent of an insert can be capable of receiving gases produced during operation of a battery assembly without receiving electrolyte. A vent can be capable of directing gases from one or more electrochemical cells and through a plurality of channels and toward one or more valves (e.g., a vent in an insert of a vent channel). A vent can be capable of directing one or more fluids from one or more valves, valve holes, and / or ports toward and / or through one or more channels (e.g., a vent in an insert of a fill channel), one or more slots, into an electrochemical cell, or a combination thereof.

[0082] The battery assembly may include one or more channels. The one or more channels may serve as one or more venting, filling, cooling, and / or heating channels; accommodate one or more columns; distribute one or more columns throughout the interior of the battery assembly; prevent liquid electrolyte from contacting one or more columns or other components; allow one or more fluids to circulate within the interior of the battery assembly; collect one or more gases; or any combination thereof. The one or more channels may be formed by one or more openings in one or more end plates, electrode plates, and / or separators that are aligned. The one or more channels may be formed by one or more channel openings in one or more end plates, electrode plates, and / or separators that are aligned with one or more channel openings in other (e.g., adjacent) end plates, electrode plates, and / or separators. The one or more channels may be referred to as one or more integrated channels, transverse channels, or both. The one or more channels may pass through one or more electrochemical cells, active areas, or both. By passing through one or more electrochemical cells, the one or more channels may also pass through liquid electrolyte, one or more active materials, separators, or a combination thereof. The channels may be sealed to prevent electrolyte and gases released during operation from entering the channels. The one or more channels may be partially unsealed to collect and vent gases released during operation, receive and distribute one or more fluids, or both. Any sealing method that achieves this purpose may be utilized. One or more seals, such as inserts, of one or more end plates, electrode plates, and separators may interlock and enclose one or more channels to prevent leakage of liquid electrolyte into the one or more channels. The one or more channels may extend transversely through the battery assembly to form one or more transverse channels.

[0083] The size and shape of the channels can be any size or shape that allows them to accommodate one or more columns. The cross-sectional shape of the channels can be circular, oval or polygonal, such as square, rectangular, hexagonal, etc. The cross-sectional shape can be determined by the cross-sectional shape of one or more openings, inserts, columns, ports, exhaust ports, etc. The size of the channel that accommodates one or more columns is selected to accommodate the columns used. The diameter of the channel can be equal to the diameter of the opening that is aligned to form the one or more channels. The multiple channels can have the following cross-sectional dimensions: about 2 mm or greater, about 4 mm or greater or about 6 mm or greater. The upper limit of the cross-sectional dimension of the channel is determined by practicality, if the size is too large, the efficiency of the assembly will be reduced. The channel can have the following cross-sectional dimensions: about 30 mm or less, about 25 mm or less, or even about 20 mm or less.

[0084] The one or more channels may comprise a series of openings in the component. The series of openings may be arranged to: allow a post to be placed in the formed channel; allow fluid to be transferred through the channel for cooling and / or heating; allow for venting; allow for filling with one or more fluids; allow for dispensing one or more fluids into one or more electrochemical cells; allow for maintaining one or more fluids sealed within the channel; or any combination thereof.

[0085] The number of channels is selected to support the edges of the end plates, electrode plates, and substrate to prevent leakage of electrolyte and gases released during operation, and to prevent compressive forces generated during operation from damaging components and seals of individual electrochemical cells. Multiple channels may be present to disperse the compressive forces generated during operation. The number and design of the channels are sufficient to minimize edge stresses that exceed the fatigue strength of the seals. The locations of the multiple channels are selected to disperse the compressive forces generated during operation. The channels can be evenly dispersed by stacking to better handle stress.

[0086] One or more channels through which one or more fluids pass may be referred to as one or more heating channels, cooling channels, filling channels, exhaust channels, or combinations thereof. One or more heating, cooling, filling, and / or exhaust channels may be converted into and / or used as one or more support channels. For example, after one or more fluids pass through a channel, the fluids may be emptied, and a channel may have a column positioned therethrough. One or more channels with one or more columns passing therethrough may be referred to as one or more support channels.

[0087] The one or more channels may include one or more fill channels. The one or more fill channels may be used to receive one or more fluids and distribute the one or more fluids to one or more electrochemical cells; serve as vent channels; collect one or more gases from one or more electrochemical cells; direct one or more gases out of the battery; or any combination thereof. The one or more fill channels may be one or more channels that may be suitable for receiving and distributing electrolytes, receiving and distributing gases for discharge, or both. The one or more fill channels may be formed by one or more fill openings, inserts, inserts with vents, or any combination thereof. The one or more fill channels may include one or more ports, valves, or both or be in fluid communication with one or more ports, valves, or both. The one or more fill channels may be in fluid communication with one or more fill ports, vent ports, or both.

[0088] The one or more channels may include one or more exhaust channels. The one or more exhaust channels may be used to collect and release one or more gases. The one or more gases may be generated from within the battery assembly. The one or more gases may be generated during pickling, forming, thermal cycling, charging, discharging, etc., or a combination thereof. The one or more gases may include hydrogen, oxygen, or both. The one or more exhaust channels may function similarly to, but inversely to, the one or more fill channels. The one or more exhaust channels may be the same as or separate from the one or more fill channels.

[0089] Gas collection can allow for accelerated battery corrosion. Accelerated battery corrosion can allow for accelerated life testing of battery components. Accelerated life testing can allow battery components to be tested more quickly in a research environment than the expected number of cycles before reaching end of life.

[0090] The battery assembly may include one or more channel seals. The one or more channel seals can prevent leakage of electrolyte and gases released during operation from the battery cells into the channels, prevent one or more fluids circulating through the one or more channels from leaking into the one or more battery cells, or both. The one or more channel seals can be positioned in the channel, around the outside of the channel, around the column; or a combination thereof. The channel seals can be one or more diaphragms, sleeves, gaskets, bushings and / or a series of matching inserts inserted into the channel and / or residing in the opening of the end plate, electrode plate and / or separator. The one or more gaskets can include molded compliant features, liquid gaskets suitable for curing, flat gaskets, O-rings, etc. The channel can be formed by a series of sleeves, gaskets, bushings, inserts or a combination thereof inserted into or integrated into the end plate, electrode plate and / or separator. The one or more channel seals can be compressible or able to interlock with each other to form a leak-proof seal along the channel. The channel seals can be made of any material that can withstand exposure to electrolytes, circulating fluids, operating conditions of the electrochemical cell, forces due to the insertion of a column in the channel or applied by the column, or a combination thereof. One or more channel seals can be made of one or more polymeric materials. One or more polymeric materials can be substantially rigid, elastic, or a combination of the two. For example, one or more sleeves and / or inserts can be relatively rigid. For example, one or more gaskets, bushings, and / or diaphragms can be substantially elastic. One or more heating, cooling, venting, and / or filling channels can be converted into one or more support channels by including one or more channel seals. One or more channel seals can temporarily and / or permanently cover one or more vents of one or more inserts.

[0091] A battery assembly may include one or more posts. The one or more posts can be used to hold the component stack together in a manner that prevents damage to the components or compromise of the seal between the edges of the stacked components, ensures consistent compression on the separator material, and ensures a consistent thickness of the separator material. The one or more posts may or may not be reusable. One or more posts may have an overlapping portion at each end that engages the outer surface of opposing end plates, such as the sealing surface of each end plate. The overlapping portion can be used to apply pressure on the outer surface of the opposing end plates to prevent damage to the components or compromise of the seal between the edges of the stacked components, and to prevent bulging or other displacement of the stack during battery operation. The overlapping portion can contact the sealing surface of the end plate. The stack may have separate structural or protective end plates on the individual end plates, and the overlapping portion will contact the outer surface of the structural or protective end plate. The overlapping portion can be any structure that, in combination with the post, prevents damage to the components or compromise of the seal between the edges of the stacked components. Exemplary overlapping portions include bolt heads, nuts, molded heads, brads, cotter pins, collars, and the like. The post has a length that extends through the entire stack, and this length varies based on the desired capacity of the battery. The pillars may exhibit a cross-sectional shape and size that fills the channels. The pillars may have a cross-sectional dimension that is less than, equal to, or even greater than the cross-sectional dimension of one or more channels. The pillars may form an interference fit with one or more of the channels. The number of pillars is selected to support the end plates and edges of the substrate to prevent leakage of electrolyte and gases released during operation, to prevent damage to components and seals for individual electrochemical cells from compressive forces arising during operation, and to minimize edge stresses that exceed the fatigue strength of the seals. Multiple pillars may be present to distribute the compressive forces generated during operation. Fewer pillars may be present compared to channels where one or more of the channels functions as cooling channels, heating channels, vent channels, filling channels, or a combination thereof. For example, there may be four channels, three of which have pillars located therein, and one channel may function as a cooling, heating vent, and / or filling channel. As another example, there may be six total transverse channels, with five supporting channels having one pillar therein and one filling channel. The pillars may include molded pillars, threaded pillars, or pillars with one or more end fittings. The pillars may be incorporated into portions of the stack, such as the substrate, inserts in the channels, and the like. The bond may be formed by gluing or fusing polymeric materials such as thermoplastics. Where the parts are threaded, the stacked structural parts are threaded to receive the threaded post. The post may have a head at one end and a nut, a hole for a corner pin or cotter pin at the other end, or may have a nut, a hole for a corner pin or cotter pin on both ends. This is generally the case with non-molded posts. Matching nuts and / or washers may be used with the posts to compress the plates adjacent to them when in place. If the post is molded, it may be molded separately or molded in situ.If molded in place, channel seals may need to be present in the channels to hold the molten plastic in place.

[0092] The battery assembly may include one or more heat exchangers. The one or more heat exchangers may be used to control the temperature, heating, cooling, or a combination thereof of the battery assembly. The one or more heat exchangers may control the temperature of the battery assembly externally, internally, or a combination thereof. The one or more heat exchangers may be positioned around all or at least a portion of the exterior, interior, or a combination thereof of the battery assembly. The one or more heat exchangers may be attached to at least a portion of the exterior of the battery assembly, end plates, unipolar plates, or a combination thereof. The one or more heat exchangers may include one or more active exchangers, passive exchangers, or both. The one or more heat exchangers may include one or more fluid heat exchangers, shell and tube heat exchangers, plate heat exchangers, radiators, phase change heat exchangers, waste heat recovery units, thermoelectric devices (TEDs), etc., or any combination thereof. The one or more heat exchangers may be in communication with one or more channels, located within one or more channels, adjacent to one or more channels, or a combination thereof. The one or more heat exchangers may include one or more tubular members, a fluid contained therein, one or more channels, or a combination thereof. For example, one or more tubular members located within one or more channels through which a fluid passes may be considered a heat exchanger. One or more fluids may include one or more gases, liquids, or combinations thereof. One or more fluids may include air, water, ammonia, nitrogen, oxygen, neon, hydrogen, helium, refrigerants (e.g., 1,1,1,2-tetrafluoroethane), alkali metals, heat exchange fluids, electrolytes, etc., or any combination thereof. For example, water may be positioned in one or more sealed tubular members (e.g., rods sealed at both ends). As another example, air may flow through one or more at least partially unsealed tubular members (e.g., tubular members open at one or both ends). As another example, one or more radiators may be positioned at one or both ends of one or more channels, communicated with one or more channel members, or both. One or more heat exchangers (such as radiators) positioned outside the battery assembly and communicated with one or more channels may be advantageous for dissipating the heat of one or more channels and the battery assembly. One or more heat exchangers may be located near the diaphragm, between the diaphragm and the end plate, and the diaphragm may be located between the heat exchanger and the end plate, or a combination thereof.

[0093] The battery assembly may include one or more flow mechanisms or be at least temporarily connected to one or more flow mechanisms. The one or more flow mechanisms may be connected to one or more channels. The connection may be direct or indirect. Direct may refer to direct attachment to the channel, such as an opening in an end plate. Indirect may refer to accessing the channel via another fluid path, such as a valve. The one or more flow mechanisms may be used to create flow, circulate, evacuate, introduce one or more fluids in the one or more channels, or a combination thereof. The one or more flow mechanisms may include one or more vacuum devices, pumps, fans, valves, etc., or any combination thereof. The one or more flow mechanisms may be temporarily, semi-permanently, or permanently attached as part of the battery assembly. The one or more flow mechanisms may be considered as part of one or more heat exchangers or separate from one or more heat exchangers. The one or more flow mechanisms, or a combination thereof, may be removed, attached, engaged, or opened during one or more steps of preparing the battery assembly, operating the battery assembly, or any combination thereof. The one or more flow mechanisms, or a combination thereof, may be attached, engaged, or opened during curing, evacuation, filling, pickling, forming, drying, thermal control cycles, etc., or a combination thereof.

[0094] The battery assembly may include an outer seal. The outer seal may be used to seal around the exterior of one or more electrochemical cells; protect the outer edges of one or more electrode plates; isolate one or more electrochemical cells and the liquid electrolyte contained therein; or any combination thereof. The outer seal may include an edge seal, a separator, a housing, or the like, or any combination thereof. The outer seal may be part of one or more edges of an electrode plate, or located directly on the one or more edges. The edge may be the outer peripheral surface of the frame of the electrode plate. The separator may be bonded to the edge of the electrode plate, to one or more or all sides of the electrode plate stack, or both. The separator may be a thin sheet of polymer material that seals the edges of the electrode plates and, thereby, seals and isolates the electrochemical cells. The separator may be a thermoplastic polymer. The separator may be a thermoplastic polymer that may be melt-bonded, vibration-welded, or molded around the substrates of the monopolar and bipolar plates. The separator may also function as a housing. One or more suitable separators are disclosed in PCT Publication WO 2013 / 062623 and U.S. Patent No. 10,141,598, which are incorporated herein by reference in their entirety. The one or more edge seals may include one or more integrated edge seals. The integrated edge seals may be integral with one or more electrode plates. One or more suitable edge seals are disclosed in PCT publication WO 2020 / 0243093, which is incorporated herein by reference in its entirety.

[0095] A battery assembly may include one or more valves. The one or more valves may be used to evacuate a vacuum from within the battery assembly; fill the battery assembly with electrolyte; fill or drain fluid from one or more channels; and / or vent the battery assembly during operation. The one or more valves may allow one or more fluids, gases, or both to flow through them in a single direction or in two opposing directions. The one or more valves may prevent backflow (e.g., out of the battery assembly), allow backflow, or both. The one or more valves may include pressure relief valves, pressure valves, check valves, fill valves, safety valves, or any combination thereof. The assembly may include one or more pressure relief valves to relieve pressure in the battery cells if one or more of the battery cells reaches a dangerous internal pressure. Including one or more pressure relief valves may make the battery assembly a valve-regulated battery, such as a valve-regulated lead acid (VRLA) battery. The pressure relief valves may be designed to prevent catastrophic failure in a manner that would damage the system in which the battery is used. Once the pressure relief valve is released, the battery ceases to function. The assembly may include one or more pressure relief valves. One or more pressure relief valves may be used to prevent backflow (e.g., external to the battery assembly). One or more pressure valves can be used to open and allow flow through them into the interior of the battery assembly. The pressure valve can allow one or more fluids to flow into the battery assembly. Two or more valves can work together. For example, a pressure relief valve can be used in conjunction with a pressure valve. One valve can allow flow into the battery assembly, while another valve can allow flow out of the battery assembly. Alternatively, the battery assembly may have only one valve. The valve can allow bidirectional flow through it. If a single valve is used, it can be a two-way valve, such as a two-way pressure valve. The disclosed assembly may include a single check valve that releases pressure from the entire assembly when or before a dangerous pressure is reached. One or more valves may be connected to and / or communicate with one or more channels formed by one or more openings in the end plates, electrode plates, separators, or any combination thereof. One or more valves may communicate with the channels. The battery assembly may include one or more valves, as described in US2014 / 0349147, which is incorporated herein by reference.

[0096] A battery assembly may include one or more ports. The one or more ports may be used to draw a vacuum from the interior of the battery assembly; fill the battery assembly with electrolyte; fill or drain fluid from one or more channels; and / or vent the battery assembly during operation. The one or more ports may include one or more valves, openings, or both. The one or more ports may be synonymous with or separate from the one or more valves. The one or more ports may house or be attached to one or more valves. The one or more ports may allow one or more fluids and / or gases to flow through them in a single direction or in two opposing directions. The one or more ports may be permanently plugged (e.g., permanently sealed), temporarily plugged (e.g., temporarily sealed), or both. The one or more ports may be sealed using a removable plug, a permanent seal (e.g., molded-in), one or more valves, one or more posts (e.g., overlapping portions), or a combination thereof. The one or more removable plugs may be any plug suitable for maintaining a seal under manufacturing and operating conditions. For example, the removable plug may have a threaded engagement with the port. The one or more ports may include a single port or multiple ports. The multiple ports may include two or more ports. The one or more ports may include one or more filling ports, drain ports, or both. One or more vent ports may be configured to evacuate effluent and / or other fluids from the interior of the battery, to evacuate, or both. A single port may be a fill port and an evacuation port. One or more ports may be a fill port, while one or more other ports are evacuation ports. One or more ports used during pickling, forming, curing and / or drying may be permanently and / or temporarily sealed before operation (e.g., charging or discharging). One or more ports may be part of one or more channels or be in fluid communication with one or more channels. One or more ends of one or more channels may provide one or more ports. One or more ports may be part of one or more heating, cooling, ventilation and / or filling channels, or be in fluid communication with one or more heating, cooling, ventilation and / or filling channels. For example, the opening of a channel in an end plate (e.g., a unipolar plate) may be a port. One or more ports may be separated from one or more channels and be in indirect communication with one or more channels. For example, one or more vents in the head space may be considered as ports.

[0097] The battery assembly may include one or more terminals. The one or more terminals can be used to transfer electrons generated in the electrochemical cell to a system that utilizes the generated electrons (in the form of electricity), such as an external load. The one or more terminals may pass through one or more end plates, one or more electrode plates, a separator and / or a casing. The one or more terminals may extend from the end plate through the electrode plate to the outside, or through the side of the casing or separator, substantially parallel to the plane of the end plate around the assembly. The terminal matches the polarity of the anode or cathode of the monopolar plate. The cathode of the monopolar plate and the cathode of one or more bipolar plates with cathode current collectors in the bipolar plate can be connected to an independent positive terminal. The anode of the monopolar plate and the anode of one or more bipolar plates with anode current collectors in the bipolar plate can be connected to an independent negative terminal. The cathode current collectors can be connected in parallel, and the anode current collectors can be connected in parallel. The separate terminals can be covered in a separator, exposing only a single connected positive terminal and a single connected negative terminal.

[0098] The battery assembly may include a headspace. The headspace may allow for the collection of one or more fluids for filling, one or more gases for exhaust, or both. The headspace may be formed on one or more sides of the battery assembly. The headspace may be formed as part of or in a manifold. The headspace may be in fluid communication with one or more vents, valves, ports, channels, slots, openings, or any combination thereof. Exemplary headspaces may be found in PCT Publication WO 2013 / 062623, which is incorporated herein by reference.

[0099] The disclosed assembly can be attached to a load and form a circuit including the battery cell. Electrons flow to the terminals and to the load (the system that uses the electricity). This flow is maintained as long as the battery cell can generate electricity. If the battery cell stack is fully discharged, the battery needs to undergo a charging step before further use. If the substrate used for the bipolar plate contains a conductive material blend at the operating temperature of the battery assembly below the phase transition temperature of the battery assembly, the substrate has a conductive path through the material blend between the first surface and the opposite second surface of the substrate, and at a temperature above the phase transition temperature of the conductive material blend, the conductive material blend undergoes a phase change that causes the conductivity through the conductive path to fail. This allows the battery to be disabled before any adverse consequences occur. Once the battery is discharged, it can be recharged by forming a circuit with an electron source. During charging, the electrodes change function, and the anode becomes the cathode during discharge, and the cathode becomes the anode during discharge. Essentially, the electrochemical cell causes electrons and ions to flow in the opposite direction compared to discharge.

[0100] Method for preparing a battery assembly

[0101] The present disclosure relates to methods for preparing battery assemblies according to the teachings of the present disclosure. Preparing the battery assembly may include assembling. Preparing the battery assembly may include curing. Preparing the battery assembly may include draining. Preparing the battery assembly may include filling. Preparing the battery assembly may include acid washing. Preparing the battery assembly may include forming. Preparing the battery assembly may include thermal control cycling. Preparing the battery assembly may include removing lead materials. Preparing the battery assembly may include post-processing. Preparing the battery assembly may include charging. Preparing the battery assembly may include discharging. Preparing the battery assembly may include draining. Preparing the battery assembly may include one, some, or all of these steps.

[0102] One or more of these steps may occur sequentially, simultaneously, repeatedly, or any combination thereof. Some of these steps may be substeps of each other. One or more of these steps may not be performed. One or more of these steps may be repeated. For example, one or more steps may include evacuation and filling. As another example, evacuation and filling may be part of a thermal control cycle. As another example, the thermal control cycle may be part of a curing, pickling, forming, drying, or the like, or a combination thereof.

[0103] The method for preparing a battery assembly may include one or more of the following: assembly, curing, drying, draining, filling, pickling, forming, thermal cycling, charging, discharging, lead removal, post-processing, draining, etc., or any combination thereof. One or more of these steps may occur sequentially, simultaneously, repeatedly, or any combination thereof. One or more of these steps may not be performed. One or more of these steps may be repeated.

[0104] One or more fluids may flow through the battery assembly during preparation, after preparation, during operation, after operation, or any combination thereof. One or more fluids may flow within the battery assembly during draining, filling, curing, drying, pickling, forming, thermal control cycles, lead removal, charging, discharging, etc., or a combination thereof. The one or more fluids may include one or more fluids as described above. The one or more fluids may include electrolytes, air, drying fluids, lead collection fluids, reactive materials, electrolyte removal fluids, etc., or a combination thereof. The one or more fluids may include one or more reactive materials. During one or more stages of preparing and operating the battery assembly, the reactive material may flow through the channel, the groove, or both. The stages may include draining, filling, curing, drying, pickling, forming, thermal control cycles, lead removal, etc., or a combination thereof.

[0105] Preparation of the battery assembly can be completed at one or primarily one workstation. More than one step of preparation of the battery assembly can be completed at a single workstation. A workstation can refer to a workstation configured for an employee, a workstation to which all equipment is attached, or both. A single workstation can include all equipment used to prepare the battery assembly. A single workstation can include all equipment used to assemble, cure, evacuate, fill, pickle, form, dry, initial charge prior to operation, or combinations thereof. It can be feasible to complete all, if not most, of the preparation at the same workstation as a curing oven, water bath, or both can be avoided. The pasting process can be completed prior to the workstation, integrated at the workstation, or both.

[0106] Assembling

[0107] A method for preparing a battery assembly can include assembling the battery assembly. Assembling can produce a structure of the battery assembly prior to having electrochemical activity. Assembling can include forming one or more electrode plates; forming an electrode plate stack; compressing the electrode plate stack; applying an outer seal; or combinations thereof. Compressing and applying can occur prior to, during, and / or after curing, during pickling, forming, or combinations thereof.

[0108] Assembling the battery assembly can include forming one or more electrode plates. Forming one or more electrode plates can produce one or more electrodes useful within the battery assembly. Forming one or more electrode plates can include forming one or more substrates, frames, or both. Forming one or more electrode plates can include forming one or more slots as part of an electrode plate, separator, or both. Forming one or more electrode plates can include positioning one or more electrically conductive materials in one or more electrically conductive openings, placing one or more current collectors on a substrate, or both. Forming one or more electrode plates can include positioning one or more active materials on one or both surfaces of a substrate. One or more active materials can be pasted onto a substrate. One or more active materials can be applied via the application processes of PCT Publication Nos. 2018 / 213730 and WO 2020 / 102677, which are incorporated by reference herein in their entireties. Formation of an electrode plate can include applying a separator. One or more active materials can be disposed on a separator prior to being positioned onto a substrate. Alternatively or in addition, one or more separators can be stacked between electrode plates while forming an electrode plate stack.

[0109] Assembling may include forming a stack of electrode plates. Forming a stack of electrode plates may include aligning and stacking a plurality of electrode plates to form one or more electrochemical cells therebetween. One or more separators may be located between each pair of electrode plates. During forming the plates, the separators may be located on the electrode plates. During stacking, the separators may be located between the cells. When aligning and stacking a plurality of electrode plates, the electrode plates and separators may be stacked in an alternating arrangement. One or more frames, inserts, or both of one or more electrode plates may be aligned and / or interlocked with one or more frames, inserts, or both of adjacent electrode plates and / or separators. The peripheral surface of the one or more frames may form part of the outer surface of the electrode plate stack. The alignment and interlocking of the plurality of inserts may form one or more channels.

[0110] Assembly may include compressing the electrode plate stack. Compression may allow one or more seals to be maintained around one or more electrochemical cells, channels, or both; resist expansion during operation; resist buckling during filling or emptying of electrolyte; or any combination thereof. Compression may include positioning and / or forming one or more posts within one or more channels. Compression may include forming one or more overlapping portions of one or more posts so as to apply a compressive force to one or more end plates and / or unipolar plates. Compression may apply the compressive force using one or more interlocking features, such as frames, inserts, etc., or a combination thereof. For example, one or more shafts may be inserted into one or more channels and then secured in place by positioning one or more heads thereon. As another example, one or more used posts may have been made of a thermoplastic material that is melted during and / or after removal from the used battery assembly and then melt-bonded into one or more channels of the battery assembly.

[0111] Assembling the battery assembly may include applying an external seal. Applying the external seal may include forming an integrated seal or not forming an integrated seal, applying a separator, inserting the electrode plate stack into a housing, or a combination thereof.

[0112] Curing

[0113] A method for preparing a battery assembly includes curing one or more materials. Curing can be used to bring one or more materials to their final state, fully harden, be useful for the operation of the battery, etc. Curing of one or more materials may occur before, during, and / or after assembling the electrode plate stack, filling, pickling, forming, or a combination thereof. For example, curing of one or more active materials may occur after forming the electrode plate and after forming the electrode plate stack, or both. As another example, curing of one or more active materials may occur after forming the electrode plate and before forming the electrode plate stack. As even another example, curing may occur after forming. The method may not require curing.

[0114] Curing may involve a typical curing oven process.For a typical curing oven process, after applying one or more active materials to one or more substrates, the electrode plate may be inserted into a curing oven and exposed to the elevated temperature of the curing oven.

[0115] Curing may involve filling and / or emptying. Based on the advantages of fluid flow throughout the battery assembly, curing may be performed after the electrode plate stack is formed. Curing may occur when one or more fluids are circulated through the battery assembly. Circulation may include the flow of fluids through one or more valves, ports, vents, openings, channels, grooves, electrochemical cells, etc., or a combination thereof. Circulation may involve repeatedly filling and emptying one or more fluids, filling and emptying one or more fluids simultaneously, or both. Emptying and filling may occur as disclosed below. During curing, one or more fluids may flow through one or more channels, grooves, electrochemical cells, or a combination thereof. The one or more fluids used for curing may include air, dry fluid, or both. Air may be particularly useful for curing. It may be advantageous to pass dry air, moist air, or both during curing. Moist air may be circulated through the battery assembly before dry air. Dry air may be circulated through the battery assembly before moist air. Moist air and dry air may be circulated through the battery assembly simultaneously.

[0116] During curing, one or more materials may be exposed to an increased temperature. The increased temperature may help to accelerate curing compared to ambient temperature. The increased temperature may raise the internal temperature of the battery assembly to cure one or more active materials and / or other materials. The temperature of the fluid flowing through the battery assembly during curing may be about 35°C or higher, about 40°C or higher, about 50°C or higher, about 60°C or higher. The temperature of the fluid flowing through the battery assembly during curing may be about 100°C or lower, about 90°C or lower, about 80°C or lower, or even about 70°C or lower. For example, the increased temperature may be about 50°C or higher to about 80°C or lower. The temperature of the fluid flowing through the battery assembly may be the temperature of one or more fluids circulated through the battery assembly during curing. As an example, the temperature may refer to the temperature of the air circulated through the battery assembly during curing.

[0117] Empty

[0118] A method for preparing a battery assembly may include evacuation. Evacuation may be used to remove one or more fluids from the interior of the battery; allow fluids to be filled under vacuum; allow one or more fluids to be replaced with other fluids; allow for faster filling; or any combination thereof. Evacuation may include drawing a vacuum; displacing one or more fluids; pulling one or more fluids; draining one or more fluids; or any combination thereof.

[0119] Evacuation to vacuum can produce a lower pressure in the interior of the battery assembly than the environment (e.g., atmospheric pressure) surrounding the battery assembly. Evacuation to displace or drain one or more fluids can create space for filling of one or more other fluids. Evacuation can extract one or more fluids from one or more channels, grooves, electrochemical cells, openings, ports, vents, valves, etc., or any combination thereof. Evacuation can extract one or more fluids from one or more channels sealed relative to one or more electrochemical cells. For example, one or more heating and / or cooling channels. Evacuation can extract one or more fluids from one or more channels, grooves, or both that are in fluid communication with one or more electrochemical cells. For example, one or more filling and / or exhaust channels. For example, one or more grooves are in fluid communication with one or more filling and / or exhaust channels.

[0120] Evacuation can remove one or more fluids from the interior of a battery assembly. The fluids can include one or more liquids, gases, or both. The one or more fluids can include electrolyte, air, drying fluid, lead collection fluid, reactive material, electrolyte removal fluid, or a combination thereof.

[0121] Draining can be part of, done before, during, and / or after, assembly, filling, pickling, forming, thermal cycling, curing, drying, charging, discharging, etc., or any combination thereof. Draining can be done at the same or a different workstation than assembly, filling, pickling, forming, curing, drying, charging, or any combination thereof.

[0122] Emptying may include flowing one or more fluids from one or more vents into one or more ports; from one or more channels into one or more ports; from one or more channels into one or more vents; from one or more openings into one or more channels and / or vents; from one or more slots into one or more channels and / or vents; or combinations thereof. Filling may include flowing one or more fluids from one or more inlet slots into one or more channels; from one or more main slots into one or more channels; from one or more branch slots into one or more channels; from one or more main slots into one or more inlet slots; from one or more branch slots into one or more main slots; from one or more branch slots into one or more inlet slots, etc.; or combinations thereof. Emptying may include flowing one or more fluids in a reverse flow fill.

[0123] The evacuation may utilize one or more flow mechanisms. One or more flow mechanisms may be attached, engaged, and / or opened to initiate evacuation. The one or more flow mechanisms may be directly and / or indirectly attached to one or more valves, ports, openings, channels, or the like, or combinations thereof. The one or more flow mechanisms may include one or more fluid flow lines.

[0124] Venting may include attaching the one or more fluid flow lines to one or more valves, ports, openings, channels, or a combination thereof.The one or more fluid flow lines may be adapted for one or more fluids communicated therein.

[0125] Emptying can be accomplished via one or more heating, cooling, filling, and / or venting channels. Emptying can be accomplished at the same or a different port than the port used for filling. Emptying can be accomplished via an emptying port, while filling can be accomplished via a filling port. Emptying can be accomplished via a port that functions as both an emptying port and a filling port.

[0126] Draining can include draining one or more initial fluids prior to replacing (e.g., filling) with one or more other fluids. Draining can include draining one or more fluids used during curing prior to filling. Draining can include draining one or more electrolytes used during pickling and / or forming prior to filling with electrolytes.

[0127] The draining can be partial and / or complete. Partial can refer to draining and removing only a portion of one or more fluids from the interior of the battery assembly. Complete can refer to draining and removing substantially all of the one or more fluids from the interior of the battery assembly.

[0128] filling

[0129] A method for preparing a battery assembly may include filling. Filling may be used to initially fill one or more electrochemical cells with one or more fluids; allow one or more fluids (e.g., electrolytes) to begin wicking into one or more separators; replace one or more fluids; cause fluids to flow through the battery assembly; or any combination thereof. Filling may include causing one or more intermediate fluids, permanent fluids, or both to flow into the interior of the battery assembly. Intermediate fluids may include one or more fluids used during the preparation of the battery assembly, one or more fluids not intended to be used within the battery during operation, or both. Permanent fluids may still be removable. Permanent fluids may include one or more operating fluids. Operating fluids may be fluids that are within the battery assembly during operation (e.g., attachment to a load). Filling may include causing one or more fluids to flow through one or more ports, valves, vents, channels, grooves, openings, or a combination thereof; at least partially or completely filling one or more electrochemical cells with one or more fluids; replacing one or more fluids with one or more other fluids; or any combination thereof.

[0130] Filling may include flowing one or more fluids through one or more ports into one or more vents; flowing from one or more ports into one or more channels; flowing from one or more vents into one or more channels; flowing from one or more channels and / or vents into one or more openings; flowing from one or more channels and / or vents into one or more slots; or a combination thereof. Filling may include flowing one or more fluids from one or more channels into one or more inlet slots; flowing from one or more channels into one or more main slots; flowing from one or more channels into one or more branch slots; flowing from one or more inlet slots to one or more main slots; flowing from one or more main slots to one or more branch slots; flowing from one or more inlet slots to one or more branch slots, etc.; or a combination thereof.

[0131] Filling can be part of, done before, during, and / or after, assembly, evacuation, pickling, forming, thermal cycling, curing, drying, charging, discharging, etc., or any combination thereof. Filling can be done at the same or different workstations as assembly, evacuation, pickling, forming, thermal cycling, curing, drying, charging, discharging, etc., or any combination thereof.

[0132] Filling can include flowing one or more fluids into the interior of the battery assembly. The fluids can include one or more liquids, gases, or both. The one or more fluids can include electrolytes, air, drying fluids, lead collection fluids, reactive materials, electrolyte removal fluids, or combinations thereof.

[0133] Filling may include filling the battery assembly with one or more fluids while the interior of the battery assembly is at atmospheric pressure.

[0134] Filling can be performed under vacuum. Filling can include filling the battery assembly with one or more fluids when the interior of the battery assembly is below atmospheric pressure. Below atmospheric pressure can be achieved by evacuation. Below atmospheric pressure can be considered as filling under vacuum. The vacuum can include a separate port for simultaneously evacuating the vacuum chamber when filling one or more fluids, utilizing a single port as a vacuum port (e.g., an evacuation portion) and a filling port, etc., or any combination thereof. Exemplary solutions for filling battery assemblies with electrolytes under vacuum are disclosed in US Publication Nos. 2014 / 0349147 and 2017 / 0077545, which are incorporated herein by reference in their entirety.

[0135] During filling, one or more fluids may partially or completely fill the electrochemical cell. The one or more fluids may include a liquid electrolyte. The electrolyte during the filling step may fill voids (e.g., open spaces, pores, etc.) in the electrochemical cell. The one or more fluids may fill the cell so that the cell is 60% full or more, 70% full or more, or even 80% or more. The one or more fluids may fill the cell so that the cell is 100% full or less, 95% full or less, or even 90% or less. For example, the initial filling step may fill the electrochemical cells of the battery assembly to 90% full.

[0136] The electrolyte used during the filling step may be below, at, or above ambient temperature. The electrolyte may be frozen. Frozen can mean below ambient temperature, below the internal temperature of the battery, or both. For example, the frozen state may be below or at both ambient temperature and below the internal temperature of the battery. As another example, the frozen state may be above ambient temperature but below the internal temperature of the battery. Using a frozen electrolyte during the pickling and forming steps can aid in thermal control of subsequent exothermic reactions. For example, during the pickling and / or forming steps, the exothermic reaction may heat the frozen electrolyte to ambient temperature or above. The frozen electrolyte may be at a temperature of about 0°C or above, about 2°C or above, or even about 5°C or above. The frozen electrolyte may be at a temperature of about 50°C or below, about 40°C or below, about 30°C or below, about 25°C or below, about 20°C or below, about 15°C or below, or even about 10°C or below. Upon entering the electrochemical cell, the electrolyte may begin to wick (e.g., be absorbed) into one or more separators. The wicking process may also be referred to as absorption, soaking, etc. The filling process may include routing the electrolyte through one or more slots of one or more separators.After the initial filling step, an acid wash process may occur.

[0137] One or more flow mechanisms can be utilized for filling. One or more flow mechanisms can be attached, engaged and / or opened to begin filling. The one or more flow mechanisms can be identical or separate from the one or more flow mechanisms for emptying. The one or more flow mechanisms can be directly and / or indirectly attached to one or more valves, ports, openings, channels, etc. or a combination thereof. The one or more flow mechanisms can be attached to an opening, port and / or valve for filling that is identical or different from the opening, port and / or valve to which the one or more flow mechanisms are attached for emptying. The one or more flow mechanisms that can be used for emptying can be removed or kept in place during filling. The one or more flow mechanisms can include one or more fluid flow lines.

[0138] Filling can include attaching one or more fluid flow lines to one or more valves, ports, openings, channels, or combinations thereof. Filling can involve positioning one or more fluid flow lines in place. For example, one or more fluid flow lines used for venting can be used for filling. As another example, one or more fluid flow lines different from those used for venting can be used for filling. One or more fluid flow lines can be suitable for one or more fluids passed therein.

[0139] Pickling

[0140] A method for preparing a battery assembly can include pickling. Pickling can be used to improve battery assembly performance; extend the life and / or improve the performance of one or more active materials of the battery assembly; speed up the solidification of one or more active materials; or combinations thereof. Pickling can include adding one or more reactants to the battery assembly. The one or more reactants can be added to the electrolyte, one or more active materials, electrochemical cells, separators, or combinations thereof. The one or more reactants can be added before, during, or after an assembly step, a filling step, or both. As an example, the one or more reactants can be mixed with the electrolyte before the filling step, such that both the reactants and the electrolyte fill the electrochemical cells simultaneously. As another example, the reactants can be applied to one or more active materials before the electrolyte fills the electrochemical cells. For example, one or more electrode plates having one or more active materials thereon can be dipped into a modification aid, have the reactants applied thereon, or both. Pickling can occur before, during, or after the solidification and / or drying of one or more active materials.

[0141] The pickling process can be exothermic. The pickling process can heat one or more fluids within the battery assembly. The pickling process can heat the electrolyte to a temperature higher than the initial fill temperature, to a temperature closer to or equal to the internal temperature of the battery, or both. During pickling, the electrolyte can be heated to a temperature higher than ambient temperature. Electrolyte heated by the internal temperature of the battery can be considered warmed electrolyte. The exothermic reaction can facilitate speeding up the solidification of one or more active materials. The exothermic reaction can occur between one or more active materials and one or more reactants. The exothermic reaction can produce one or more hydrates.

[0142] For example, a tetrabasic lead sulfate or tribasic lead sulfate (e.g., active material) can undergo an exothermic reaction with sulfuric acid (e.g., reactant), which can produce lead sulfate compounds and hydrates as products. An example reaction equation can be:

[0143] Tetrabasic pickling reaction: (PbO)4PbSO4+ 4H2SO4→ 5PbSO4+ 4H2O

[0144] Three-base pickling reaction: (PbO)3PbSO4+3H2SO4→4PbSO4+3H2O

[0145] During the pickling process, temperature cycling can assist in controlling the battery components. Temperature cycling can occur through thermal control cycling. For example, if the pickling process occurs after the battery components are assembled and filled with electrolyte, the thermal control cycling process can occur simultaneously with, after, or both. The pickling process can occur without applying a charge to the battery components. Applying a charge can initiate the formation process. Formation can occur after the initial pickling process is complete. The initial pickling process can be completed when the reaction between the one or more active materials and the one or more reactants is complete, such as before applying a charge.

[0146] The method for preparing the battery assembly can also eliminate the need for acid washing. Eliminating the acid washing process can provide significant time savings when preparing the battery assembly. One or more active materials can be selected to avoid the need for acid washing while still providing the performance and life of the battery assembly.

[0147] The pickling process may include circulating one or more fluids therethrough. The one or more fluids may be circulated during the thermal control cycle. The one or more fluids may be referred to as pickling fluids. The thermal control cycle may include draining the one or more fluids from the battery assembly; filling the battery assembly with the one or more fluids; or both. The one or more fluids may include one or more fluids described herein. For example, the one or more fluids may include an electrolyte. As another example, during the pickling process, the one or more pickling fluids may include a diluted electrolyte.

[0148] form

[0149] A method for preparing a battery component may include forming. Forming (also referred to as formation) may be used to solidify one or more active materials; charge one or more electrode plates; produce a subsequent pickling; or any combination thereof. Forming may include applying a charge to one or more electrode plates, the battery component, or both. The charge may be applied to a battery component as disclosed herein. For example, via a pair of conductive terminals. Formation may be endothermic, exothermic, or both. Formation may include a reaction between the charge, the active material, and one or more products from a pickling process. For example, formation may include a reaction between the charge, a lead sulfate compound, and a hydrate. The formation reaction may produce one or more products. The one or more products may include one or more reactants that initiate a subsequent pickling process.

[0150] For example, the one or more products may include lead sulfate, one or more sulfuric acid compounds, and additional lead. An exemplary formation reaction equation may be:

[0151] e - +2PbSO4+2H2O→PbO2+2H2SO4+Pb(m)

[0152] The formation reaction that produces one or more products with one or more reactants can be the endothermic portion of the formation step. Once the formation has produced enough resulting products (e.g., reactants), a subsequent pickling process can be started. In addition, during the formation period, Joule heating can occur due to internal resistance. This Joule heating can also result in a temperature increase during the formation period. Before, during, and / or after the formation and / or pickling, a thermal control cycle can occur.

[0153] Formation may include circulating one or more fluids therethrough. The one or more fluids may be circulated during the thermal control cycle. The thermal control cycle may include draining the one or more fluids from the battery assembly; filling the battery assembly with the one or more fluids; or both. The one or more fluids may include one or more fluids described herein. The one or more fluids may be formation fluids. For example, the one or more fluids may include an electrolyte. As another example, during formation, the one or more formation fluids may include a diluted electrolyte.

[0154] Forming can eliminate the need for filling and / or forming canisters. Avoiding the use of canisters can help reduce the workspace required to prepare the battery assembly. Forming can occur at the same workstation as curing, draining, filling, pickling, thermal cycling, charging, draining, lead removal, etc., or combinations thereof. Eliminating canisters can be made possible by circulating fluids through the battery assembly, thermally controlled cycling, draining, filling, etc., as disclosed herein.

[0155] Thermal control cycle

[0156] A method of preparing a battery assembly may include a thermal control cycle. The thermal control cycle can be used to control the temperature of the battery assembly during the following periods: during an exothermic reaction; during pickling, forming, curing, drying, charging and / or discharging; or any combination thereof.

[0157] The thermal control cycle may be part of, concurrent with, completed before, during, and / or after evacuation, filling, pickling, forming, curing, drying, charging, discharging, or the like, or any combination thereof. The thermal control cycle may be completed at the same or a different workstation than assembling, evacuation, filling, pickling, forming, curing, drying, charging, or the like, or any combination thereof.

[0158] One or more thermal control cycle processes can be used to maintain the internal temperature of the battery component above, at, and / or below a threshold temperature. The threshold temperature can be a temperature that may produce unsafe operating conditions (such as overpressure and / or heat). Unsafe conditions can be those that cause the battery component to bulge, blister, short circuit, etc. The threshold temperature can be a temperature that solidifies one or more active materials over a period of time. The threshold temperature can be a temperature that causes one or more materials to dry out over a period of time. The threshold temperature can refer to the internal temperature of the battery component. The internal temperature can be the temperature of one or more electrochemical cells, channels, electrolytes, etc., or a combination thereof, within the battery component. The threshold temperature can be about 35°C or higher, about 40°C or higher, about 50°C or higher. The threshold temperature can be about 100°C or lower, about 90°C or lower, about 80°C or lower, about 70°C or lower, or even about 60°C or lower.

[0159] The thermal control cycle may include fluid circulation, an external water bath, a heat blanket, etc., or any combination thereof.

[0160] Fluid circulation can include circulating one or more fluids through the battery components. Fluid circulation can include one or more repetitions of draining, filling, or both. Draining and / or filling can occur as disclosed herein. Fluid circulation can include one or more repetitions of partial draining, complete draining, partial filling, complete filling, or a combination thereof. Fluid circulation can include exchanging one or more fluids for one or more other fluids. The one or more other fluids can be the same or different fluids. The different fluids can include a first fluid and a second fluid. Fluid circulation can include flowing separate fluids through the battery components. Separate can mean that the fluids can mix or not come into contact with each other. For example, one or more fluids can flow through one or more fill and / or vent channels into one or more electrochemical cells, while one or more other fluids flow through one or more heating / cooling channels that are sealed and isolated from the electrochemical cells. Different or the same fluids can be used in the same or different steps of the battery preparation process. For example, one or more pickling fluids can be the same as one or more forming fluids. As another example, air can be used during curing, while pickling and / or forming fluids, such as electrolytes, can be used during pickling and / or forming. As another example, air and / or drying fluid may be used during drying, while electrolyte may be used during pickling, forming, and / or final filling prior to operation.

[0161] Thermal control cycling can include electrolyte cycling. Electrolyte cycling can be used to provide internal heat dissipation; remove and / or add heated electrolyte; maintain the battery assembly at or below a threshold temperature from within the battery assembly; or any combination thereof. Electrolyte cycling can include partially draining, completely draining, partially filling, or completely filling the battery assembly with electrolyte. Electrolyte cycling can at least partially replace some electrolyte with other electrolyte. Thermal control cycling can include draining an initial or previous electrolyte and replacing it with a subsequent electrolyte. Draining and filling can refer to electrochemical cells and their available volume for holding electrolyte.

[0162] Draining may include draining warmed electrolyte. Warmed electrolyte may be electrolyte that has been exposed to any exothermic reaction or other heating occurring within the battery assembly. For example, warmed electrolyte may result from pickling, formation, or both. Warmed electrolyte may be partially or completely drained during the thermal control cycle.

[0163] Draining during the thermal control cycle may include reducing the degree to which each electrochemical cell is filled with electrolyte. After draining, the electrolyte of each electrochemical cell may be about 50% full or more, 60% full or more, or even 70% full or more. After draining, the electrolyte of each electrochemical cell may be about 95% full or less, about 90% full or less, or even about 80% full or less.

[0164] Filling during the thermal control cycle may include filling with electrolyte. The electrolyte may be a refrigerated electrolyte, a heated electrolyte, or both. Filling may include partially or completely replacing the drained electrolyte with a refrigerated electrolyte, a heated electrolyte, or both. Filling may include partially or completely replacing the drained electrolyte with an electrolyte at or below the temperature of the drained electrolyte.

[0165] Filling may include filling below, equal to, or above an initial fill level. Filling may include replacing emptied electrolyte at, below, or above a 1:1 ratio.

[0166] Partial draining and / or filling can take about 5 seconds or longer, about 10 seconds or longer, or even about 20 seconds or longer. Partial draining and / or filling can take about 2 minutes or less, 1 minute or less, or even about 30 seconds or less. Partial draining may take less, about the same, or even more time than partially filling the same volume of electrolyte.

[0167] The thermal control cycle may be repeated until the pickling, forming, curing, drying, or a combination thereof is complete. The thermal control cycle may be repeated 1 or more times, 2 or more times, or even 3 or more times. The thermal control cycle may be repeated 10 or fewer times, 7 or fewer times, or even 5 or fewer times. The thermal control cycle may be repeated as needed, depending on the size of the battery components and the duration of the pickling and / or forming process.

[0168] During the thermal control cycle, the electrolyte filled may be different from the electrolyte emptied. For example, the refrigerated electrolyte used to replace the emptied warmed electrolyte may have a higher specific gravity. The initial electrolyte may have a lower specific gravity than the subsequent electrolyte. The initial electrolyte may refer to the electrolyte used for the first fill before pickling and / or forming, or the electrolyte used during any process occurring during the operation of the battery assembly.

[0169] The above teachings on electrolyte and electrolyte circulation can also be used with any other fluid. For example, there can be air circulation during curing. There can be air and / or drying fluid circulation during drying.

[0170] dry

[0171] The method for preparing a battery assembly may include drying one or more materials. Drying may allow the battery assembly to be stored for long-term storage, battery transport, flow of one or more fluids therethrough, or any combination thereof. Drying the battery assembly may extend shelf life. Drying the battery assembly may provide a dry-charged battery. Drying may occur after curing, pickling, forming, draining, emptying, lead removal, or any combination thereof. For example, drying may occur after forming. As another example, drying may occur after curing. After drying, the battery assembly may be finished to seal any ports and / or valves.

[0172] Drying can be used to dry one or more materials in the interior of the battery assembly. The one or more materials may include active materials, separators, substrates, channel surfaces, grooves, channels, vents, ports, valves, etc., through the electrochemical cell, or any combination thereof. Drying can be used to remove one or more fluids from the electrochemical cell to any position between the port, valve or other outlet and / or the entrance to the interior of the battery assembly. The one or more fluids may include liquid electrolytes, water, etc., or a combination thereof. Drying can occur after draining and / or emptying. Drying can occur before and / or after rinsing with one or more liquids. For example, drying can occur after draining (e.g., draining) the liquid electrolyte from the battery assembly and then rinsing with water (e.g., filling and then draining).

[0173] Drying may involve filling and / or emptying. Drying may occur when one or more fluids are circulated through the battery assembly. Circulation may involve repeatedly filling and emptying one or more fluids, simultaneously filling and emptying one or more fluids, or both. Emptying and filling may occur as disclosed herein. During drying, one or more fluids may flow through one or more channels, slots, electrochemical cells, or a combination thereof. The one or more fluids may include a drying fluid. One or more drying fluids may be particularly suitable for circulation during drying. Dry air may be particularly useful for circulation during drying. One or more other drying fluids may be circulated prior to the drying air.

[0174] Drying can include circulating one or more fluids therethrough. The one or more fluids can be circulated during the thermal control cycle. The thermal control cycle can include draining the one or more fluids from the battery assembly; filling the battery assembly with the one or more fluids; or both. The one or more fluids can include one or more fluids described herein. The one or more fluids can be a drying fluid, air, a lead collection fluid, the like, or a combination thereof.

[0175] Post-processing

[0176] The method for preparing a battery assembly may include post-processing. Post-processing may involve sealing any ports and / or valves used during solidification evacuation, filling, pickling, forming, thermal cycling, drying, etc., or a combination thereof. Post-processing may include installing one or more seals at one or more ports. The one or more seals may be permanently and / or temporarily positioned in the port. One or more ports may be sealed with a removable plug, a permanent seal (e.g., molded), one or more valves, one or more columns (e.g., overlapping portions), or a combination thereof. Post-processing may include blocking one or more filling ports. One or more filling ports may be blocked after formation is complete. Post-processing may occur permanently and / or temporarily after any one of the steps of preparing the battery assembly.

[0177] Removal of lead substances

[0178] A method for preparing a battery assembly may include removing one or more lead species. Removing the one or more lead species may be used to extend the life of the battery assembly; collect recyclable components of the battery assembly; or both. Lead species may be generated during operation, during discharge of the battery, or both. Lead species may be generated within one or more electrochemical cells during electrochemical reactions within the cells. The lead species may include lead sulfate. Discharging may include discharging during operation. Removing the lead species may include complete discharge, draining, and filling.

[0179] Removing lead species can include evacuating one or more fluids from the battery assembly. The battery assembly can be a used battery assembly. Used can refer to the battery assembly having undergone one or more charge and discharge cycles. The one or more fluids can include electrolyte from the battery assembly. Evacuating can include any of the process steps as discussed herein with respect to evacuating.

[0180] Removing lead species can include flowing one or more lead collection fluids through the battery assembly. The lead collection fluids can be used to collect one or more lead species as they flow through the battery assembly. Flowing can include circulating through one or more channels, slots, openings, vents, ports, valves, etc., or combinations thereof. Flowing one or more lead collection fluids can be accomplished similarly to the filling and thermal control circulation processes discussed herein. The one or more lead collection fluids can be added before, after, or concurrently with evacuating. For example, the one or more lead collection fluids can be mixed with the already used electrolyte. As an example, the used electrolyte can be partially evacuated first, and then the lead collection fluids can be mixed with the remaining electrolyte. As another example, the used electrolyte can be completely evacuated, and then the lead collection fluids can be flowed into the electrochemical cells.

[0181] After the one or more lead collection fluids have collected one or more lead species, the lead collection fluids can be removed from the battery assembly. Such removal can facilitate removal of the lead species, such as lead sulfate.

[0182] After removing the lead collection fluids, the battery assembly can undergo evacuation and / or filling with fresh electrolyte. After refilling, the battery assembly can be reused.

[0183] After removing the lead collection fluids, the battery assembly can be discarded. Discarding can include recycling, reprocessing, etc.

[0184] Draining used electrolyte

[0185] A method for preparing a battery assembly can include draining used electrolyte. Draining used electrolyte can allow for collection, recycling of electrolyte, or both. Draining used electrolyte can occur with evacuating, filling, or both. The battery assembly can be evacuated to collect electrolyte. The battery assembly can be filled with one or more fluids to collect electrolyte. The one or more fluids can displace electrolyte, enabling collection of electrolyte. The used electrolyte can flow through one or more ports and / or valves.

[0186] Draining can utilize one or more flow mechanisms.Can attach, engage and / or open one or more flow mechanisms to start draining.Described one or more flow mechanisms can be identical or separate with one or more flow mechanisms for emptying, filling or above both.One or more flow mechanisms can be directly and / or indirectly attached to one or more valves, ports, openings, channels etc. or its combination.One or more flow mechanisms can be attached to the opening, port and / or valve that is identical or different with the opening, port and / or valve that one or more flow mechanisms are attached to for emptying, filling or above both for filling.One or more flow mechanisms that can be used for emptying and / or filling can be removed or remain in place during draining.One or more flow mechanisms may comprise one or more fluid flow lines.

[0187] Draining can include attaching one or more fluid flow lines to one or more valves, ports, openings, channels, or combinations thereof. Draining can involve positioning one or more fluid flow lines in an appropriate location. For example, one or more fluid flow lines used for draining and / or filling can be used for draining. As another example, one or more fluid flow lines different from those used for draining and / or filling can be used for draining. The one or more fluid flow lines can be tailored to the fluid or fluids being transferred therethrough.

[0188] Illustrative Examples

[0189] The following description of the drawings is provided to illustrate the teachings of this document and is not intended to limit its scope. The features of any one embodiment may be employed in another embodiment. For example, Figures 1 to 3 Any combination of slots can be combined with each other.

[0190] Figure 1 A cross section of a stack 5 of electrode plates 12 forming at least a portion of a battery assembly 1 is shown. The cross section of the battery assembly 1 is taken to expose the separators 10. The separators 10 are positioned within the formed stack 5 of electrode plates 12. Multiple separators 10 are stacked alternately with multiple electrode plates 12. The separators 10 rest within a frame 14 of adjacent electrode plates 12. It is also contemplated that the frame 14 may be part of the separators 10, such as Figure 6. The separator 10 is in the form of a thin sheet 16. The thin sheet 16 can be an absorbent glass mat 18. The separator 10 includes a plurality of openings 20. The openings 20 can form part of one or more transverse channels 30 or have one or more transverse channels 30 extending therethrough. The openings 20 of the separator 10 include an insert 22 extending therethrough. The insert 22 is part of and extends from the adjacent electrode plate 12. Some of the openings 20 include one or more posts 24 positioned therethrough. The posts 24 can pass through the openings 20 of the insert 22, as well as the openings 20 of the separator 10. The openings 20 of the separator 10 and / or the insert 22, including the one or more posts 24 therethrough, can be referred to as support openings 36. The support openings 36 can be part of one or more support channels 38 (not shown). One or more of the inserts 22 include a vent 26 formed therein. The vent 26 is in fluid communication with the opening 20. The openings 20 without the one or more posts 24 can be referred to as fill openings 28. Fill opening 28 may be part of one or more fill channels 32 (not shown). Separator 10 also includes a plurality of slots 34 formed therein. Slots 34 are in fluid communication with each other and with fill opening 28. Slots 34 extend between the plurality of openings 20. Slots 34 are formed such that sheet 16 has a smaller thickness at the slots 34 than the remainder of sheet 16.

[0191] Figure 2 The electrode plate 12 is depicted. The electrode plate 12 includes a substrate 56. The substrate 56 includes a frame 14 surrounding its periphery. The frame 14 protrudes from the substrate 56. The frame 14 is integral with the substrate 56. The substrate 56 includes an insert 22 protruding therefrom. The substrate 56 includes an insert 22 protruding therefrom. The insert 22 includes an opening 20. The opening 20 of the insert 22 passes through the insert 22 and the substrate 56. The insert 22 protrudes through the opening 20 of the separator 10 and the active material 60. The opening 20 is formed into one or more active materials 60 and a gap 58 in the separator 10. The separator 10 can also be a transfer sheet 62 (as shown) or be used in conjunction with a transfer sheet 62 (e.g., layered with a transfer sheet). A peripheral gap 35 between the separator 10 and the frame 14 forms a slot 34. The peripheral gap 35 is in fluid communication with the exhaust port 26. The peripheral gap 35 is in fluid communication with one or more slots 34 formed in the separator 10. The peripheral opening 35 is also free of active material 60 .

[0192] Figure 3The electrode plate 12 is depicted. The electrode plate 12 includes a base plate 56. The base plate 56 includes a frame 14 around its periphery. The frame 14 protrudes from the base plate 56. The frame is integral with the base plate 56. The frame 14 includes a slot 34. The slot 34 is formed in the inward-facing surface 15 of the frame. The slot 34 is formed as a recess, such as a groove. The slot 34 extends along the length of the inward-facing surface 15. The slot 34 surrounds the separator 10 (not shown) when located within the frame 14. The slot 34 can be aligned with one or more slots 34 formed in the separator, such as Figure 1 and Figure 2 ), one or more vents 26, one or more openings 20, one or more transverse passages 30 (not shown), or a combination thereof. The base plate 56 includes an insert 22 protruding therefrom. The insert 22 is integral with the base plate 56. The insert 22 includes an opening 20. The opening 20 of the insert 22 extends through the insert 22 and the base plate 56.

[0193] Figure 4 and Figure 5 A partial cross-sectional view of a battery assembly 1 is depicted. The battery assembly 1 includes a stack 5 of electrode plates 12 with separators 10 (not visible) located between the electrode plates. An outer seal 40 is located around the stack 5 of electrode plates 12 and separators 10. The outer seal 40 is shown as partially cut away or transparent. The battery assembly 1 includes a pair of conductive terminals 42. The battery assembly 1 includes a vent 44 in communication with a valve 46. The valve 46 can be a check valve, a fill valve, a pressure relief valve, a pressure valve, or other valve. The vent 44 and valve 46 can be aligned with one or more transverse channels 30 ( Figure 5 ) or misalignment ( Figure 4 ). The valve 46 can be connected to the head space 68 (such as Figure 5 ) fluidly connected. It is also possible that the valve 46 may be positioned at one or more openings 20 at the end of one or more transverse channels 30. The end of one or more open transverse channels 30 may be one or more ports 66. The battery assembly 1 includes a plurality of transverse channels 30. The one or more transverse channels 30 may be synonymous with one or more channels that pass transversely through the plurality of electrode plates 12 and separators 10. Some of the transverse channels 30 are support channels 38. At least one of the transverse channels 30 is a filling channel 32. The filling channel 32 may include a port 66 on one or more ends, such as Figure 5. Port 66 can be a fill and / or empty port. The fill channel 32 can be in fluid communication with the vent 44. The vent 44 can be aligned with one or more transverse channels 30, such as the fill channel 32. In the exposed portion of the battery assembly 1, one of the electrode plates 12 is shown. The electrode plate 12 positioned at the end of the stack of electrode plates 12 is a unipolar plate 48. The unipolar plate 48 includes an opening 20. The opening 20 includes an insert 22 around its periphery. The opening 20 is aligned with a plurality of other openings 20 to form a transverse channel 30, particularly a support channel 38. A post 24 is positioned within the support channel 38. The post 24 extends laterally along the length of the transverse channel 30.

[0194] Figure 6 A partially exploded stack 5 of electrode plates 12 forming a battery assembly 1 is shown. Battery assembly 1 can be identified as a bipolar battery assembly. Opposing end plates 50 (e.g., a first end plate and a second end plate) are shown. End plates 50 are also unipolar plates 48. End plates 50 include internal reinforcement structures 52. End plates 50 include a plurality of openings 20. Each opening 20 is partially surrounded by an insert 22. Inserts 22 protrude from a base 64 of end plates 50. Base 64 is also a substrate 56 of unipolar plate 48. Frame 14 is positioned around substrate 56. Separator 10 is adjacent to unipolar plate 48. Separator 10 is in the form of one or more thin sheets 16. Separator 10 includes a plurality of openings 20. The openings 20 of separator 10 allow inserts 22 of electrode plate 12 to pass therethrough. Bipolar plate 54 is adjacent to separator 10. Bipolar plate 54 includes substrate 56. Substrate 56 of bipolar plate 54 includes a frame 14 around its periphery. The frame 14 forms a protruding edge around the perimeter of the base plate 56. The bipolar plate 54 includes a plurality of openings 20. Each opening 20 is partially surrounded by an insert 22. The insert 22 protrudes from the base plate 56 of the bipolar plate 54. The inserts 22 of the electrode plates 12 (monopolar plates 48 and bipolar plates 54) and the openings 20 of the electrode plates 12 are aligned and interlocked to form one or more transverse channels 30 through the stack 5 of electrode plates 12. One or more of the transverse channels 30 can receive one or more posts 24 (not shown) therethrough. One or more slots 34 can be part of the stack 5. For example, as Figures 1 to 3 One or more grooves 34 shown in any of the examples may be incorporated into the battery assembly 1. The battery assembly 1 may include one or more active materials 60 (not shown) and / or one or more transfer sheets 62 (not shown), such as in Figure 2 Shown in the middle.

[0195] Figure 7A partially exploded stack 5 of electrode plates 12 forming a battery assembly 1 is shown. The electrode plates 12 include opposing unipolar plates 48 at the ends of the stack and a bipolar plate 54 between the unipolar plates. The electrode plates 12 are arranged alternately with separators 10 such that a separator 10 is positioned between each pair of electrode plates 12. An end plate 50 is shown as the unipolar plate 48. The end plate 50 includes an internal reinforcement structure 52. The unipolar plate 48 includes a plurality of openings 20. Each opening 20 is surrounded by an insert 22. The insert 22 protrudes and projects from a base 64 of the unipolar plate 48. The base 64 is also the substrate 56 of the unipolar plate 48. The separator 10 is adjacent to the unipolar plate 48. The separator 10 includes a frame 14. The frame 14 forms a raised edge around the periphery of the separator 10. The separator 10 includes a sheet 16. The sheet 16 can be a glass mat, such as an absorbent glass mat (AGM) 18. The sheet 16 is positioned within the interior of the frame 14 and adjacent to the frame 14. The sheet 16 can be integral with or attached to the frame 14. The separator 10 includes a plurality of openings 20. Each opening 20 is at least partially surrounded by an insert 22. The insert 22 protrudes from the separator 10, such as from the sheet 16. The bipolar plate 54 is adjacent to the separator 10. The bipolar plate 54 includes a base plate 56 and a frame 14. The frame 14 forms a protruding edge around the periphery of the base plate 56 of the bipolar plate 54. The bipolar plate 54 includes a plurality of openings 20. Each opening 20 is at least partially surrounded by an insert 22. The insert 22 protrudes from the base plate 56 of the bipolar plate 54. The inserts 22 and the channel openings 20 are aligned and interlock with each other to form one or more transverse channels 30 through the stack of electrode plates 12. One or more transverse channels 30 may receive one or more posts 24 (not shown) therethrough, such that one or more posts 24 (not shown) extend through one or more of the transverse channels 30. The battery assembly 1 may include one or more active materials 60 (not shown) and / or one or more transfer sheets 62 (not shown), such as in Figure 4 The battery assembly 1 may include one or more slots 34 (not shown), such as Figures 1 to 3 Shown in the middle.

[0196] Figure 8A perspective view of a cross-section of a battery assembly 1 is depicted. The cross-section is taken through a plurality of transverse channels 30. The battery assembly 1 includes opposing unipolar plates 48 as end plates 50. The unipolar plates 48 include internal reinforcement structures 52. The battery assembly 1 includes a stack 5 of multiple electrode plates 12 alternating with separators 10. The electrode plates 12 include opposing unipolar plates 48 and a plurality of bipolar plates 54 positioned therebetween. The electrode plates 12 include inserts 22. The inserts 22 are aligned with and interlocked with each other. Some inserts 22 may be formed as part of or adjacent to the frame 14. The inserts 22 include openings 20 therethrough. The openings 20 are aligned with each other to form transverse channels 30. The transverse channels 30 extend transversely through the battery assembly 1. The transverse channels 30 extend through the electrode plates 12, the separators 10, the active material 60, and the electrolyte 70 (not shown) positioned between the multiple pairs of electrode plates 12. One or more of the transverse channels 30 may have one or more posts 24 (not shown) extending therethrough. One or more of the transverse channels 30 are fill channels 32. The fill channels 32 can be in fluid communication with the headspace 68. The headspace 68 can be an area outside the active area having one or more vents 26, vent holes 44, valves 46, ports 66, or a combination thereof. The headspace 68 can be an area that receives a liquid electrolyte or other fluid (not shown). The electrode plates 12 and separators 10 include respective frames 14. The frames 14 are aligned and interlocked with each other around the perimeter of the battery assembly 1. The insert 22 includes vent holes 44.

[0197] Figure 9 The diagram shows a separator 10 assembly formed from a plurality of thin sheets 16. Some of the thin sheets 16 are outer sheets 16a, while others are inner sheets 16b. The inner sheet 16b can be a single sheet or a plurality of sheets. The thin sheets 16 may or may not have openings 20 formed therein before being stacked to form the separator 10. The openings 20 are aligned when the plurality of thin sheets 16 are stacked to form the separator 10. The inner sheet 16b includes a plurality of slots 34. The plurality of thin sheets 16 are stacked such that an outer sheet 16a has one or more inner sheets 16b positioned therebetween. The stack of thin sheets 16 forms the separator 10. The plurality of slots 34 formed in the inner sheet 16b are enclosed by the outer sheet 16a.

[0198] Figure 10 and Figure 11 Each shows a cross section of the battery assembly 1. The cross section of the battery assembly 1 is cut to expose the separator 10. Figure 10 The separators include Figure 1 The groove 34 is shown in FIG. Figure 11 The separator does not include the groove 34. Figure 10 and Figure 11 The electrolyte 70 is depicted absorbed into the separator 10 .

[0199] Figure 12A graph showing the duration of time taken to fill a battery assembly 1 (not shown) with electrolyte 70 (not shown) is shown. The graph shows the duration of time taken to fill a battery assembly 1 (not shown) with a tank A (as shown in FIG. Figure 10 ) is filled, compared with the battery component without groove B (as in Figure 11 (drawing) fill.

[0200] Figure 13 A flow chart of a method for preparing a battery assembly is depicted. The method may begin by assembling 100 the battery assembly. After assembly, the method may include curing 110. Curing may be accomplished by circulating one or more fluids through the battery assembly. Fluid circulation may be referred to as or operate similarly to a thermal control cycle as described herein. Curing may be accomplished by circulating humid and / or dry air through the battery assembly. One or more fluids during curing may flow through a Figures 1 to 3 One or more slots shown in Figures 6 to 8 1 . After curing, the assembly may be evacuated 120. Evacuation may include applying a vacuum. Simultaneously with or after evacuation, the battery assembly may be filled with an initial electrolyte 130. Optionally, an acid wash 140 may be initiated. It is possible to skip the acid wash step and instead move to forming 150. During the acid wash and / or forming process, one or more fluids may be circulated through the battery assembly. Fluid circulation may be referred to as a thermal control cycle as described herein. For example, the fluids may include one or more electrolytes. After forming 160, the battery assembly may optionally be dried 160. Drying may utilize one or more fluids flowing through the battery assembly. Fluid circulation during drying may be referred to as a thermal control cycle as described herein or operate similarly to a thermal control cycle. After forming 150 or drying 160, the battery assembly may be filled with a final electrolyte 170. After filling, the assembly may then be post-processed 180. Thermal control cycles may be useful during one or more steps during this method. Thermal control cycles may involve evacuating one fluid and filling with the same or another fluid. A thermal control cycle may include filling with a fluid at the same or a different temperature than the fluid being evacuated. A thermal control cycle may include repeatedly evacuating and filling the battery assembly with one or more fluids. Steps indicated by dashed lines may be specific to a thermal control cycle.

[0201] Comparative Examples

[0202] Figures 10 to 12The graph illustrates how the addition of the grooves 34 can significantly speed up the flow of electrolyte 70 throughout the battery assembly 1. The graph illustrates how the grooves 34 allow the battery assembly 1 to be 90% filled with electrolyte in approximately 1 minute, as compared to a battery assembly without the grooves, which was 90% filled in approximately 14 minutes. To achieve 100% electrolyte fill, the grooves provide a fill time of 14 minutes and 26 seconds, while no groove provides a fill time of approximately 46 minutes.

[0203] Any numerical value listed in the above application includes all values ​​from the lower limit to the upper limit in increments of one unit, provided that there is a gap of at least 2 units between any lower limit and any higher value. These are only examples of what is specifically intended, and all possible combinations of numerical values ​​between the lowest and highest values ​​listed will be considered to be expressly stated in this application in a similar manner. Unless otherwise specified, all ranges include both endpoints and all numbers between the endpoints.

[0204] The terms "substantially" or "substantially" describing angular measurements may refer to about + / - 10° or less, about + / - 5° or less, or even about + / - 1° or less. The terms "substantially" or "substantially" describing angular measurements may refer to about + / - 0.01° or more, about + / - 0.1° or more, or even about + / - 0.5° or more. The terms "substantially" or "substantially" describing linear measurements, percentages, or ratios may refer to about + / - 10% or less, about + / - 5% or less, or even about + / - 1% or less. The terms "substantially" or "substantially" describing linear measurements, percentages, or ratios may refer to about + / - 0.01% or more, about + / - 0.1% or more, or even about + / - 0.5% or more.

[0205] The term "consisting essentially of" describing a combination will include the identified elements, ingredients, components, or steps, and such other elements, ingredients, components, or steps that do not materially affect the basic and novel characteristics of the combination. Use of the terms "comprising" or "including" herein to describe a combination of elements, ingredients, components, or steps also contemplates embodiments consisting essentially of the recited elements, ingredients, components, or steps.

[0206] A plurality of elements, ingredients, components or steps may be provided by a single integrated element, ingredient, part or step. Alternatively, a single integrated element, ingredient, part or step may be divided into separate multiple elements, ingredients, parts or steps. Disclosure of "a" or "an" to describe an element, ingredient, part or step is not intended to exclude additional elements, ingredients, parts or steps.

Claims

1. A method for preparing a battery assembly, the method comprising: a) providing an assembled battery stack having a plurality of electrochemical cells, wherein the battery stack comprises: i) a plurality of stacked electrode plates, each electrode plate having a substrate with one or more active materials in the form of a paste thereon; ii) one or more channels extending transversely through the plurality of stacked electrode plates, through the substrate comprising each electrode plate and through the one or more active materials; and iii) one or more grooves formed within the one or more electrochemical cells and in fluid communication with at least one of the one or more channels, wherein the one or more grooves are substantially perpendicular to the one or more channels; and b) pickling the battery components while flowing one or more pickling fluids through the battery components; wherein the pickling comprises circulating the pickling fluid through one or more electrochemical cells and allowing the pickling fluid to soak into the one or more active materials; c) forming the cell assembly by applying an electrical charge and simultaneously flowing one or more forming fluids through the cell assembly; and d) filling the battery assembly with one or more finishing fluids prior to operation of said battery assembly; wherein the one or more finishing fluids have a higher specific gravity than the one or more pickling fluids and the one or more forming fluids.

2. The method according to claim 1, wherein The one or more finishing fluids have a specific gravity of 1.05 to 1.4, and the one or more pickling fluids and the one or more forming fluids have a specific gravity of 1.05 to 1.

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3. The method according to claim 1, wherein The one or more pickling fluids, the one or more forming fluids, and the one or more finishing fluids are each a liquid electrolyte comprising one or more reactants; and wherein the concentration of the one or more reactants in the one or more pickling fluids and the one or more forming fluids is lower than the concentration of the one or more reactants in the one or more final fluids.

4. The method of claim 1 , wherein the method comprises curing, drying, or curing and drying the one or more active materials positioned on one or more substrates of one or more electrode plates; as well as in, The curing includes hardening the one or more active materials; wherein the drying comprises removing one or more fluids from the battery assembly; and Wherein, the one or more fluids include the one or more pickling fluids, one or more forming fluids, one or more finishing fluids or a combination thereof.

5. The method of claim 4, wherein the curing, drying, filling, or a combination thereof involves flowing one or more fluids through the one or more channels, the one or more slots, or both.

6. The method of claim 5, wherein said method comprises said curing, and said one or more fluids used for said curing comprises humid air.

7. The method of claim 4, wherein the method includes the drying, and the drying occurs after the curing, the forming, the filling, or a combination thereof.

8. The method of claim 5, wherein said method comprises said drying, and said one or more fluids used for said drying involve dry air, one or more drying fluids, or both.

9. The method of claim 2, wherein the one or more liquid electrolytes comprise a frozen electrolyte cooled to a temperature below ambient temperature, and wherein: The frozen electrolyte is cooled to a temperature of 0° C. or higher and 20° C. or lower.

10. The method of claim 3, wherein the one or more pickling fluids comprise one or more diluted liquid electrolytes.

11. The method of claim 1 , wherein the one or more forming fluids comprise one or more liquid electrolytes; and The one or more liquid electrolytes include a frozen electrolyte, a heated electrolyte, or both the frozen electrolyte and the heated electrolyte.

12. The method of claim 11, wherein the one or more forming fluids comprise one or more diluted liquid electrolytes.

13. The method of claim 1, wherein the method comprises filling the plurality of electrochemical cells of the assembled battery stack with a liquid electrolyte via the one or more channels, the one or more grooves, or both to form a battery component.

14. The method of claim 13, wherein the method comprises draining the one or more pickling fluids, the one or more forming fluids, or both from the assembled battery stack prior to or concurrently with filling with the liquid electrolyte.

15. The method of claim 14, wherein after said filling, one or more ports are permanently and / or temporarily sealed; and in, The method includes adding one or more valves, terminals, caps, diaphragms, tapes, labels, or combinations thereof.

16. The method of claim 7, wherein the method cures, dries, or both cures and dries the one or more active materials without the use of a curing oven, a drying oven, or both.

17. The method of claim 13, wherein the method does not utilize a filling and forming tank during the pickling, forming, filling, or a combination thereof.

18. The method of claim 1, wherein the assembled battery stack includes one or more separators, the separators comprising: a) one or more sheets that are porous and non-conductive and configured to allow passage of electrolytes, ions, electrons, or a combination thereof therethrough; b) one or more openings in the sheet, the one or more openings adapted to align with one or more other openings of an adjacent electrode plate to form one or more channels; c) one or more grooves formed in the sheet as one or more channels of reduced thickness of the sheet and adapted to direct the flow of electrolyte of the battery assembly; and wherein the one or more slots include a plurality of slots, and the plurality of slots include a main slot and one or more branch slots; wherein the main tank is in direct fluid communication with the one or more openings; and The one or more branch grooves are separated from the one or more openings and are in fluid communication with the main groove.

19. The method of claim 1, wherein the battery assembly is prepared at a single workstation including all equipment for assembly, curing, draining, filling, pickling, forming, drying, initial charging before operation, lead removal, draining, or a combination thereof; in, The method includes providing the assembled battery stack at the single workstation.

20. The method according to claim 3, wherein The temperature of the one or more pickling fluids during the pickling, the temperature of the one or more forming fluids during forming, or both, is higher than the temperature of the one or more fill fluids during operation of the battery assembly.

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