Electrode stack assembly for metal hydrogen battery

Abstract

An electrode stack may include: a plurality of anode assemblies, each anode assembly including at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly comprising at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge arranged to engage each anode tab of each of the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each of the plurality of cathode assemblies; an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feed-through terminal coupled to the cathode feed-through bridge, in which the plurality of anode assemblies and the plurality of cathode assemblies are alternately arranged and separated by the plurality of separators to form an electrode stack. The invention also provides a battery.

Description

Related Applications

[0001] This disclosure claims priority to non-provisional patent application No. 17 / 830,193 filed on June 1, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0002] Embodiments of the present invention relate to metal hydride batteries, and more particularly, to configurations of metal hydride batteries. Background Art

[0003] In order for renewable energy sources such as wind and solar to compete with traditional fossil fuels, large-scale energy storage systems are needed to mitigate their inherent intermittency. To build large-scale energy storage, cost and long service life are primary considerations. Currently, pumped hydro dominates the grid energy storage market because it is an inexpensive way to store large amounts of energy over long periods of time (about 50 years), but it is constrained by the lack of suitable sites and environmental footprint. Other technologies such as compressed air and flywheel energy storage also show some different advantages, but their relatively low efficiency and high cost should be significantly improved for grid storage. Rechargeable batteries provide an excellent opportunity to achieve large-scale energy storage systems with low cost, high capacity and high reliability. Improving the reliability of rechargeable batteries has become an important issue in realizing large-scale energy storage.

[0004] Therefore, better metal hydride battery configurations are needed. Summary of the invention

[0005] According to an embodiment of the present disclosure, an electrode stack and a battery formed using the electrode stack are disclosed.

[0006] According to some embodiments, an electrode stack assembly for a metal hydrogen battery includes: a plurality of anode assemblies, each anode assembly including at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly including at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge arranged to engage each anode tab of each anode assembly in the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each cathode assembly in the plurality of cathode assemblies; an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies and the plurality of cathode assemblies are alternately arranged and separated by the plurality of separators to form an electrode stack.

[0007] According to some embodiments, a metal hydride battery includes: an electrode stack assembly, the electrode stack assembly including: a plurality of anode assemblies, each anode assembly including at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly including at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge arranged to engage each anode tab of each anode assembly in the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each cathode assembly in the plurality of cathode assemblies; an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies, the plurality of cathode assemblies and the plurality of separators are alternately arranged to form an electrode stack; a pressure vessel surrounding the electrode stack assembly such that the cathode feedthrough terminal extends through the pressure vessel; and an electrolyte contained within the pressure vessel.

[0008] According to some embodiments, a method for forming an electrode stack assembly for a metal hydride battery includes: preassembling components of the electrode stack assembly by: assembling a plurality of cathode assemblies, each cathode assembly having a cathode tab attached to one or more cathode material layers, assembling a plurality of anode assemblies, each anode assembly having an anode tab coupled to one or more anode material layers, forming a plurality of separators from a separator material, forming a frame top and a frame bottom, forming an anode feedthrough bridge assembly, and forming a cathode feedthrough bridge assembly; stacking the separators, the anode assemblies, and the cathode assemblies in an alternating manner between the frame top and the frame bottom to capture electrodes between the frame top and the frame bottom; pressing the electrodes, the frame top, and the frame bottom; forming an electrode stack by attaching the frame top to the frame bottom to form a frame; attaching the cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly; and attaching the anode tabs of the plurality of anode assemblies in the electrode stack to the anode feedthrough bridge assembly.

[0009] According to some embodiments, a method of forming a hydrogen metal battery includes: forming an electrode stack assembly, wherein forming the electrode stack assembly includes: assembling a plurality of cathode assemblies, each cathode assembly having a cathode tab attached to one or more cathode material layers, assembling a plurality of anode assemblies, each anode assembly having an anode tab coupled to one or more anode material layers, forming a plurality of separators from a separator material, forming a frame top and a frame bottom, forming an anode feedthrough bridge assembly including an anode feedthrough terminal, forming a cathode feedthrough bridge assembly including a cathode feedthrough terminal, stacking separators, anode assemblies, and cathode assemblies in an alternating manner between the frame top and the frame bottom to capture the frame top. The electrode stack is formed by attaching the frame top to the frame bottom to form a frame, attaching the cathode tabs of multiple cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly, and attaching the anode tabs of multiple anode assemblies in the electrode stack to the anode feedthrough bridge assembly; attaching the anode end cap to the side wall of the container; inserting the electrode stack assembly into the side wall of the container so that the anode feedthrough terminal engages with the anode end cap; attaching the cathode end cap to the side wall of the container so that the cathode feedthrough terminal passes through the feedthrough in the cathode end cap.

[0010] These and other embodiments are discussed below with reference to the figures. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] An understanding of the features and advantages of the techniques described in this disclosure will be gained by referring to the following detailed description, which sets forth illustrative aspects with reference to the accompanying drawings.

[0012] Figure 1 An example of a metal hydride battery according to some aspects of the present disclosure is shown.

[0013] Figure 2A , Figure 2B , Figure 2C and Figure 2D Examples of electrode stack assemblies according to some aspects of the present disclosure are shown.

[0014] Figure 3A , Figure 3B , Figure 3C , Figure 3D , Figure 3E , Figure 3F and Figure 3G Some aspects of electrode stack assemblies according to some aspects of the present disclosure are further illustrated.

[0015] Figure 4A , Figure 4B and Figure 4C A divider pocket according to some aspects of the present disclosure is shown.

[0016] Figure 4D and Figure 4E A separator according to some aspects of the present disclosure is shown.

[0017] Figure 5A , Figure 5B , Figure 5C , Figure 5D and Figure 5E An anode assembly according to some embodiments of the present disclosure is shown.

[0018] Fig. 6A , Figure 6B , Figure 6C , Fig.6D , Fig. 6E , Fig. 6F , Figure 6G and Figure 6H A cathode assembly according to some embodiments of the present disclosure is shown.

[0019] Fig. 7A , Figure 7B , Figure 7C , Fig.7D , Fig. 7E , Figure 7F , Figure 7G , Figure 7H , Fig.7I and Figure 7J An electrode stack assembly framework is shown according to some embodiments of the present disclosure.

[0020] Figure 8 The assembly of an electrode stack according to some embodiments of the present disclosure is shown.

[0021] Fig. 9A , Fig. 9B and Fig. 9C A separator of an electrode stack assembly according to some embodiments of the present disclosure is shown.

[0022] Fig. 10A , Fig. 10B and Fig. 10C An electrode shield according to some embodiments of the present disclosure is shown.

[0023] Fig.11A , Fig. 11B , Fig. 11C , Fig.11D , Fig.11E and Fig.11F An anode feed-through bridge and an anode feed-through terminal are shown according to some embodiments of the present disclosure.

[0024] Fig. 12A , Fig. 12B , Fig. 12C , Fig.12D , Fig.12E and Fig.12F A cathode feedthrough bridge and cathode feedthrough terminals are shown according to some embodiments of the present disclosure.

[0025] Fig.13A and Fig. 13B The assembly of a battery according to some embodiments of the present disclosure is shown.

[0026] Fig.14A and Fig. 14B A feedthrough shoulder is shown according to some embodiments of the present disclosure.

[0027] Fig.15A and Fig. 15B A fill tube according to some embodiments of the present disclosure is shown.

[0028] Fig.16A , Fig. 16B , Fig. 16C and Fig.16D The following are some examples according to the present disclosure: Fig.13A and Fig. 13B An example of a feedthrough is shown.

[0029] Fig.17A , Fig. 17B , Fig. 17C and Fig.17D An example of an anode end cap according to some embodiments of the present disclosure is shown.

[0030] Fig.18A , Fig.18B , Fig.18C , Fig.18D , Fig.18E , Fig.18F , Figure 18G and Fig.18H An example of a cathode end cap according to some embodiments of the present disclosure is shown.

[0031] Fig.19A , Fig.19B and Fig.19C Examples of container bodies according to some embodiments of the present disclosure are shown.

[0032] Fig. 20A , Fig. 20B , Fig. 20C , Fig.20D , Fig.20E , Fig.20F , Figure 20G , Fig. 20H , Fig.20I , Fig. 20J , Figure 20K , Figure 20L , Figure 20M , Fig.20Nand FIG. 20O illustrate example methods of constructing electrode stack assemblies and batteries according to aspects of the present disclosure.

[0033] These figures are discussed further below. DETAILED DESCRIPTION

[0034] In the following description, the specific details describing some aspects of the present invention are set forth. However, it will be apparent to those skilled in the art that some embodiments may be practiced without some or all of these specific details. The specific embodiments disclosed herein are intended to be illustrative rather than restrictive. Those skilled in the art may realize other elements within the scope and spirit of the present disclosure although not specifically described herein. Such modifications may include replacing any aspect of the present disclosure with known equivalents, so as to achieve the same result in substantially the same manner.

[0035] Thus, this specification describes aspects and embodiments of the present invention, which should not be construed as limiting the invention protected by the claims. Various changes may be made without departing from the spirit and scope of the description and claims. In some cases, well-known structures and techniques are not shown or described in detail in order not to obscure the present invention.

[0036] Unless the context requires otherwise, throughout this specification and claims, the words "include" and its variants (e.g., "comprising" and "containing") are to be interpreted in an open, inclusive sense, i.e., "including but not limited to". Throughout this specification, the recitation of a numerical range of values ​​is intended to be used as a convenient way of referring to each individual value falling within the range (including the values ​​limiting the range), and each individual value is incorporated into this specification as if it were recited individually herein. In addition, the individual values ​​provided for specific components are merely examples and are not to be considered limiting. The specific dimensional values ​​of various components are only used to provide specific examples, and those skilled in the art will recognize that aspects of the present disclosure can be provided with any dimensions. In addition, unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" include plural referents.

[0037] Throughout the specification, references to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, throughout this specification, the phrases "in one embodiment" or "in an embodiment" appearing in various places do not necessarily all refer to the same embodiment, but in some cases may. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0038] In the drawings, unless otherwise noted, the relative sizes of components are not meaningful and should not be considered limiting. The sizes of the components in the drawings are designed to better describe the various features and structures without regard to the displayed sizes relative to other components. In addition, although one example of a battery is described with specific dimensions, these specific dimensions are provided only as examples and are not limiting. According to the aspects disclosed below, the battery can be formed to have any size, wherein the components have any relative sizes.

[0039] Metal hydride cells can be configured in a variety of ways. In each case, the cell itself includes an electrode stack having a series of electrodes (alternating cathodes and anodes) separated by an electrically insulating separator. The electrode stack is housed in a pressure vessel that contains an electrolyte and hydrogen gas. The electrode stack can provide an array of battery cells (i.e., cathode electrode and anode electrode pairs) that can be electrically coupled in series or in parallel. The electrode stacks according to aspects of the present disclosure are arranged so that the battery cells formed in the electrode array are coupled in parallel. The electrode stacks can be arranged in individual pressure vessels (IPVs), wherein each electrode stack is housed in an individual IPV.

[0040] An embodiment according to the present disclosure includes an electrode stack including stacked alternating cathode electrodes and anode electrodes. Each of the cathode electrodes and the anode electrodes includes a tab. The tab from the cathode electrode can be inserted into a slot in the cathode bridge, and the tab from the anode electrode can be inserted into a slot in the anode bridge. Terminals can be attached to the cathode bridge and the cathode bridge to complete the electrode stack assembly.

[0041] Figure 1 A schematic diagram of an IPV metal hydride cell 100 according to some aspects of the present disclosure is depicted. The metal hydride cell 100 includes an electrode stack assembly 104 that includes stacked electrodes separated by a separator 110. The electrodes include a cathode 112, an anode 114, and a separator 110 disposed between the cathode 112 and the anode 114. The separator 110 is filled with an electrolyte 126. In some embodiments, in addition to electrically separating the cathode 112 and the anode 114, the separator 110 also provides a reservoir for the electrolyte 126 that buffers the electrodes from drying out or overflowing during operation.

[0042] Each pair of cathode 112 and anode 114 can be considered a battery cell, although there may be additional electrode layers that are not paired. The electrode stack assembly 104 can be housed in a pressure vessel 102. An electrolyte 126 is disposed in the pressure vessel 102. The cathode 112, the anode 114, and the separator 110 are porous to retain the electrolyte 126 and allow ions in the electrolyte 126 to be transmitted between the cathode 112 and the anode 114. In some embodiments, the separator 110 can be omitted as long as the cathode 112 and the anode 114 can be electrically insulated from each other. For example, the space occupied by the separator 110 can be filled with the electrolyte 126. The metal hydrogen battery 100 may also include a filling tube 122, which is configured to introduce an electrolyte or a gas (e.g., hydrogen) into the pressure vessel 102. The fill tube 122 may include one or more valves (not shown) to control flow into and out of the housing of the pressure vessel 102, or the fill tube 122 may be sealed after the pressure vessel 102 is charged with the electrolyte 126 and hydrogen gas.

[0043] like Figure 1 As shown, the electrode stack assembly 104 includes multiple stacked layers of alternating cathodes 112 and anodes 114 separated by separators 110. A battery cell can be formed by a pair of cathodes 112 and anodes 114. Although the battery cells in the electrode stack assembly 104 can be coupled in parallel or in series, in Figure 1 In the example of battery 100 shown, the battery cells are coupled in parallel. Specifically, each of cathodes 112 is coupled to conductor 118, and each of anodes 114 is coupled to conductor 116. Figure 1 The fill tube 122 is shown to be located on the side of the cathode conductor 118 , but the fill tube 122 may alternatively be placed on the side of the anode conductor 116 , or anywhere on the pressure vessel 102 .

[0044] like Figure 1 As shown, a conductor 116 coupled to the anode 114 is electrically coupled to an anode feed-through terminal 120, which may represent the negative terminal of the battery 100. The terminal 120 may include a feed-through to allow the terminal 120 to extend to the outside of the pressure vessel 102, or the conductor 116 may be directly connected to the pressure vessel 102. Similarly, a cathode conductor 118 coupled to the cathode 112 may be coupled to a cathode feed-through terminal 124, which represents the positive side of the battery 100. The terminal 124 also passes through an insulating feed-through to allow the terminal 124 to extend to the outside of the pressure vessel 102.

[0045] As discussed above, each battery cell included in the electrode stack 104 includes a cathode 112 and an anode 114 separated by a separator 110. The electrode stack assembly 104 is located in a pressure vessel 102, wherein an electrolyte 126 is maintained, and ions in the electrolyte 126 can be transmitted between the cathode 112 and the anode 114. As further discussed below, the cathode 112 is formed by a porous conductive substrate coated with a porous compound. Similarly, the anode 114 is formed by a porous conductive substrate coated with a porous catalyst. The separator 110 is a porous insulator that can separate the alternating layers of the cathode 112 and the anode 114 to maintain the electrolyte 126 and allow the ions in the electrolyte 126 to be transmitted between the cathode 112 and the anode 114. In some embodiments, the electrolyte 126 is an alkaline (pH greater than 7) aqueous electrolyte. Each of the anode 114 and the cathode 112 can be formed as an anode assembly or a cathode assembly having a multilayer structure, as further discussed below.

[0046] like Figure 1 As shown, the electrode stack 104 can be fixed within the frame 106. In addition, the electrode stack assembly 104 can be organized with anode layers 114 on both sides adjacent to the frame 106 so as to isolate the cathode layer 112 from the frame 106. In addition, a separator 110 can be included adjacent to the frame 106 for further isolation, or in some embodiments, the top and bottom anode layers 114 can be directly adjacent to the frame 106.

[0047] The electrode stack assembly 104 (the core of the battery 100) operates chemically via the hydrogen evolution reaction (HER) and the hydrogen oxidation reaction (HOR) to charge and discharge the battery 100. Mechanistically, these reactions are more complex under alkaline conditions than under acidic conditions. Active alkaline HER / HOR catalysts tend to have more dynamic surfaces. Under acidic conditions, the reaction proceeds via H + Reduction to H2 or oxidation of H2 to H + The activity of the catalysts for these reactions under acidic conditions is closely related to the binding energy of hydrogen to the metal surface. If the hydrogen binding is too strong or too weak, the catalytic process will not proceed effectively and the kinetic overpotential will be large. Platinum has an ideal hydrogen binding energy and exhibits better HER / HOR performance than any other catalyst in low pH solutions. Under alkaline conditions, free H +The concentration of is essentially zero, so HER first proceeds via the breaking of the HO bonds of water molecules to generate surface-adsorbed hydrogen atoms and hydroxide anions according to Equation 1 below. This step is slow on metal surfaces, resulting in alkaline HER exchange current densities that are two to three orders of magnitude smaller than acidic ones on the same metal. Hydrogen is generated according to Equation 2 or Equation 3 below. This step (Equation 1) is opposite to the last step of HOR and is also rate-determining because the metal surface does not strongly interact with the hydroxide anions required to complete this reaction and form HO.

[0048] H2O + M + e- MH ad + OH- Reaction 1

[0049] MH ad + H2O + e- M + H2 + OH- Reaction 2

[0050] MHad + MHad 2M + H2 Reaction 3

[0051] To accelerate HER and HOR on catalysts, catalyst materials are provided that contain (i) metal sites that bind to hydrogen and (ii) metal oxide / metal hydroxide sites that bind to hydroxide anions. The interface where the metal and metal oxide meet is highly active for both HER and HOR, and an optimal ratio of metal to metal oxide is maintained to achieve high catalyst activity. If the catalyst surface becomes over-oxidized during long periods of time or high overpotentials (HOR), the catalyst surface may become deactivated and thus the cell performance will be affected.

[0052] Therefore, the anode 114 is a catalytic hydrogen electrode. In some embodiments, as discussed above, the anode 114 includes a porous conductive substrate having a catalyst layer, which covers the porous conductive substrate. The catalyst layer of the anode 114 can cover the outer surface of the porous conductive substrate of the anode 114, and because the porous conductive substrate has internal pores or interconnected channels, it can also cover the surface of these pores and channels. The catalyst layer includes a bifunctional catalyst for catalyzing both HER and HOR at the anode 104. In some embodiments, the porosity of the porous conductive substrate of the anode 114 can be at least about 10%, at least about 20%, at least about 30%, at least about 40%, or at least about 50%, and up to about 80%, up to about 90%, up to about 95% or more. In some embodiments, the porous conductive substrate of the anode 114 can be a metal foam, such as nickel foam, copper foam, iron foam, steel foam, aluminum foam, etc. In some embodiments, the porous conductive substrate of the anode 114 can be a metal alloy foam, such as nickel molybdenum foam, nickel copper foam, nickel cobalt foam, nickel tungsten foam, nickel silver foam, nickel molybdenum cobalt foam, etc. Other conductive substrates may be used, such as metal foils, metal meshes, and fiber conductive substrates. In some embodiments, the conductive substrate of anode 114 is a carbon-based material, such as carbon fiber paper, carbon cloth, carbon felt, carbon mat, carbon nanotube film, graphite foil, graphite foam, graphite mat, graphene foil, graphene fiber, graphene film, and graphene foam.

[0053] In some embodiments, the bifunctional catalyst of the catalyst layer of the anode 114 can be a nickel-molybdenum-cobalt (NiMoCo) alloy. The present disclosure encompasses other transition metals or metal alloys as bifunctional catalysts, such as nickel, nickel-molybdenum, nickel-tungsten, nickel-tungsten-cobalt, nickel-carbon, and nickel-chromium-based composites. In some embodiments, the bifunctional catalyst is a transition metal alloy that includes two or more of Ni, Co, Cr, Mo, Fe, Mn, and W. The present disclosure encompasses other precious metals and their alloys as bifunctional catalysts, such as platinum, palladium, iridium, gold, rhodium, ruthenium, rhenium, osmium, silver, and alloys thereof with precious metals and non-precious transition metals (e.g., platinum, palladium, iridium, gold, rhodium, ruthenium, rhenium, osmium, silver, nickel, cobalt, manganese, iron, molybdenum, tungsten, chromium, etc.). In some embodiments, the bifunctional catalyst is a combination of HER and HOR catalysts. In some aspects, the bifunctional catalyst of the metal hydrogen battery 100 includes a mixture of different materials (e.g., transition metals and their oxides / hydroxides), which overall contribute to hydrogen evolution and oxidation reactions. In some embodiments, the catalyst layer of the anode 114 includes nanostructures of a bifunctional catalyst having a size (or average size) ranging, for example, from about 1 nm to about 100 nm, from about 1 nm to about 80 nm, or from about 1 nm to about 50 nm. In some embodiments, the catalyst layer includes microstructures of a bifunctional catalyst having a size (or average size) ranging, for example, from about 100 nm to about 500 nm, from about 500 nm to about 1000 nm.

[0054] In some embodiments, in order to generate different affinities with respect to the electrolyte (e.g., electrolyte 126) on the anode 114, the catalyst layer may be partially coated with a surface affinity modifying material. For example, when the catalyst layer of the anode 114 on the porous substrate of the anode 114 is hydrophilic to the electrolyte, the catalyst layer of the anode 114 may be partially or fully coated with a material having hydrophobicity to the electrolyte. Conversely, when the catalyst layer of the anode 114 on the porous substrate of the anode 114 is hydrophobic to the electrolyte, the catalyst layer of the anode 114 may be partially or fully coated with a material having hydrophilicity to the electrolyte. This structure may facilitate the movement of hydrogen in the pores of the anode 114 and improve the HOR during discharge.

[0055] The cathode 112 may include a conductive substrate and a coating covering the conductive substrate. The coating may include a redox reaction material, which includes a transition metal. In some embodiments, the conductive substrate of the cathode 112 is porous, such as having a porosity of at least about 10%, at least about 20%, at least about 30%, at least about 40%, or at least about 50% and up to about 80%, up to about 90% or more. In some embodiments, the conductive substrate of the cathode 112 may be a metal foam (such as nickel foam) or a metal alloy foam. The present disclosure encompasses other conductive substrates, such as metal foils, metal meshes, and fiber conductive substrates. In some embodiments, the transition metal included in the redox reaction material is nickel. In some embodiments, nickel is included as nickel hydroxide or nickel oxyhydroxide. In some embodiments, the transition metal included in the redox reaction material is cobalt. In some embodiments, cobalt is included as cobalt oxide or cobalt zinc oxide. In some embodiments, the transition metal included in the redox reaction material is manganese. In some embodiments, manganese is included as manganese oxide or doped manganese oxide (e.g., doped with nickel, copper, bismuth, yttrium, cobalt or other transition or post-transition metals). The present disclosure contemplates other transition metals, such as silver. In some embodiments, cathode 112 is a cathode and anode 114 is an anode. In some embodiments, the size (or average size) of the coating microstructure of the redox reactive material can be in a range of, for example, about 1 μm to about 100 μm, about 1 μm to about 50 μm, or about 1 μm to about 10 μm.

[0056] In some embodiments, the electrolyte 126 is an aqueous electrolyte. The aqueous electrolyte is alkaline and has a pH greater than 7, such as about 7.5 or greater, about 8 or greater, about 8.5 or greater, or about 9 or greater, or about 11 or greater, or about 13 or greater. As non-limiting examples, the electrolyte 126 may include KOH or NaOH or LiOH or a mixture of LiOH, NaOH and / or KOH.

[0057] Although hydrogen oxidation catalysts such as cheap transition metals are suitable for metal hydrogen cells, they may be passivated during long HORs, and this may seriously hinder their use in practical devices. According to some embodiments of the present disclosure, the catalyst of the anode 114 may be a bifunctional TMA (transition metal alloy). In some embodiments, a combination of Ni, Co, Cr, Mo, Fe, and W may be used as a substitute for the bifunctional TMA catalyst. For example, a catalyst composed of Ni and decorated with CrOx particles on the surface may be used. A small amount of Pt may be added to further increase the activity. One such TMA catalyst is described in U.S. patent application 16 / 373,247, the entire contents of which are incorporated herein by reference.

[0058] Furthermore, each of cathode 112 and anode 114 may include multiple material layers as described above. One example of a multi-layer structure anode 114 is provided in US Provisional Application 63 / 214,514, the entire contents of which are incorporated herein by reference.

[0059] Figure 2A , Figure 2B , Figure 2C and Figure 2D Further shown is an electrode stack assembly 104 according to some embodiments. According to some aspects of the present disclosure, each of the cathode 112, the anode 114, and the separator 110 is substantially planar, having approximately the same planar surface area. As further discussed below, each of the cathode 112, the anode 114, and the separator 110 can be made from a sheet of material of a suitable material as discussed above, and cut appropriately to form the electrode stack assembly 104 as discussed here and further below. Figure 2A and Figure 2B A top view and a side view are shown, respectively, of the electrode stack assembly 104. In this reference, "top" refers to a view toward the planar side of the cathode 112, anode 114, and separator 110, and "side" refers to a view into (i.e., along) the planar side of the cathode 112, anode 114, and separator 110, which is perpendicular to the top view. Figure 2C is an anode end view, where each of the anodes 114 is connected, and Figure 2D is a cathode end view, where each of the cathodes 112 are connected.

[0060] like Figure 2A As shown in the top view shown, the electrode stack assembly 104 can be contained within a frame 106. The frame 106 can be a metal structure that allows the electrolyte 126 to flow into the layered electrode stack 104. As shown, and visible through this embodiment of the frame 106, the separator 110 can be a top layer (and bottom layer) to electrically insulate whichever first electrode is below the top separator 110 in the electrode stack 104. However, in some embodiments, the anode layer 114 can form the top and bottom layers of the electrode stack assembly 104. In some embodiments, the frame 106 can include a solid plate above the separator 110 or the anode layer 114 in the stack. As shown in FIG. Figure 2A As further shown, according to some aspects of the present disclosure, Figure 1Each of the separators 110 shown may include one or more wick tabs 202. When the electrode stack assembly 104 is placed in the pressure vessel 102, the wick tabs 202 may extend to contact the inside surface of the pressure vessel 102. The length of the wick tabs 202 may be sufficient to allow the electrolyte 126 to be wicked from the inside surface of the pressure vessel 102 into the electrode stack assembly 104, which allows the electrolyte 126 to circulate. It should be noted that the "bottom" view of the electrode stack 104 is similar to the bottom view of the electrode stack 104. Figure 2A The top views shown appear identical.

[0061] Figure 2B A side view of an electrode stack assembly 104 is shown, in accordance with some aspects of the present disclosure. Figure 2B Layers of anodes 114 and cathodes 112 are shown separated by separators 110. In some embodiments, each of cathodes 112 can be bagged (i.e., enclosed within a bag) with an insulating material to provide further insulation between the electrode layers. As shown, each of separators 110 includes at least one wicking sheet 202. Although three wicking sheets 202 are shown for each of separators 110 and for each side of stack 104 in this example, any number of wicking sheets 202 can be included.

[0062] like Figure 2B As further shown, the frame 106 includes a top 220 and a bottom 222 connected by side supports 206. Figure 2A As shown, top 220 and bottom 222 cover insulating separator 110 on the top and bottom of electrode stack assembly 104, respectively. As further shown, each of cathodes 112 is electrically connected to conductor 118, while each of anodes 114 is electrically connected to conductor 116.

[0063] like Figure 2B As further shown, the top 220 and the bottom 222 are structurally connected to the side supports 206. There can be any number of side supports (also referred to as fingers) 206 on each side. For example, the side supports 206 can be welded to secure the top 220 and the bottom 222, thereby securing the stacked electrodes of the electrode stack assembly 104 within the fixed frame 106. As discussed in further detail below, the electrode stack can be formed between the bottom 222 and the top 220, pressure is applied to the stack, and the side supports 206 are welded to the top 220 and the bottom 222 to form the frame 106 while the pressure is applied. As discussed further below, in some embodiments, the top 220 and the bottom 222 can be formed separately, and the side supports are used to secure the top 220 relative to the bottom 222.

[0064] Figure 2C FIG. 2 shows an end view of the anode conductor 116 according to some embodiments. Figure 2C As shown, the anode conductor 116 can be formed by connecting tabs that are attached to each of the anodes 114 through slots 224 of an anode feedthrough bridge 226. As discussed further below, the tabs can be attached to the anode feedthrough bridge 226, for example, by mechanical fasteners, crimping, resistance welding, arc welding, ultrasonic welding, laser welding, brazing, soldering, or other conductive bonding methods. Figure 2C As further shown, the terminal 120 can be attached to the anode feedthrough bridge 226, for example, by mechanical fasteners, crimping, resistance welding, arc welding, ultrasonic welding, laser welding, brazing, soldering, or other conductive bonding methods. In some embodiments, the terminal 120 can be formed as a single piece with the feedthrough bridge 226. Once the tab is attached through the slot 224 of the feedthrough bridge 226, the anode conductor 116 is formed.

[0065] Similarly, Figure 2D The cathode conductor 118 is shown. The cathode conductor 118 can be formed by connecting the tabs attached to each of the cathodes 112 to the cathode feedthrough bridge 228 via the slot 230, such as by mechanical fasteners, crimping, resistance welding, arc welding, ultrasonic welding, laser welding, brazing, soldering, or other conductive bonding methods. In some embodiments, the terminal 124 can also be attached to the cathode feedthrough bridge 228 by mechanical fasteners, crimping, resistance welding, arc welding, ultrasonic welding, laser welding, brazing, welding, or other conductive bonding methods. In some embodiments, the terminal 124 can be formed as a single piece with the cathode feedthrough bridge 228. Once the tabs are inserted into the slots 230 and attached in place, the cathode conductor 118 is formed.

[0066] Figures 3A to 3G 1 shows aspects of an electrode stack assembly 104 according to some aspects of the present disclosure. Figure 3A As shown, the electrode stack assembly 104 includes an electrode stack 302 that is electrically coupled to the cathode feedthrough bridge 228 and the anode feedthrough bridge 226. Figure 3A As shown, the electrode stack 302 includes cathode tabs 312, each cathode tab 312 is connected to a separate cathode 112, and the cathode tabs 312 are connected to the cathode feedthrough bridge 228 through the slots 230 to form the cathode conductor 118. In some embodiments, a plurality of cathode tabs 312 are inserted into one of the slots 320, bent 90 degrees, and resistance welded to the cathode feedthrough bridge 228. In some embodiments, a plurality of tabs 312 (e.g., a group of four tabs 312) can be inserted into each slot 230 of the cathode feedthrough bridge 228.

[0067] Similarly, the electrode stack 302 includes anode tabs 314, each connected to a separate anode 112, which are connected to the anode feedthrough bridge 226 through the slots 224 to form the anode conductor 116. In some embodiments, the anode tab 314 is inserted into one of the slots 224 of the anode feedthrough bridge 226, bent 90 degrees, and resistance welded to the anode feedthrough bridge 306 to form the anode conductor 116. In some embodiments, multiple tabs 314 (e.g., groups of three (3) tabs 314 in some embodiments) can be inserted into the slots 224 to form the anode conductor 116.

[0068] like Figure 3A As further shown, the cathode feed-through conductor 124 is soldered to the cathode feed-through bridge 228. Additionally, the anode feed-through conductor 120 is soldered to the anode feed-through bridge 226.

[0069] like Figure 3A As further shown, the separator 304 is located between the electrode stack 302 and the cathode feedthrough bridge 228. Figure 3A As shown, the separator 304 includes a connector 318, which can be mated with the connector 316 of the electrode stack 302. Similarly, the separator 306 is located between the electrode stack 302 and the anode feedthrough bridge 226. The separator 306 also includes a connector 316, which can be mated with the connector 316 of the electrode stack 302.

[0070] like Figure 3A As further shown, separator shields 308 and 310 may be mounted to the support 206 proximate the cathode conductor 118. The separator shields 308 and 310 protect the stack 104 during the welding process of forming the pressure vessel 102 (eg, when the pressure vessel 102 is welded shut).

[0071] Figure 3B The assembly of the electrode stack 302 is shown. Figure 3B As shown, the side support 206 can be fixed to the bottom 222 of the frame 204. The cathode assembly 322, the separator 110 and the anode assembly 320 can be appropriately stacked to form a stacked electrode. As shown, the anode assembly 320 is positioned directly adjacent to the top 220 and the bottom 222 of the frame 106. The cathode assembly 322 can include a cathode bagged with a separator material. The top 220 is located at the top of the stacked electrode. In some embodiments, the stacked electrode can be formed in a fixture that uses the alignment features of the bottom 222, the separator 110, the anode assembly 320 and the cathode assembly 322 to align the components. Pressure can then be applied to the stacked components and the side support welded to the top 220 to form an electrode stack 302.

[0072] Figure 3CA top plan view of an electrode stack 302 according to some embodiments is shown. As shown, for example, some of the wicking sheets 202 include alignment holes 326 that can assist in positioning. In addition, the top 220 and bottom 222 can each include alignment features 328 and 330, respectively, to help align during formation.

[0073] Figure 3D Further shown is an end view of electrode stack 302 . Figure 3D The connector 316 and the wicking sheet 202 of the separator 110 are further shown.

[0074] Figure 3E A side view of the electrode stack 302 is shown. The frame 204 is assembled so that the support 206 is welded to the top 220 and the bottom 222. In addition, the tabs 312 and 314 are shown. A connector 316 is also shown. As shown, once assembled, the electrode stack 302 has a thickness of Tes. In some specific embodiments, for example, Tes can be about 71 mm.

[0075] Figure 3F and Figure 3G Shows the use of FIG. 3A to FIG. 3E The electrode stack assembly 104 of the electrode stack 302 shown in FIG. Figure 3F As shown, the tab 312 is connected to the feedthrough bridge 228 to which the cathode feedthrough 124 is already connected. As discussed above, the combination of the tab 312 and the feedthrough bridge 228 forms the cathode conductor 118. Figure 3F Further shown is a separator shield 310 attached to the support 206 closest to the cathode conductor 118 .

[0076] Figure 3G Further shown are separator shields 308 and 310 , feedthrough bridge 228 , and cathode feedthrough 124 . Figure 3G A connector 318 is further shown.

[0077] Figure 4A , Figure 4B and Figure 4C A separator bag 404 is shown as part of the cathode assembly 322 according to some embodiments. Figure 4A and Figure 4B An example separator component 402 is shown, which Figure 4C 4. The separator member 402 may be cut from a sheet of separator material. Figure 4A and Figure 4B As shown, the separator member 402 may have L sc Length, W sc Width, and T sc Thickness.

[0078] like Figure 4A As further shown, notches 406 and 408 are shown at each corner of the divider member 402. As shown, the notches 406 and 408 can be spaced from the width W sc The edge of the sc As further shown in the figure, the notch 408 can be arranged so that the depth of the corner area of ​​the notch 408 is L sc 1. In addition, the notch 406 may have L sc 2. The depth can be different to provide alignment and orientation.

[0079] In the specific example of component 402, the dimensions may be as follows: L sc =244.0mm; W sc =75.0mm; T sc =.25mm; L sc 1=8.5mm; L sc 2 = 9.5 mm; and θ sc =45 o In addition, the separator component 402 is formed of a separator material, as discussed above. This particular example is not intended to be limiting, but merely provides a particular example of the separator component 402. The separator component 402 can be formed to have any dimensions consistent with other components of the electrode stack assembly 104.

[0080] Figure 4C Shows the use of Figure 4A and Figure 4B The two parts 402 shown are used to form a bag 410. Figure 4C As shown, bag 410 includes sealed end 414 and open end 412. Specifically, except for open end 412, bag 410 can be formed by attaching edges of two parts 402, such as heat welding parts 402 together, to form bag 410, as discussed below, into which the cathode assembly can be inserted.

[0081] Figure 4D and Figure 4E 1 shows a separator 110 according to some embodiments. Figure 4D and Figure 4E As shown, the separator 110 has a body 428 and a wicking sheet 202. The body 428 has a s Width, L s The length of T s As further shown in the figure, the body 428 has notches 418 and 420, which are located on opposite sides of the length of the body 428. As shown in the figure, the notches 418 and 420 are formed by cutting the body 428 from the width side by α sThe cutting depth of the notch 418 is L s 1, and the cutting depth of the notch 420 is L s 2. As discussed above, the depth L s 1 and L s 2 may be different to aid alignment during assembly of the electrode stack assembly 104.

[0082] like Figure 4D As further shown, the wicking sheet 202 extends from the body 428. The wicking sheet can take any shape and can be Figure 4D In the illustrated embodiment, the wicking sheets are symmetrically positioned along the length centerline 422 and the width centerline 424. The wicking sheets 202 may include angled sheets 430 and 432 and a straight sheet 434. The angled sheet 430 is angled with the end having the notch 420, while the angled sheet 432 is angled with the end having the notch 418. The straight sheet 434 is positioned along the centerline 424. Some of the wicking sheets 202 may include alignment holes 426. Figure 4D In the example shown, one of the inclined pieces 430 and one of the straight pieces 434 (both located on the same side of the body 428) include an alignment hole 426. The alignment hole 426 in this example is located at a distance W from the centerline 422. s 1, and separated by a distance L on the wicking sheets 430 and 434. s 3. In some embodiments, the alignment hole 426 may have a diameter D s .

[0083] In the specific example of a separator 110, the dimensions discussed above may be given by: L s =244.0mm; W s =75.0mm; T s =0.25mm; L s 1=9.5mm; L s 2=8.5mm; L s 3 = 59.8 mm; W s 1 = 46.5 mm; and α s =45 o Additionally, the separator 110 is formed of a separator material, as discussed above. This particular example is not intended to be limiting, but merely provides a particular example of the separator 110. The separator 110 may be formed to have any dimensions consistent with the other components of the electrode stack assembly 104.

[0084] FIG. 5A to FIG. 5E Shows Figure 3B The anode assembly 320 is shown. Figure 5A As shown, the anode assembly 320 includes the anode 114 and the anode tab 314. Figure 5B(which is a cross-sectional view of anode assembly 320), it is shown that anode 114 may include multiple layers, of which layers 508, 510, and 512 are shown. Layers 508, 510, and 512 may be formed from a sheet of anode material. Anode tab 314 may be formed from a conductor (e.g., nickel), although other conductive materials may be used. Anode tab 314 may include body 506 and tabs 502 and 504. Although two tabs (tabs 502 and 504) are shown, any number of tabs may be present. Figure 5B As shown, the anode tab 314 is attached to the stacked anode layers 508, 510, and 512, for example by compressing the body 506 with the anode layers 508, 510, and 512 and then welding the anode tab 314 to the body 506. The anode layers 508, 510, and 512 may be arranged to enhance the flow of the electrolyte 126. For example, the anode 510 may be corrugated to facilitate the flow of the electrolyte 126.

[0085] Figure 5C , Figure 5D and Figure 5E A specific example of an anode assembly 320 is shown. Figure 5C and Figure 5D As shown, the anode assembly 320 has L A 1. The length of the anode 114 is L A 2. As further shown in the figure, the total width of the anode assembly 320 is W A 2. As Figure 5D As further shown, the anode assembly 320 may include notches 514 and 516, wherein the notch 514 is located on the edge of the anode 114 where the anode tab 314 is located, and the notch 516 is located on the opposite edge of the anode 114. As shown, the angle between the edges of the anode 114 is θ A As further shown, the notches 514 and 516 form an angle α with the edge of the anode 114. A .like Figure 5D As shown, the notch 516 leaves a width W at the edge of the anode 114. A 1.

[0086] Figure 5E Shows Figure 5D FIG. 1 is an enlarged view of portion A shown in FIG. 1 , which includes the anode tab 314 attached to the anode 114. Figure 5E As shown, the body 506 of the anode tab 314 is shaped to match the notch 514, so that the same edge as the notch 514 has a A Therefore, the body 506 has an angle L along the anode 114. A 3. Therefore, the notch 514 has a length L along the anode 114. A 4 in length.

[0087] like Figure 5E As further shown, anode tab 314 includes tabs 502 and 504, which are symmetrically positioned about centerline 518. Specifically, the inner edge of tab 504 is a distance W from centerline 518. A 4, and the distance from the outer edge to the center line 518 is W A 3. As shown in relation to the pole ear 502, the edge of the pole ear 502 is β A 1, and the angle between the edge of the tab 502 and the main body 506 is β A 2. The edges of the tabs 502 and 504 are cut to form a radius R A 1 rounded edges.

[0088] In a particular exemplary embodiment of anode assembly 320, the dimensions may be given by: L A 1 = 252.5 mm; L A 2 = 240.0 mm; L A 3=2.5mm; L A 4=7.1mm; L A 5=12.5mm; W A 1=60.0mm; W A 2=70.0mm; W A 3 = 27.9 mm; W A 4=9.9mm; T A 1=1.8mm;θ A =90 o ; α A =45 o β A 1=90 o ; and β A 2=90 o . In addition, the anode assembly 320 is formed of anode layers 508, 510 and 512 (which are formed of anode material, as discussed above) and anode tab 314 (which is formed of a conductive material (e.g., nickel)). This particular example is not intended to be limiting, but merely provides a particular example of the anode assembly 320. The anode assembly 320 can be formed to have any dimensions consistent with the other components of the electrode stack assembly 104. After forming the anode assembly 320, further processing can include anode coating, drying, and sintering to finally complete the anode assembly 320. In addition, the anode assembly 320 can include any number of anode material layers.

[0089] 6A to 6H An example of a cathode assembly 322 is shown. Fig. 6A A plan view of cathode assembly 322 is shown. Fig. 6AAs shown, cathode assembly 322 includes cathode 112 inserted in separator bag 410, as described above with respect to FIG. 4A to FIG. 4C discussed. Figure 6B A cross-sectional view of an example cathode assembly 322 is shown. Figure 6B In the example shown, cathode 112 is formed of two cathode components 602. Cathode components 602 are inserted into separator pockets 410.

[0090] Figure 6C , Fig.6D and Fig. 6E Shows Figure 6B An example of a cathode assembly 602 is shown. Figure 6C and Fig.6D As shown, cathode assembly 602 includes cathode portion 606 and tab portion 604. As discussed above, cathode portion 606 can be formed by cutting from a cathode sheet. In some embodiments, the cathode sheet can include tab material. In this case, when cathode portion 606 is cut, tab portion 604 can also be cut from the cathode sheet. Figure 6C and Fig.6D As further shown, cathode component 602 may have an overall length L C 1 and the total width W C 1. The cathode portion 606 may have a thickness T C As discussed above, the tab portion 604 may be formed of a conductive material (eg, nickel).

[0091] like Fig.6D As shown, the length of cathode portion 606 may be L C 2. As shown, a notch 616 is formed in the cathode portion 606 adjacent to where the tab portion 604 is attached, while a notch 614 is formed on the opposite side of the cathode portion 606. Fig.6D and Fig. 6E In the example shown, the notch 614 forms an α C The edge of the cathode portion 606 forms an angle θ C .like Fig.6D As shown, the notch 614 is cut so that the width of the edge of the cathode portion 606 opposite to the tab portion 604 is W C 2 gives, remove width W from this edge C 3.

[0092] Fig. 6E Shows Fig.6D The area marked as area A in Fig.6D and Fig. 6EAs shown, the tab portion 604 includes a tab 608 and a tab body 610. The tab body 610 is attached to the cathode portion 606 and has a notch to fit the notch 616. In some embodiments, the tab body 610 can be attached to the cathode portion 606, for example, by welding. As discussed above, in some embodiments, the tab 608 and the tab body 610 can be included in the cathode sheet from which the cathode 602 is cut, in which case the cathode portion 606 and the tab body 610 are already attached. Fig. 6E As shown, the depth of the notch 616 is L C 3, and the length of the notch body 610 attached to the cathode portion 606 is L C 4. As Fig. 6E As shown, the tab 608 extends from the edge of the tab body 610 so that the outer edge of the tab is a distance W from the center line 612. C 5, the center line 612 is delayed by the length of the cathode component 602. The distance between the inner edge of the tab body 610 and the center line 612 is W C 4. As Fig. 6E As shown, the edge of the pole ear 608 forms an angle β on the inner edge. C 1, and forms an angle β on the outer edge C 2. The corners on the tab 608 may be rounded to have a radius R C .

[0093] FIG. 6F to FIG. 6G A cathode assembly 322 is shown, which is formed by a separator bag 410 and two cathode components 602. Fig. 6F and Figure 6G As shown, two cathode components 602 are stacked so that tabs 608 are arranged on either side of cathode assembly 322 and attached to form cathode tab 312. This is arranged by rotating one of the two cathode components 602 about a central axis 612 and stacking it directly on the other of the cathode components 602. Fig. 6F A cross-sectional view of the separator bag 410 over the anode 112 and cathode tab 312 is shown.

[0094] Figure 6G 3 shows a plan view of an assembled cathode assembly 322. As shown, the cathode 112 having the cathode tab 312 is inserted into the separator bag 410. Figure 6G As shown, the thickness of the weld along the perimeter of the separator bag 410 is determined by d C In addition, the notch 616 of the cathode component 602 and the notch 406 of the separator bag 410 can be aligned. Similarly, the notch 614 of the cathode component 602 is aligned with the notch 408 of the separator bag 410. As shown in the figure, the distance between the edge of the separator bag 410 and the center of the notch 614 of the cathode component 602 is L C6 is given. In addition, the angle α C and Figure 4A The angle θ shown sc The resulting total width of cathode assembly 322 is W sc , that is, the width of the separator bag 410.

[0095] Figure 6H Shows Figure 6G A magnified view of area A shown in FIG. Figure 6H As shown, the tab 608 extends from the body 610 by a distance L C 7. The spacing between the cathode component 602 and the edge of the separator bag 410 is determined by W C 6. The separator pocket 410 may extend a distance L from the edge of the body 610. C 8.

[0096] In the specific example of cathode assembly 322, L C 1=252.5mm; L C 2 = 240.0 mm; L C 3=6.1mm; L C 4=2.5mm; L C 5=254.5mm; L C 6=3.0mm; L C 7=12.5mm; L C 8=2.0mm; W C 1=68.0mm; W C 2 = 62.0 mm; W C 3=3.0mm; W C 4=9.9mm; W C 5=27.9mm; W C 6=3.5mm; T C =0.51mm; R C =1.0mm; d C =1.0mm; α C =45 o θ c =90 o β C 1=90 o ; and β C 2=90 o As discussed above, cathode assembly 322 is formed from bag 410 and cathode component 602 as described above. This particular example is not intended to be limiting, but merely provides a particular example of cathode assembly 322. Cathode assembly 322 may be formed to have any dimensions consistent with the other components of electrode stack assembly 104.

[0097] also, 6A to 6HThe example of cathode 112 shown is exemplary only, and cathode 112 including tab 312 may be formed in other ways. 6A to 6H A cathode 112 having two cathode portions 602 is shown, but any number of cathode portions 602 may be stacked to form the cathode 112. Additionally, any number of tabs 312 may be formed within the cathode 112.

[0098] 7A to 7J An example of a framework 106 is shown in accordance with some embodiments of the present disclosure. 7A to 7E An upper portion 220 of the frame 106 is shown. FIG. 7F to FIG. 7J A lower portion 222 of the frame 106 is shown. Fig. 7A A plan view from the top of the upper portion 220 is shown, showing the top plate 706. As shown, the upper portion 220 has L F The length of 1 and W F 1. Fig. 7A As further shown, each corner of the top surface 706 of the upper portion 220 can be cut out to have a notch 716. Fig. 7A As shown, a centerline 702 along the length of the top plate 706 and a centerline 704 along the width of the top plate 706 may be defined.

[0099] Figure 7B An edge view along the length of upper portion 220 (ie, into centerline 702 ) is shown. Line 718 is perpendicular to centerlines 704 and 702 . Figure 7B The thickness of the material forming the upper portion 220 is shown to be T F 1. In addition, the upper portion 220 includes a lip 708 on each side, which is formed by a radius R F 1 is bent from the plane of the plate 706. The lip 708 forms an angle θ with the plane of the plate 706 F 1. Lip 708 has L from the plane of plate 706 F 2 in length. In addition, Figure 7B A connector 316 is shown including a portion 712 that is bent in a direction opposite to the direction in which the lip 712 is bent.

[0100] Figure 7C A side view (ie, along centerline 704 ) of upper portion 220 is shown. Figure 7C Lip 708 is shown, and a cross-section of connector 316 is also shown, further showing connector tab 710 and portion 712 .

[0101] Fig.7D Shows Fig. 7A This is an enlarged view of the area marked A in FIG. This shows a detailed example of the connector tab 710. Fig.7DIn the example shown, the connector tab 710 includes a barb 716. As shown, the connector tab 710 has a surface substantially parallel to the plane of 706 and has a length L F 3. The barbs 716 are spaced apart along the length of the connector tab 710. The first barb is spaced apart from the portion 712 by a distance L. F 4. In one example, the barb 716 is characterized by an inner width W from the centerline 702. F 2 and outer width W F 2. The tip of the barb 716 may have an R F 2. In some embodiments, the barbs 716 can have a downward orientation.

[0102] Fig. 7E Shows Figure 7B An enlarged view of area B is shown. Figure 7B An edge view of the connector tab 710 is shown and a portion 712 is shown. As shown, the portion 712 may have an L F 5. As further shown, two inserts 714 are formed on either side of the tab 710. The inserts 714 may be characterized by a radius R F 3. The circular hole with radius R F 4Transition to the straight section.

[0103] FIG. 7F to FIG. 7J Shown is the bottom portion 222. The bottom portion 222 includes the plate 706, lip 708, notch 716, and connector 316 as described above with respect to the top portion 220, and additionally has the side supports 206 added. Figure 7F A plan view of the bottom portion 222 is shown with the side supports 206 attached to the lip 708 as shown. Figure 7G An edge view of the bottom 222 is shown. Figure 7G As shown, the side support 206 is attached to the lip 708 (eg, by welding) such that the side support 206 forms an angle θ with the plate 706. F 2.

[0104] Figure 7H and Fig.7I An example of a side support 206 is shown according to some embodiments. Figure 7H and Fig.7I As shown, the side support member 206 is of length L F 6. Width W F 4 and thickness T F 2 boards. Fig.7I As further shown, the corners may be rounded to have an R F A radius of 5.

[0105] Figure 7JThe attachment of the side support 206 to the lip 708 is shown, as discussed above. As shown, the side support 206 is located on the lip 708 at a distance L from the plate 706. F 9, and forms an angle θ with the edge of the lip 708 F 3, which edge is parallel to the plane of the plate 706. As further shown, the side supports 206 are symmetrically positioned about the line 718 and are at a length L from the line 718. F 7 and L F 8. As further shown, the side support 206 is welded to the lip 708 at the weld point 722.

[0106] In the specific example of frame 106, L F 1=241.2mm; L F 2 = 12.5 mm; L F 3=6.5mm; L F 4=1.5mm; L F 5=6.5mm; L F 6=58.0mm; L F 7=99.2mm; L F 8=33.0mm; L F 9=6.5mm; W F 1=83.0mm; W F 2=2.0mm; W F 3=3.0mm; W F 4=10.0mm; T F 1=1.5mm; R F 2 = 1.5 mm; R F 1=5.0mm; R F 2=0.2mm; R F 3 = 1.5 mm; R F 4=1.0mm; R F 5=2.0mm;θ F 1=90 o θ F 2=90 o , and θ F 2=90 o Additionally, the frame 106 is formed of any material (eg, stainless steel). This particular example is not intended to be limiting, but merely provides a particular example of the frame 106. The frame 106 may be formed to have any dimensions consistent with the other components of the electrode stack assembly 104.

[0107] Figure 8 Shows Figure 3B The assembly of the electrode stack 302 is shown. Figure 8As shown in FIG. 8A , the electrode stack 302 is assembled on a fixture 800 that positions each of the cathode assembly 322 , the anode assembly 320 , the separator 110 , the upper portion 220 , and the lower portion 222 relative to each other.

[0108] The fixture 800 includes a base 802 on which the components of the fixture 800 are mounted. These components include a cathode end alignment piece 804 and an anode end alignment piece 806. As shown, the cathode end alignment piece 804 includes a recess 812 that accommodates the tab 312 of the cathode assembly 322. Similarly, the anode end alignment piece 806 includes a recess 814 that accommodates the tab 314. The anode end alignment piece 806 and the cathode end alignment piece 804 are further formed to accommodate the shape of the anode assembly 320 and the cathode assembly 322 as discussed above, and hold them in place. Another alignment piece 808 is included, which is mounted between the cathode end alignment piece 804 and the cathode end alignment piece 806 and includes a recess 816 that accommodates the center wicking piece 202. As an additional feature, a carrier component 810 can be mounted to the base 802 to allow easy transportation of the fixture 800 when loading components.

[0109] like Figure 8 As shown, the components of the electrode stack 302 are assembled by first loading the lower portion 222, then stacking alternating layers of anode assemblies 320 and cathode assemblies 322 to appropriately reach the appropriate number of anodes and cathodes in the stack, with separators 110 placed between each layer. Finally, the top portion 220 is placed on top. The fixture 800 loaded with the electrode stack 302 is then placed in the press and pressure is applied. Once the appropriate pressure is applied and the electrode stack 302 is at a thickness of Tes, as shown in FIG. Figure 3E As shown, the side supports 206 of the lower portion 222 are then engaged and welded to the top portion 220 to secure the electrode stack 302. Once welded, the electrode stack 302 may be removed from the fixture 800.

[0110] Fig. 9A , Fig. 9B and Fig. 9C An isolator 900 is shown, which can be used Figure 3A Isolators 304 and 306 are shown. Fig. 9A The isolator 900 shown in plan view includes a frame 912 surrounding a hole 902. The frame 912 includes an indentation 904 in the frame 912. In addition, the frame 912 includes tabs 906 on two opposing sides formed with connectors 318. The connector 318 is a hole through the frame 912 that is connected to the connector 318 as shown. 7A to 7J The connector 316 on the frame 106 shown is mated. Fig.7DThe barbs 716 shown can engage with the connector 318 so that when positioned, the barbs 716 of the connector 318 hold the isolator 900 in place. Fig. 9A As further shown, the size of the hole 902 is designed to allow the tabs 312 and 314 of the electrode stack 302 to pass through. The size of the groove 904 is designed to accommodate Figure 3A Feedthrough 226 or feedthrough 228 is shown.

[0111] exist Fig. 9A In the particular example of the isolator 900 shown, the isolator 900 has L I The total length of 1 and W I 1. Fig. 9B (which is a cross-sectional view of the isolator 900), the thickness of the isolator 900 is T I 1. The hole 902 may have a length L I 3 and width W I 3. The groove 904 may have a length L I 2 and width W I 2. As Fig. 9C (It is through Fig. 9A As shown in the cross-sectional view along line AA, the groove 904 has a T I 2. In some embodiments, the corners of hole 902 may be rounded to have a radius R I 2, and the groove 904 may have a radius R I 1. As further shown in the figure, the connector 318 can be a width W I 4 is positioned to receive the barb 716 of the connector 316. Fig. 9A Also shown are features 908 and 910 in conjunction with tab 906. Features 908 and 910 assist in insulating electrode stack 302 and are formed to position the fully assembled electrode stack assembly 104 within pressure vessel 102.

[0112] In the specific example of isolator 900, L I 1=106.2mm; L I 2 = 70.0 mm; L I 3=66.0mm; W I 1=74.2mm; W I 2 = 66.4 mm; W I 3 = 62.4 mm; W I 4=4.5mm; T I 1=5.2mm; T I 2=3.5mm; R I 1 = 5.0 mm; and R I2 = 3.0 mm. In addition, separator 900 may be formed of any insulating material, for example, plastic such as UHMW PE may be used. This particular example is not intended to be limiting, but merely provides a particular example of separator 900. Separator 900 may be formed to have any dimensions consistent with other components of electrode stack assembly 104.

[0113] Fig. 10A , Fig. 10B and Fig. 10C An example of a separator shield 1000 is shown, which can be used as Figure 3A The separator shields 308 and 310 are shown. The separator shield 1000 includes a scalloped portion 1002 and a flat portion 1004. The scalloped portion 1002 is folded away from the flat portion 1004 along a fold line 1006. Fig. 10A The flat portion 1004 is shown before being folded along fold line 1006, which may be cut from a single sheet of material before being folded. As shown, the flat portion 1004 has a length L Sh 1 and width W Sh 1. The flat portion 1004 may have a radius R Sh The rounded corner of the fan-shaped portion 1002 is θ Sh The angle 1 extends from the flat portion 1004 to a distance W from the fold line 1006. Sh 2. Then, the sector 1002 extends through the angle θ Sh 2. Fig. 10B A cross section of a separator shield 1000 is shown. Fig. 10B As shown, the thickness of the sheet of material forming the separator shield 1000 is T Sh .

[0114] Fig. 10C The separator shield 1000 is shown after being folded so that the scalloped portion 1002 extends away from the flat portion 1004. Figure 3A As shown, the separator shroud 1000 (either the separator shroud 308 or the separator shroud 310 ) is attached to the side support 206 of the frame 106 closest to the cathode tab 312 , such as by welding.

[0115] In the specific example of the separator shield 1000, L Sh 1=58.0mm; W Sh 1=11.0mm; W Sh 2 = 10.1 mm; T Sh =0.1mm; θ Sh 1=45 o ; and θ Sh 2=130 oIn addition, the separator shield 1000 can be formed from any conductive material (e.g., stainless steel). This particular example is not intended to be limiting, but merely provides a particular example of the separator shield 1000. The separator shield 1000 can be formed to have any dimensions consistent with the other components of the electrode stack assembly 104.

[0116] FIG. 11A to FIG. 11F The anode bridge 226 and the anode feed-through terminal 120 are shown in greater detail, as well as the mounting of the anode feed-through terminal 120 to the anode bridge 226 . Fig.11A and Fig. 11B An example of an anode bridge 226 is shown, and Fig. 11C and Fig.11D An example of an anode feed-through terminal 120 is shown. Fig.11E and Fig.11F The attachment of the anode feed-through terminal 120 to the anode bridge 226 is shown.

[0117] Fig.11A and Fig. 11B For example, the above Figure 2C An example of the anode bridge 226 discussed. Fig.11A As shown, the anode bridge 226 is formed of a metal plate having a slot 224 arranged to receive the tab 314 from the anode assembly 320. Fig.11A and Fig. 11B As shown, the anode bridge 226 has a length L AB 1. Width W AB 1 and thickness T AB 1. In some embodiments, the edges may be tapered so that the anode bridge 226 may better fit into the groove 904 of the separator 900, as shown in FIG. Fig. 9A In addition, the corners of the anode bridge 226 may be bent to have R AB 2. In addition, the opposite end of the anode bridge 226 may include a radius R AB 1. The notch 1102 is arranged along a centerline 1102, which is located in the center and extends along the length of the anode bridge 226. The slots 224 are elongated relative to the width of the anode bridge 226 and are symmetrically arranged relative to the centerline 1104, and are also symmetrically arranged relative to a centerline 1106 that is perpendicular to the centerline 1104. Fig.11A In the particular example shown, seven (7) slots 224 are arranged on each side of the centerline 1104 (a total of fourteen (14) slots are shown). It should be appreciated that any number of slots 224 may be formed on either side of the centerline 1104. The number of slots 224 included in the anode bridge 226 and the location of the slots 224 depend on the structure of the anode assembly 320 and the number of anode assemblies 320 included in the electrode stack 302.

[0118] like Fig.11A As shown, each slot 224 has a width W AB 4 and thickness T AB 2. As Fig.11A As shown, the left edges of the seven slots 224 on the left side of the center line 1104 are spaced a distance W from the left edge of the anode bridge 226. AB 3. The left edge on the right side of the center line 1102 is spaced a distance W from the left edge of the anode bridge 226. AB 2. The bottom edge of the groove 224 is spaced L from the bottom of the anode bridge 226. AB 2. L AB 3. L AB 4. L AB 5. L AB 6. L AB 7 and L AB 8. It should be noted that the terms left, right, top and bottom are used for convenience only.

[0119] Fig. 11C and Fig.11D An example of an anode feed-through terminal 120 is shown. Fig.11D As shown, the anode feed-through terminal 120 may be formed of a metal rod to form a metal rod having a diameter W. AB 5 and length L AB The first part 1110 of 11, the smaller diameter (diameter W AB 6) A second portion 1112, the second portion 1112 extending from the end of the first portion 1110 to a length L AB 11 to length L AB 10. The third portion 1114 extends from the end of the second portion 1112 to a length L AB 10 to length L AB 9. The third portion 1114 has threads, and the thread characteristics are Th AB The centerline 1116 may extend down the center of the feed-through terminal 120 and along the length of the anode feed-through terminal 120 . Fig.11D This is a view along centerline 1116 from portion 1114 .

[0120] Fig.11E and Fig.11F The anode feed-through terminal 120 is shown attached to the anode bridge 226 to form an anode bridge structure 1120. Fig.11E As shown, the anode feed-through terminal 120 is welded to the center of the anode bridge 226 at welding point 1122. Fig.11F As shown, the feed-through terminal 120 is welded to the anode bridge 226 such that the centerline 1116 intersects the intersection of the centerlines 1104 and 1106 of the anode bridge 226 .

[0121] In the specific example of the anode bridge structure 1120, L AB 1=69.6mm; L AB 2 = 64.4 mm; L AB 3 = 54.2 mm; L AB 4=44.0mm; L AB 5=33.8mm; L AB 6=23.6mm; L AB 7=13.4mm; L AB 8=3.2mm; L AB 9=53.0mm; L AB 10=43.0mm; L AB 11=39.0mm; W AB 1=66.0mm; W AB 2 = 41.9 mm; W AB 3=4.10mm; W AB 4=20.0mm; W AB 5=10.0mm; W AB 6=7.0mm; T AB 1=1.6mm; T AB 2=2.0mm;Th AB =M6x1;R AB 1 = 2.5 mm; and R AB 2 = 5.0 mm. In addition, the anode bridge structure 1120 can be formed of any conductive material or combination of conductive materials. For example, the anode bridge 226 can be formed of nickel, and the anode feed-through terminal 120 can be formed of stainless steel coated copper. This particular example is not intended to be limiting, but only provides a particular example of the anode bridge structure 1120. The anode bridge structure 1120 can be formed to have any size consistent with other components of the electrode stack assembly 104.

[0122] FIG. 12A to FIG. 12F The cathode bridge 228 and the cathode feed-through terminal 124 as well as the mounting of the cathode feed-through terminal 124 to the cathode bridge 228 are shown in greater detail. Fig. 12A and Fig. 12B An example of a cathode bridge 228 is shown, while Fig. 12C and Fig.12D An example of a cathode feed-through terminal 124 is shown. Fig.12E and Fig.12F The attachment of the cathode feed-through terminal 124 to the cathode bridge 228 is shown.

[0123] Fig. 12A and Fig. 12B For example, the above Figure 2D An example of the cathode bridge 228 discussed. Fig. 12AAs shown, cathode bridge 228 is formed of a metal plate having a slot 230 arranged to receive a tab 312 from cathode assembly 322. Fig. 12A and Fig. 12B As shown, the cathode bridge 226 has a length L CB 1. Width W CB 1 and thickness T CB 1. In some embodiments, the edges may be tapered so that the cathode bridge 228 may better fit into the groove 904 of the separator 900, as shown in FIG. Fig. 9A In addition, the corner of the cathode bridge 228 may be bent to have R CB 2. In addition, the opposite end of the cathode bridge 228 may include a radius R CB 1. The notch 1202 is arranged along a center line 1202, which is located in the center and extends along the length of the cathode bridge 228. The slots 230 are elongated relative to the width of the cathode bridge 228, and are symmetrically arranged relative to the center line 1204, and are also symmetrically arranged relative to a center line 1206 that is perpendicular to the center line 1204. Fig. 12A In the particular example shown, five (5) slots 230 are arranged on each side of the centerline 1204 (a total of ten (10) slots 230 are shown). It should be appreciated that any number of slots 230 may be formed on either side of the centerline 1204.

[0124] like Fig. 12A As shown, each notch 230 has a width W CB 4 and thickness T CB 2. As Fig. 12A As shown, the left edges of the five slots 230 on the left side of the center line 1204 are spaced a distance W from the left edge of the cathode bridge 228. CB 3. The left edge of the groove 230 on the right side of the center line 1202 is spaced from the left edge of the cathode bridge 228 by a distance W. CB 2. The bottom edge of the groove 230 is spaced L from the bottom of the cathode bridge 228. CB 2. L CB 3. L CB 4. L CB 5 and L CB 6. It should be noted that the terms left, right, top, and bottom are used here for convenience only. It should be noted that the number and position of the slots 230 depend on the configuration of the cathode assembly 322 and the number of cathode assemblies 322 included in the electrode stack 302.

[0125] Fig. 12C and Fig.12D An example of a cathode feed-through terminal 124 is shown. Fig.12D As shown, the cathode feed-through terminal 124 may be formed of a metal rod to form a metal rod having a diameter W. CB5 and length L CB 9 of the first portion 1210, the smaller diameter (diameter W CB 6) A second portion 1212 extending from the end of the first portion 1210 to a length L CB 9 to length L CB 8. The third portion 1214 extends from the end of the second portion 1212 to a length L CB 8 to length L CB 9. The third portion 1214 has threads, and the thread characteristics are Th CB The centerline 1216 may extend down the center of the feed-through terminal 124 and along the length of the cathode feed-through terminal 124 . Fig.12D This is a view along centerline 1216 from portion 1214 .

[0126] Fig.12E and Fig.12F The cathode feed-through terminal 124 is shown attached to the cathode bridge 228 to form a cathode bridge structure 1120. Fig.12E As shown, cathode feed-through terminal 124 is welded to the center of cathode bridge 228 at welding point 1222. Fig.12F As shown, the feed-through terminal 124 is welded to the cathode bridge 228 such that the centerline 1216 intersects the intersection of the centerlines 1204 and 1206 of the cathode 228 .

[0127] In the specific example of cathode bridge structure 1220, L CB 1=69.6mm; L CB 2 = 61.0 mm; L CB 3 = 47.4 mm; L CB 4=33.8mm; L CB 5=20.2mm; L CB 6=6.6mm; L CB 7=86.0mm; L CB 8=76.0mm; L CB 9=72.0mm; W CB 1=66.0mm; W CB 2 = 41.9 mm; W CB 3=4.10mm; W CB 4=20.0mm; W CB 5=10.0mm; W CB 6=7.0mm; T CB 1=1.6mm; T CB 2=2.0mm;Th CB =M6x1;R CB 1 = 2.5 mm; and R CB2 = 5.0 mm. In addition, the cathode bridge structure 1120 can be formed of any conductive material or combination of conductive materials. For example, the cathode bridge 228 can be formed of nickel, and the cathode feed-through terminal 124 can be formed of stainless steel coated copper. This particular example is not intended to be limiting, but only provides a specific example of the anode bridge structure 1120. The cathode bridge structure 1220 can be formed to have any size consistent with other components of the electrode stack assembly 104.

[0128] As shown above, the electrode stack assembly 104 can be Figure 8 The electrode stack 302 shown begins assembly. In one particular example, the electrode stack 302 may include twenty (20) cathode assemblies 322 and twenty-one (21) anode assemblies 320, although other arrangements may be formed. For example, Figure 3A As shown, isolators 304 and 306 (as described above with respect to 9A to 9C 120) is attached to the connector 316 of the frame 106. The tabs 312 are then inserted into the slots 230 in the cathode bridge structure 1220, and the cathode bridge structure 1220 is positioned in the recess 904 of the separator 304. In a specific example, four (4) tabs 312 can be inserted into each slot 230 to reflect the twenty cathode assemblies 322. Similarly, the tabs 314 of the anode assemblies 320 are inserted into the slots 230 of the anode bridge structure 1120, such that three (3) tabs are inserted into each slot 230 to reflect the twenty-one anode assemblies 320 in the electrode stack 302. The separators 308 and 310 can be attached to the electrode stack 302 as described above at any time after the electrode stack 302 is formed.

[0129] Fig.13A and Fig. 13B FIG. 1 shows an assembly of a pressure vessel 102 and a battery 100 according to some embodiments of the present disclosure. Fig.13A In the example shown, the pressure vessel 102 is formed by a cathode end cap 1302, a vessel body 1306, and an anode end cap 1304. As shown, the cathode end cap 1302 is welded to one side of the vessel body 1306 at weld 1308, and the anode end cap 1304 is welded to the opposite side of the vessel body 1306 at weld 1310. The cathode end cap 1302, the vessel body 1306, and the anode end cap 1304 are symmetrically arranged about a central axis extending through the cell 100. In some examples, welds 1308 and 1310 can be formed by, for example, a gas tungsten arc welding (GTAW) technique, although other welds can be formed. Fig.13A As further shown, the resulting length of the battery 100 is LB. In a specific example, LB may be 390.4 mm.

[0130] exist Fig.13AIn the example shown, the fill tube 122 is attached through the anode end cap 1304. The fill tube 122 can be passed through the anode end cap 1304 and welded in place. As further shown, the anode feed-through terminal 120 extends through the anode end cap 1304 along a central axis 1312. A feed-through shoulder 1320 can be inserted onto the anode feed-through terminal 120. As shown, the anode feed-through terminal 120 can be welded to the anode end cap 1304 at a weld 1316. The weld 1316 can also be formed by a GTAW technique.

[0131] like Fig.13A As further shown, cathode feedthrough terminal 124 extends through feedthrough 1314, which is attached to cathode end cap 1302. In some embodiments, feedthrough 1314 is welded to cathode end cap 1302 at weld 1326, which may be formed by GTAW techniques, as discussed above. Feedthrough shoulder 1318 may be placed on cathode feedthrough terminal 124. Fig.13A As shown, the cathode feed-through terminal 124 and the anode feed-through terminal 120 are aligned along the central axis 1312 .

[0132] Fig. 13B 1 shows the assembly of the battery 100 according to some embodiments. As shown, the anode end cap 1304 with the fill tube 122 attached is welded to one end of the container body 1306. As further shown, the feedthrough 1314 includes a metal body 1322 and an insulator 1324. The metal body 1306 is welded to the cathode end cap 1302. Then, the electrode stack assembly 104 can be inserted into the container body 1306 so that the anode feedthrough terminal 120 extends through the anode end cap 1304 and can be welded in place. It should be noted that the features 908 and 910 of the separator 900 are positioned to support the electrode stack assembly 104 within the container body 1306. Once in place, the feedthrough insulator 1324 can be inserted into the feedthrough body 1322 and the cathode feedthrough terminal 124 passes through the feedthrough 1314. The cathode end cap 1302 can then be welded to the container body 1306, and the feedthrough 1314 is sealed to the cathode feedthrough terminal 124. Feedthrough shoulders 1318 and 1320 may then be placed on cathode feedthrough terminal 124 and anode feedthrough terminal 120 , respectively.

[0133] Fig.14A and Fig. 14B A feedthrough shoulder 1400 is shown, which may be used for the feedthrough shoulders 1318 and 1320 discussed above. Fig.14A As shown, the feed-through shoulder 1400 includes a diameter D FS The inner and outer diameters of 2 are D FS 1 of the metal portion 1402. Fig. 14B As shown, the thickness is T FSIn some embodiments, the feedthrough shoulder 1400 may be formed of metal (eg, copper). In a specific example, the dimensions may be given by: D FS 1=20.0mm; D FS 2 = 7.0 mm; and T FS =4.0 mm. In some embodiments, the edge of the feed-through shoulder 1400 may be beveled. Fig.13A and Fig. 13B As shown, the feed-through shoulders 1318 and 1320 can be placed on the cathode feed-through terminal 124 and the anode feed-through terminal 120, as shown above, so that the feed-through shoulder 1318 presses on the portion 1212 of the cathode feed-through terminal 124, and the feed-through shoulder 1320 presses on the portion 1112 of the anode feed-through terminal 120. This particular example is not intended to be limiting, but merely provides a particular example of the feed-through shoulder 1400. The feed-through shoulder 1400 can be formed to have any dimensions consistent with other components of the electrode stack assembly 104.

[0134] Fig.15A and Fig. 15B A fill tube 122 is shown according to some embodiments. Fig.15A and Fig. 15B As shown, the filling tube 122 is of length L T 1. The outer diameter is DT T 1 and inner diameter D T 2. In some embodiments, the fill tube 122 can be formed of stainless steel and can be sized L T 1=55.0mm; D T 1 = 6.4 mm; and D T 2=4.6 mm. This specific example is not intended to be limiting, but merely provides a specific example of a fill tube 122. The fill tube 122 may be formed to have any dimensions consistent with the other components of the electrode stack assembly 104.

[0135] Fig.16A , Fig. 16B , Fig. 16C and Fig.16D 13 shows an embodiment of a feedthrough 1314 according to some aspects of the present disclosure. Fig. 13B As shown, the feedthrough 1314 includes Fig.16A and Fig. 16B The main body 1322 shown and Fig. 16C and Fig.16D The feedthrough 1314 is assembled by mating the insulator 1324 with the body 1322 such that the cathode feedthrough terminal 124 extends through the insulator 1324 and can be sealed to the insulator 1324. The body 1322 can be formed of any material capable of physically attaching and sealing to the cathode end cap 1302, such as a metal.

[0136] like Fig.16A As shown, an example of the body 1322 (whose shape is cylindrical) may have L FT 1. The body 1322 includes a base portion 1604 and a body portion 1606 that are integrated with each other (eg, formed as a single piece or otherwise attached). The base portion 1604 may be FT 5 has W FT 1. Measured from the bottom of the base portion 1604, at a length L FT 3 and L FT 2, the main body 1606 has W FT 2. The outer diameter at the top of the base portion 1204 and the length L FT 4, the main body 1606 has W FT 3. Outer diameter. In length L FT 2 and L FT 1 and L FT 4 and L FT 3, the main body 1606 is at a diameter W FT 2 and W FT The main body 1322 has an internal structure configured to accommodate the insulator 1324.

[0137] Fig. 16B A cross-sectional view of the body 1322 is shown, wherein the body portion 1606 and the base portion 1604 are viewed from the top. As shown, the center portion 1614 forms a hole. The center portion 1614 of the body portion 1606 has an internal thread, which can be a standard thread characterized by TS FT 1. The thread depth is TD FT 1.

[0138] Fig. 16C and Fig.16D An example of an insulator 1324 of a feedthrough 1314 is shown. The insulator 1324 includes a body portion 1612 and a base portion 1610 and may be formed of an insulating material. Fig. 16C As shown, the insulator 1324 has L FT 6 in length, while the base portion 1610 has a length of L FT 7 in length. The insulator 1324 includes a diameter W FT The through hole 1616 of 4 accommodates the cathode feed-through terminal 124. Fig.16D 1 shows a cross section of the insulator 1324. Specifically, W FT 4 is designed to allow the cathode feed-through terminal 124 to pass through with sufficient tightness to form a seal. Fig.16DAs shown in the cross-section, the main body portion 1612 has a characteristic TS FT 2. Specifically, the external threads of the main body portion 1612 engage with the internal threads of the main body portion 1606 so that the insulator 1608 is screwed into the main body 1322. In some embodiments, the internal threads of the main body portion 1606 and the external threads of the insulator 1608 can be pipe threads that provide a seal when they are engaged with each other. In addition, the base portion 1610 can be a total width of W FT 5, where the edges of the sides of the octagon are at a radius of R FT The two ends of the beam are connected by a rounded shape.

[0139] In a specific example of a feedthrough 1314 consistent with the specific examples discussed above, the following dimensions and characteristics may be used: L FT 1=44.0mm; L FT 2 = 39.5 mm; L FT 3 = 10.5 mm; L FT 4=6.0mm; L FT 5=4.0mm; L FT 6=48.0mm; L FT 7=4.0mm; W FT 1=30.0mm; W FT 2 = 20.0 mm; W FT 3 = 19.2 mm; W FT 4=10.0mm; W FT 5=21.0mm;RFT=3.0mm;TS FT 1=G 3 / 8-19; TS FT 2 = G 3 / 8-19; and TD FT 1 = 0.4 mm. The body 11322 can be metallic and consistent with the material of the cathode end cap 1302 (e.g., can be welded to or otherwise attached to the cathode end cap 1302). In some examples, the body 1322 can be stainless steel. The insulator 1324 can be any insulator, such as ultra-high molecular weight polyethylene (UHMW) plastic. During assembly, the insulator 1324 can be screwed into the body 1322 after the body 1322 is welded to the cathode end cap 1302.

[0140] 17A to 17D An example of an anode end cap 1304 according to some embodiments of the present disclosure is shown. Fig.17A As shown, the anode end cap 1304 includes a dome portion 1702 and a straight portion 1704. There is a lip 1706 formed on the straight portion 1704. The total height of the anode end cap 1304 is L AC 1, and the outer diameter of the straight portion 1706 is W AC1. Wall thickness is W AC 2. As Fig. 17B As shown, the diameter is D AC The central hole 1708 of 1 is formed in the center (corresponding to the center line 1312) so that the anode feed-through terminal 120 can pass through. The diameter D AC The filling tube hole 1710 of 2 is formed at a distance W from the center of the center hole 1708. AC At position 3. Fig. 17C The lip 1706 (with an angle θ with the outer wall) is shown. AC The inclined surface reaches W from the outer edge of the straight portion 1704. AC Depth of 4.

[0141] Fig.17D The attachment of the fill tube 122 to the anode end cap 1304 is shown. As shown, the fill tube 122 is inserted into the fill tube hole 1710 so that the end of the fill tube 122 extends from the center hole 1708 into the anode end cap 1304 by a distance L AC 2.

[0142] In the specific example of anode end cap 1304, L AC 1=63.4mm; L AC 2 = 12.7 mm; W AC 1=114.3mm; W AC 2=3.0mm; W AC 3=40.0mm; W AC 4=2.2mm; D AC 1=10.2mm; D AC 2 = 6.7 mm; and θ AC =45 o The anode end cap 1304 may be formed of any material (eg, stainless steel). This particular example is not intended to be limiting, but merely provides a particular example of the anode end cap 1304. The anode end cap 1304 may be formed to have any dimensions consistent with the other components of the electrode stack assembly 104.

[0143] 18A to 18H An example of a cathode end cap 1302 according to some embodiments of the present disclosure is shown. Fig.18A As shown, the cathode end cap 1302 includes a dome portion 1802, a straight portion 1804, and a lip 1806 formed in the straight portion 1804. A flat portion 1808 is formed at the top of the dome portion 1802. Fig.18A As shown, the outer diameter of the cathode end cap 1302 at the straight portion 1804 is W CC 1, and the total height is L CC 1. The wall thickness at the straight portion 1802 is W CC2. As Fig.18A As shown, centerline 1312 extends through flat portion 1808 .

[0144] Fig.18B Shown along Fig.18A 1804 from the straight portion 1804. As shown, a through hole 1810 and a countersunk hole 1812 are formed in the flat portion 1808. The through hole 1810 is formed in the bottom of the flat portion 1808 so that the hole 1810 has a thickness T of 1800 through the bottom of the flat portion 1808. CC 1Inner diameter D CC 1. The countersunk hole 1812 has a diameter D CC 1 and is formed above the through hole 1810. Therefore, the base 1604 of the body 1322 of the feedthrough 1314 is seated in the countersunk hole 1812. It should be noted that in this context, the bottom of the flat portion 1808 refers to the portion of the flat portion 1808 that is located inside the cathode end cap 1302.

[0145] Fig.18C A cross-sectional view of the cathode end cap 1302 along line BB (ie, centerline 1312 ) is shown, and the flat portion 1808 is further shown. Fig.18D Shows Fig.18C FIG. 1 is an enlarged view of the area marked C in FIG. 1 , which further shows the edges of the flat portion 1808 and the dome portion 1802. As shown in the figure, the flat portion 1808 has a depth L in the dome portion 1802. CC 2.

[0146] Fig.18E Shows Fig.18A 1806. Fig.18E In the embodiment, the lip 1806 is formed by the edge of the straight portion 1804 at an angle θ CC Passing length W CC 3 is formed by the inclined surface.

[0147] Fig.18F , Figure 18G and Fig.18H The cathode end cap 1302 is shown assembled with the feed-through body 1322. Fig.18F As shown, the body 1322 of the feedthrough 1314 is welded to the cathode end cap 1302 at weld point 1326 . Figure 18G A cross-section through line AA (centerline 1312) is shown. As shown, body 1322 is inserted into hole 1812 and rests against the lip formed by lower diameter hole 1810 and then welded at weld 1326. As discussed above, weld 1326 may be a GTAW weld. Fig.18HA view from the straight portion 1804 is further shown. Fig.18H Further shown is the body 1322 being seated into the countersunk hole 1812 and resting against the through hole 1810.

[0148] In the specific example of cathode end cap 1302, L CC 1=62.4mm; L CC 2 = 2.4 mm; W CC 1=114.3mm; W CC 2=3.0mm; W CC 3=2.2mm; D CC 1=25.4mm; D CC 2 = 30.5 mm; TCC1 = 0.5 mm; and θ CC =45 o The cathode end cap 1302 may be formed of any material (eg, stainless steel). This particular example is not intended to be limiting, but merely provides a particular example of the cathode end cap 1302. The cathode end cap 1302 may be formed to have any dimensions consistent with the other components of the electrode stack assembly 104.

[0149] FIG. 19A to FIG. 19C An example of a container body 1306 is shown according to some embodiments of the present disclosure. Fig.19A A side view of the container body 1306 is shown, and Fig.19C A cross section of the container body 1306 is shown. Fig.19A and Fig.19C As shown, the container body 1306 has a total length of L V 1. The outer diameter is W V 1. The container body 1306 includes a lip 1902 at each end, which cooperates with similar structures of the anode end cap 1304 and the cathode end cap 1302 to form welds 1308 and 1310, as shown in FIG. Fig.13A shown. Fig.19B Shows Fig.19A FIG. 1 is an enlarged view of region A, which further illustrates lip 1902. Lip 1902 is defined by angle θ V The inclined surface extends into the side wall of the container body 1306 by a distance W. V 3.

[0150] Fig. 20A 200 to 201 show a method 2000 for producing a battery 100 according to some embodiments of the present disclosure. Fig. 20AAs shown, method 2000 begins at step 2002, where all the various components used in the construction and assembly described below are collected. From step 2002, method 2000 proceeds to box 2004, which includes a series of pre-assemblies that can be performed before assembling battery 100. Fig. 20A As shown, the steps in box 2006 indicate steps for producing the electrode stack assembly 302 according to some embodiments of the present disclosure. The remaining steps in method 2000 produce a finished battery 100.

[0151] Pre-assembly steps 2004 may include separator formation 2008, separator bag assembly 2010, cathode electrode assembly 2012, anode electrode assembly 2014, frame formation 2016, electrode shield formation 2018, anode termination / bridge assembly 2020, cathode termination / bridge assembly 2022, anode end cap formation 2024, cathode end cap formation 2026, and electrode preparation 2028. With the exception of separator bag formation 2010 and cathode electrode assembly 212, each of these steps may be performed in parallel and is not dependent on the completion of the other steps. Fig. 20A As shown, the separator 110 produced in the separator forming 2008, the cathode electrode assembly 322 produced in the cathode electrode assembly step 212, the anode electrode assembly 2014 produced in the anode electrode assembly step 2014, and the frame components 220 and 222 formed in the frame component step 2016 are combined together in the electrode stack forming step 2030. In the electrode stack forming 2030, the electrode stack 302 is formed. The electrode shields 308 and 310 formed in the electrode shield forming 2018, the anode bridge structure 1120 formed in the anode termination / bridging step 2020, and the cathode bridge structure 1220 formed in the cathode termination / bridge step 2022 are input to the electrode stack assembly step 2032, wherein the electrode stack assembly 104 is formed.

[0152] The electrode stack assembly 104, the anode end cap 1304 formed in the anode end cap forming step 2024, and the cathode end cap 1302 from the cathode end cap forming step 2026 are input to the cell assembly 2034 (wherein the structure of the cell 104 is formed), including the formation of the pressure vessel 102. In step 2036, the feedthrough 1314 is extruded to form a seal.

[0153] In step 2038, the resulting structure is leak tested. The leak test can be performed by over-pressurizing the formed pressure vessel 102 or by creating a vacuum in the pressure vessel 102. In this step, the pressure test can be performed by pressurizing (or evacuating) the pressure vessel 102 to a specific test pressure and monitoring the pressure over time. If the pressure is maintained for a set period of time, it can be determined that the pressure vessel 102 has passed the test. If the leak test is successful, then in step 2040, electrolyte and hydrogen can be input to charge the battery structure and seal the fill tube 122.

[0154] The resulting battery may then be tested in a battery testing step 2042. The electrical testing in step 2042 may include charging and discharging the resulting battery 100 over several cycles and monitoring the performance of the battery 100.

[0155] Fig. 20B Further shown is a separator forming step 2008. The separator forming step 2008 begins at step 2044, where the separator material is roughly cut into Figure 4D and Figure 4E In some embodiments, in step 2046, further cutting is performed to form the wicking sheet 202, thereby forming the separator 110. Figure 4D As shown, the wicking sheets 202 closest to the ends may be tilted toward the center to prevent damage during a subsequent welding process. As discussed above, a plurality of separators 110 will be used in the electrode stack assembly 104 .

[0156] Fig. 20C Further shown is a separator pocket forming step 2010. The separator forming step 2010 begins at step 2048, wherein the separator pocket forming step 2010 is formed according to the separator pocket forming step 2010. Figure 4A and Figure 4B The separator material is cut to the dimensions shown to form the separator pocket member 402. In step 2050, as shown in FIG. Figure 4C As shown, two divider pocket components 402 are positioned and heat welded on three sides to form a divider pocket 410 .

[0157] Fig.20D It is further shown that the 6A to 6H The cathode assembly 322 shown in FIG. 2012 is formed into a cathode assembly. The cathode assembly 322 is formed into a cathode assembly 2012 ... Figure 6C and Fig.6D In step 2054, the tab portion 604 is attached to the cathode material to form a FIG. 6C to FIG. 6EIn the case of a cathode sheet (from which the cathode components 602 including the cathode portion 606 and the tab body 610 are cut together), step 2054 has been completed. In step 2056, the two cathode components 602 are positioned, such as FIG. 6F to FIG. 6H In step 2058 , the resulting structure is inserted into a separator bag 410 to form a cathode assembly 322 .

[0158] Fig.20E It is further shown that FIG. 5A to FIG. 5E The anode electrode assembly 2014 is shown. The assembly step 2014 begins at step 2060, wherein FIG. 5C to FIG. 5E The anode material is cut according to the size shown. As discussed, the anode assembly 320 may include three anode layers, one of which may be corrugated. In step 2062, the cut anode materials are stacked so that the corrugated layer is the middle layer. In step 2064, the anode tab 314 is aligned with the stacked anode layers formed in step 2062. In step 2066, the anode tab 314 and the anode layers 508, 510 and 512 are attached. During step 2066, the anode layers 508, 510 and 512 may be attached by pressing. The anode tab 314 may then be attached by, for example, welding. In some embodiments, further processing may be performed on the anode assembly 320. Specifically, in step 2068, an anode coating may be applied. In step 2070, the anode assembly 320 may be dried. In step 2072, the resulting structure may be sintered.

[0159] Fig.20F Further shown is frame component preparation 2016. In step 2074 of frame component preparation 2016, the frame component preparation 2016 may be performed according to the 7A to 7J The material sheets are cut to the dimensions shown for the upper portion 220 and the lower portion 222. Figure 7H and Fig.7I The side supports 206 are cut to the dimensions shown. In step 2076, the resulting structure is formed into upper and lower portions 220, 222 by appropriately bending the material, as shown in FIG. 7A to 7J In step 2078, the side supports 206 are attached to the lower portion 220 by, for example, welding.

[0160] Figure 20G An electrode shield forming step 2018 is shown which results in forming an electrode shield 1000 that can be used for electrode shields 308 and 310 as described above. FIG. 10A to FIG. 10C An electrode shield 1000 is shown. Figure 20G As shown, step 2018 begins at step 2080, wherein, according to Fig. 10A and Fig. 10BIn step 2082 , the structure is bent along line 1006 to form electrode shield 1000 .

[0161] Fig. 20H shows the anode terminal / bridge formation 2020, which produces Fig.11E and Fig.11F The anode bridge structure 1120 is shown. The forming step 2020 begins at step 2084, wherein a Fig.11A and Fig. 11B In step 2086, the anode terminal bridge 226 having the structure and dimensions shown is welded, for example. Fig. 11C and Fig.11D Anode feed-through terminal 120 of the size shown is attached to the Fig.11E and Fig.11F The anode terminal bridge 226 is shown to form an anode bridge structure 1120 .

[0162] Fig.20I shows a cathode terminal / bridge formation 2022, which produces Fig.12E and Fig.12F The cathode bridge structure 1220 is shown. The forming step 2022 begins at step 2088, wherein a cathode bridge structure 1220 having a cathode bridge structure 1220 is formed. Fig. 12A and Fig. 12B In step 2090, the cathode terminal bridge 228 having the structure and size shown is welded, for example. Fig. 12C and Fig.12D The cathode feed-through terminal 124 of the size shown is attached to the Fig.12E and Fig.12F The cathode terminal bridge 228 is shown to form a cathode bridge structure 1220 .

[0163] Fig. 20J Further shown is the electrode stack formation 2030, as Figure 8 The electrode stack formation 2030 begins at step 2092 where the lower portion 222 of the frame 106 is placed in the fixture 800. In step 2094, alternating layers of anode assemblies 320 and cathode assemblies 322 are appropriately placed in the fixture 800 and separators 110 are placed between each layer until the desired number of electrodes are positioned. Figure 8 As shown, each of the anode assembly 320, separator 110, and cathode assembly 322 are positioned according to the structure of the fixture 800. In step 2096, the upper portion 220 of the frame 106 is added. In step 2098, the fixture 800 can be placed in a press, where pressure is applied to the electrode stack to achieve a specific thickness of the electrode stack 302 (e.g., as shown in FIG. 20A ). Figure 3EIn step 2001, the side supports 206, which have been attached to the lower portion 222, are welded to the upper portion 220 to complete the formation of the frame 106. The resulting structure is the electrode stack 302.

[0164] Figure 20K Further shown is an electrode stack assembly forming 2032. The electrode stack assembly forming 2032 begins at step 20032, wherein the electrode shields 308 and 310 formed in the electrode shield forming 2018 are attached to the side support 206 near the cathode side of the electrode stack 302 by, for example, welding, as shown in FIG. Figure 3A In step 20K, 9A to 9C The separators 304 and 306 are attached to the electrode stack 302. As described, the connectors 318 of the separators 304 and 306 engage with the connectors 316 of the frame 106. In step 2007, the anode tabs 314 are inserted into the slots 224 in the anode terminal bridge 226 and secured in place, for example, by welding. As described above, the anode terminal bridge 226 is seated in the separator 306, as shown in FIG. Figure 3A In step 2009, the cathode tab 312 is inserted into the slot 230 in the cathode terminal bridge 228 and fixed in place, for example, by welding. As described above, the cathode terminal bridge 228 is placed in the separator 304, such as Figure 3A Further references 9A to 9C Isolators 304 and 306 are described below.

[0165] Figure 20L Further shown is the formation of an anode end cap 2024 to form the anode cap 1304. Step 2024 begins at step 2011, where the through holes 1708 and 1710 are formed as described above. 17A to 17D In step 2013, Fig.15A and Fig. 15B The filling tube 122 is inserted into the Fig.17D The cathode end cap 1304 is formed by inserting the cathode end cap 1304 into the through hole 1710 shown and welding it in place.

[0166] Figure 20M Further shown is the cathode end cap formation 2026. Step 2026 begins at step 2015, where the through hole 1810 and the countersunk hole 1812 are formed, such as Fig.18A and Fig.18B In step 2017, Fig.16A and Fig. 16B The feed-through body 1322 is shown positioned into the hole 1810 and the countersunk hole 1812 and welded into place, as shown in FIG. FIG. 18F to FIG. 18H As shown, to form the cathode end cap 1302.

[0167] Fig.20N Further shown is a cell assembly 2034 to form the structure of the cell 100. The cell assembly 2034 begins at step 219, where the anode end cap 1304 prepared in the anode cap formation 2024 is welded to the container body 1306 at the weld 1310, as described above with respect to Fig.13A and Fig. 13B In step 2021, the electrode stack assembly 104 is inserted into the container body 1306 so that the anode feed-through terminal 120 extends through the hole 1708. In step 2023, the anode feed-through terminal 120 is welded to the anode end cap 1304 at the weld 1316, wherein the lip 1902 of the container body 1306 mates with the lip 1706 of the anode end cap 1304. In step 2025, the feed-through insulator 1324 is screwed into the feed-through body 1322, as shown in FIG. Fig. 13B As shown, feedthrough 1314 is formed. FIG. 16A to FIG. 16D 13. An example of a feedthrough insulator 1324 and a feedthrough body 1322 is shown in FIG. 20. In step 2027, the cathode end cap 1302 formed in cathode end cap formation 2026 is positioned so that the cathode feedthrough terminal 124 passes through the feedthrough insulator 1324 of the feedthrough 1314 and the lip 1806 of the cathode end cap 1302 mates with the lip 1902 of the container body 1306. In step 2029, the cathode end cap 1302 is welded to the container body 1306 at the weld 1308. In step 2039, the feedthrough shoulders 1318 and 1320 (which are located at the bottom of the feedthrough) are welded to the container body 1306. Fig.14A and Fig. 14B ) are mounted on the cathode feed-through terminal 124 and the anode feed-through terminal 120, respectively.

[0168] FIG. 200 further illustrates step 2040. In step 2040, the pressure vessel 102 is charged with the electrolyte produced in the electrolyte preparation step 2028. An example of step 2040 is shown in FIG. 200. As shown in FIG. 200, step 2040 begins with a degassing step 2031. In the degassing step 2031, the pressure vessel 102 is evacuated to allow internal degassing. In step 2033, the pressure vessel 102 may be flushed with the electrolyte 126 one or more times by filling and draining the electrolyte 126 from the pressure vessel 102 one or more times. Filling and draining may include: evacuating the pressure vessel 102 and filling the pressure vessel 102 with the electrolyte, and then applying gas under pressure to drain the pressure vessel 102. In step 2035, the electrolyte 126 is added to the pressure vessel 102 to fill the pressure vessel 102. As discussed above, this can be accomplished by repeatedly evacuating the pressure vessel 102 and adding the electrolyte 126 until the pressure vessel 102 is filled with the electrolyte 126. In step 2037, the pressure vessel 102, now filled with electrolyte 126, is allowed to stand for a period of time to allow the electrode stack 104 to absorb a sufficient amount of electrolyte 126 for operation of the battery 100. In some embodiments, this step can be long enough to allow the electrode stack 104 to be filled with electrolyte 126. Once the electrode stack 104 contains sufficient electrolyte 126, which may take several hours (e.g., about 8 hours), step 2040 proceeds to step 2039, where excess electrolyte 126 is drained. This can be done by providing hydrogen pressure to the fill tube 122 to remove excess electrolyte 126. In step 2041, the fill tube 122 is sealed to form the completed battery 100. From step 2040, the method 2000 proceeds to step 2042 for electrical testing. The electrical testing in step 2042 can include charging and discharging the resulting battery 100 over several cycles and monitoring the performance of the battery 100.

[0169] Aspects of the present disclosure describe metal hydride batteries and components thereof. Selection of aspects of the present invention may include the following aspects:

[0170] Aspect 1: An electrode stack assembly for a metal hydrogen battery, comprising: a plurality of anode assemblies, each anode assembly comprising at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly comprising at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge arranged to engage each anode tab of each anode assembly in the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each cathode assembly in the plurality of cathode assemblies; an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies and the plurality of cathode assemblies are alternately arranged and separated by the plurality of separators to form an electrode stack.

[0171] Aspect 2: The electrode stack assembly according to aspect 1, wherein each of the plurality of separators comprises a plurality of wicking sheets.

[0172] Aspect 3: The electrode stack assembly according to aspects 1 to 2, further comprising a frame arranged to hold the electrode stack.

[0173] Aspect 4: The electrode stack assembly according to aspects 1 to 3, wherein the frame includes a top and a bottom, and the top and the bottom are welded when the electrode stack encapsulated in the frame is pressed.

[0174] Aspect 5: The electrode stack assembly according to aspects 1 to 4 further includes: an anode separator located between the electrode stack and the anode feedthrough bridge; and a cathode separator located between the electrode stack and the cathode feedthrough bridge.

[0175] Aspect 6: The electrode stack assembly according to aspects 1 to 5, wherein the at least one anode layer includes three layers attached by applying pressure, and wherein the anode tab is attached to the three layers by welding.

[0176] Aspect 7: An electrode stack assembly according to Aspects 1 to 6, wherein each of the multiple cathode layers comprises: a pair of cathode components, each cathode component comprising a cathode layer attached to a pole ear, the pair of cathode components being positioned relative to each other so that the pole ears are aligned to form the cathode pole ears; and a separator bag, the pair of cathode components being inserted into the separator bag so that the cathode pole ears are exposed.

[0177] Aspect 8: The electrode stack assembly according to aspects 1 to 7, wherein the anode feedthrough assembly is formed of metal, wherein an array of slots is formed to accommodate tabs from the anode tabs.

[0178] Aspect 9: The electrode stack assembly according to aspects 1 to 8, wherein the cathode feedthrough assembly is formed of metal, wherein an array of slots is formed to accommodate the tabs from the cathode tab.

[0179] Aspect 10: A metal hydrogen battery, comprising: an electrode stack assembly, the electrode stack assembly comprising: a plurality of anode assemblies, each anode assembly comprising at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly comprising at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge, arranged to engage each anode tab of each anode assembly in the plurality of anode assemblies; a cathode feedthrough bridge, arranged to engage each cathode tab of each cathode assembly in the plurality of cathode assemblies; an anode feedthrough terminal, coupled to the anode feedthrough bridge; and a cathode feedthrough terminal, coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies, the plurality of cathode assemblies and the plurality of separators are alternately arranged to form an electrode stack; a pressure vessel, surrounding the electrode stack assembly, such that the cathode feedthrough terminal extends through the pressure vessel; and an electrolyte, contained within the pressure vessel.

[0180] Aspect 11: The metal hydride battery of aspect 10, wherein the cathode feedthrough terminal extends through a feedthrough in an end of the pressure vessel.

[0181] Aspect 12: The metal hydride battery according to aspects 10 to 11, wherein the feedthrough includes a body portion and an insulator portion, the body portion being attached to the pressure vessel, the insulator portion being inserted into the body portion and engaging the cathode feedthrough terminal.

[0182] Aspect 13: The metal hydride battery according to aspects 10 to 12, wherein the body portion is compressed to form a seal between the body portion, the insulator portion and the cathode feed-through terminal.

[0183] Aspect 14: The metal hydride battery according to aspects 10 to 13, wherein the pressure vessel is formed with a vessel side wall, a cathode end cap attached to the vessel side wall, and an anode end cap attached to the vessel side wall, the cathode end cap including the feedthrough.

[0184] Aspect 15: The metal hydride battery according to aspects 10 to 14, wherein the anode feed-through terminal is attached to the anode end cap.

[0185] Aspect 16: The metal hydride battery according to aspects 10 to 14, wherein the anode feed-through terminal extends through the anode end cap.

[0186] Aspect 17: A method for forming an electrode stack assembly for a metal hydrogen battery, comprising: preassembling components of the electrode stack assembly by: assembling a plurality of cathode assemblies, each cathode assembly having a cathode tab attached to one or more cathode material layers, assembling a plurality of anode assemblies, each anode assembly having an anode tab coupled to one or more anode material layers, forming a plurality of separators from a separator material, forming a frame top and a frame bottom, forming an anode feedthrough bridge assembly, and forming a cathode feedthrough bridge assembly; stacking the separators, the anode assemblies, and the cathode assemblies in an alternating manner between the frame top and the frame bottom to capture the electrodes between the frame top and the frame bottom; pressing the electrodes, the frame top, and the frame bottom; forming an electrode stack by attaching the frame top to the frame bottom to form a frame; attaching the cathode tabs of a plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly; and attaching the anode tabs of a plurality of anode assemblies in the electrode stack to the anode feedthrough bridge assembly.

[0187] Aspect 18: A method for forming an electrolyte stack assembly according to Aspect 17, wherein assembling a plurality of cathode assemblies comprises: for each cathode assembly, producing two cathode components, each cathode component comprising a cathode layer attached to a cathode tab structure; arranging the two cathode components so that the cathode tab structure forms the cathode tab; forming a separator bag; and inserting the cathode component into the separator bag.

[0188] Aspect 19: The method of forming an electrolyte stack assembly according to aspects 17 to 18, wherein assembling a plurality of anode assemblies comprises: stacking a plurality of anode material layers; and attaching the anode tab to the anode material layers.

[0189] Aspect 20: A method for forming an electrolyte stack assembly according to aspects 17 to 19, wherein forming an anode feedthrough bridge assembly comprises: providing an anode feedthrough bridge comprising a plurality of slots for accommodating tabs from an anode assembly; and attaching an anode feedthrough terminal to the anode terminal bridge.

[0190] Aspect 21: A method for forming an electrolyte stack assembly according to aspects 17 to 20, wherein forming a cathode feedthrough bridge assembly comprises: providing a cathode feedthrough bridge comprising a plurality of slots for accommodating tabs from a cathode assembly; and attaching a cathode feedthrough terminal to the cathode terminal bridge.

[0191] Aspect 22: A method of forming a hydrogen metal battery, comprising: forming an electrode stack assembly, wherein forming the electrode stack assembly comprises: assembling a plurality of cathode assemblies, each cathode assembly having a cathode tab attached to one or more layers of cathode material, assembling a plurality of anode assemblies, each anode assembly having an anode tab coupled to one or more layers of anode material, forming a plurality of separators from a separator material, forming a frame top and a frame bottom, forming an anode feedthrough bridge assembly including an anode feedthrough terminal, forming a cathode feedthrough bridge assembly including a cathode feedthrough terminal, stacking separators, anode assemblies, and cathode assemblies in an alternating manner between the frame top and the frame bottom to capture the frame top. and the bottom of the frame, pressing the electrodes, the frame top and the frame bottom, forming an electrode stack by attaching the frame top to the frame bottom to form a frame, attaching the cathode tabs of multiple cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly, and attaching the anode tabs of multiple anode assemblies in the electrode stack to the anode feedthrough bridge assembly; attaching the anode end cap to the side wall of the container; inserting the electrode stack assembly into the side wall of the container so that the anode feedthrough terminal engages with the anode end cap; attaching the cathode end cap to the side wall of the container so that the cathode feedthrough terminal passes through the feedthrough in the cathode end cap.

[0192] Those skilled in the art will recognize that the steps described above with respect to method 2000 can be performed in an order other than the order specifically described. In addition, the specific dimensions or descriptions described above with respect to specific components are merely exemplary and are not intended to be limiting. The embodiments of the present invention described herein are not intended to limit the present invention. Those skilled in the art will recognize that many variations and modifications within the scope of the present invention are possible. Therefore, the present invention is set forth in the appended claims.

Claims

1. An electrode stack assembly for a metal hydrogen battery, comprising: a plurality of anode assemblies, each anode assembly comprising at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly comprising at least one cathode layer attached to a cathode tab; Multiple dividers; an anode feedthrough bridge arranged to engage each anode tab of each anode assembly of the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each cathode assembly of the plurality of cathode assemblies; an anode feed-through terminal coupled to the anode feed-through bridge; as well as a cathode feedthrough terminal coupled to the cathode feedthrough bridge, The plurality of anode assemblies and the plurality of cathode assemblies are alternately arranged and separated by the plurality of separators to form an electrode stack.

2. The electrode stack assembly according to claim 1, wherein: Each of the plurality of dividers includes a plurality of wicking sheets.

3. The electrode stack assembly according to claim 1, further comprising: A frame is arranged to hold the electrode stack.

4. The electrode stack assembly according to claim 3, wherein: The frame includes a top portion and a bottom portion, which are welded when the electrode stack enclosed in the frame is pressed.

5. The electrode stack assembly according to claim 3, further comprising: an anode separator located between the electrode stack and the anode feedthrough bridge; as well as A cathode separator is located between the electrode stack and the cathode feedthrough bridge.

6. The electrode stack assembly according to claim 1, wherein: The at least one anode layer comprises three layers attached by applying pressure, and wherein the anode tab is attached to the three layers by welding.

7. The electrode stack assembly according to claim 1, wherein: Each of the plurality of cathode layers comprises: a pair of cathode components, each cathode component comprising a cathode layer attached to a tab, the pair of cathode components being positioned relative to each other such that the tabs are aligned to form the cathode tab; and A separator bag is provided into which the pair of cathode components are inserted so that the cathode tabs are exposed.

8. The electrode stack assembly according to claim 1, wherein: The anode feed-through assembly is formed of metal having an array of slots formed therein to accommodate the tabs from the anode tab.

9. The electrode stack assembly according to claim 1, wherein: The cathode feed-through assembly is formed of metal having an array of slots formed therein to accommodate the tabs from the cathode tab.

10. A metal hydrogen battery comprising: An electrode stack assembly, the electrode stack assembly comprising: a plurality of anode assemblies, each anode assembly comprising at least one anode layer attached to an anode tab, a plurality of cathode assemblies, each cathode assembly comprising at least one cathode layer attached to a cathode tab, Multiple separators, an anode feedthrough bridge arranged to engage each anode tab of each anode assembly of the plurality of anode assemblies, a cathode feedthrough bridge arranged to engage each cathode tab of each cathode assembly of the plurality of cathode assemblies; an anode feed-through terminal coupled to the anode feed-through bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies, the plurality of cathode assemblies and the plurality of separators are alternately arranged to form an electrode stack; a pressure vessel surrounding the electrode stack assembly such that the cathode feed-through terminal extends through the pressure vessel; and An electrolyte is contained in the pressure vessel.

11. The metal hydride battery according to claim 10, wherein: The cathode feedthrough terminal extends through a feedthrough in an end of the pressure vessel.

12. The metal hydride battery according to claim 11, wherein: The feedthrough includes a body portion that is attached to the pressure vessel and an insulator portion that is inserted into the body portion and engages the cathode feedthrough terminal.

13. The metal hydride battery according to claim 12, wherein: The body portion is extruded to form a seal between the body portion, the insulator portion, and the cathode feed-through terminal.

14. The metal hydride battery according to claim 12, wherein: The pressure vessel is formed with a vessel sidewall, a cathode end cap attached to the vessel sidewall, and an anode end cap attached to the vessel sidewall, the cathode end cap including the feedthrough.

15. The metal hydride battery according to claim 14, wherein: The anode feed-through terminal is attached to the anode end cap.

16. The metallic hydrogen according to claim 15, wherein: The anode feed-through terminal extends through the anode end cap.

17. A method of forming an electrode stack assembly for a metal hydride battery, comprising: The components of the electrode stack assembly are preassembled in the following manner: assembling a plurality of cathode assemblies, each cathode assembly having a cathode tab attached to one or more layers of cathode material, assembling a plurality of anode assemblies, each anode assembly having an anode tab coupled to one or more layers of anode material, forming a plurality of separators from a separator material, Forming a frame top and a frame bottom, forming an anode feedthrough bridge assembly, and forming a cathode feedthrough bridge assembly; stacking the separators, the anode assemblies, and the cathode assemblies in an alternating manner between the frame top and the frame bottom to capture the electrodes between the frame top and the frame bottom; pressing the electrode, the frame top, and the frame bottom; forming an electrode stack by attaching the frame top to the frame bottom to form a frame; attaching cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly; as well as Anode tabs of the plurality of anode assemblies in the electrode stack are attached to the anode feedthrough bridge assembly.

18. The method of forming an electrolyte stack assembly according to claim 17, wherein: Assembling the plurality of cathode assemblies comprises: for each of the cathode assemblies, producing two cathode components, each of the cathode components comprising a cathode layer attached to a cathode tab structure; Arranging the two cathode components so that the cathode tab structure forms the cathode tab; forming a divider pocket; and The cathode assembly was inserted into the separator pocket.

19. The method of forming an electrolyte stack assembly according to claim 17, wherein: Assembling multiple anode assemblies involves: stacking a plurality of anode material layers; and The anode tab is attached to the layer of anode material.

20. The method of forming an electrolyte stack assembly according to claim 17, wherein: Forming the anode feedthrough bridge assembly includes: providing an anode feedthrough bridge including a plurality of slots for receiving tabs from the anode assembly; and Attach the anode feed-through terminal to the anode terminal bridge.

21. The method of forming an electrolyte stack assembly according to claim 17, wherein: Forming a cathode feedthrough bridge assembly includes: providing a cathode feedthrough bridge including a plurality of slots for receiving tabs from the cathode assembly; and Attach the cathode feed-through terminal to the cathode terminal bridge.

22. A method of forming a hydrogen metal battery, comprising: Forming an electrode stack assembly, wherein forming the electrode stack assembly comprises: assembling a plurality of cathode assemblies, each cathode assembly having a cathode tab attached to one or more layers of cathode material, assembling a plurality of anode assemblies, each anode assembly having an anode tab coupled to one or more layers of anode material, forming a plurality of separators from a separator material, Forming a frame top and a frame bottom, forming an anode feedthrough bridge assembly including an anode feedthrough terminal, forming a cathode feedthrough bridge assembly including a cathode feedthrough terminal, stacking the separators, the anode assemblies, and the cathode assemblies in an alternating manner between the frame top and the frame bottom to capture the electrodes between the frame top and the frame bottom, Pressing the electrode, the frame top and the frame bottom, forming an electrode stack by attaching the frame top to the frame bottom to form a frame, attaching cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly, and attaching anode tabs of the plurality of anode assemblies in the electrode stack to the anode feedthrough bridge assembly; attaching the anode end cap to the container side wall; inserting the electrode stack assembly into the container side wall so that the anode feed-through terminal engages with the anode end cap; A cathode end cap is attached to the container sidewall such that the cathode feedthrough terminal passes through the feedthrough in the cathode end cap.

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