Seal for high temperature reactive material devices

Abstract

The present disclosure provides seals for devices that operate at elevated temperatures and have reactive metal vapors, such as lithium, sodium, or magnesium. In some examples, such devices include energy storage devices that may be used within an electrical grid or as part of a standalone system. The energy storage device may be charged from a power production source for later discharge, such as when power consumption is required.

Description

[0001] This application is a divisional application of the Chinese patent application with the application date of September 7, 2017, application number 202210471337.5, and invention name “Seal for High-temperature Reactive Material Device”.

[0002] The application with the application date of September 7, 2017, application number 202210471337.5, and invention name “Seal for High-Temperature Reactive Material Device” is a divisional application of the Chinese patent application with the application date of September 7, 2017, application number 201780068872.3, and invention name “Seal for High-Temperature Reactive Material Device” (the corresponding PCT application with the application date of September 7, 2017 and application number PCT / US2017 / 050544).

[0003] Cross-references

[0004] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 384,662, filed September 7, 2016, which is incorporated herein by reference in its entirety. Technical Field

[0005] Various devices are configured for use at elevated temperatures (or high temperatures). Examples of such devices include elevated temperature batteries, which are devices capable of converting stored chemical energy into electrical energy. Batteries can be used in many household and industrial applications. Another example of a high temperature device is a chemical vapor deposition chamber such as those used in the manufacture of semiconductor devices. Another example of a high temperature device is a chemical vessel, a delivery pipe, or a storage vessel designed for processing, transporting, containing and / or storing reactive metals. Another example of a high temperature device can be any high temperature device that requires electrical isolation between two parts of the outer surface of the device in order to transfer electrical energy and / or electrical signals to the device or receive electrical energy and / or electrical signals from the device. These devices can typically operate at temperatures of 200°C or above. Background Art

[0006] Various limitations associated with devices with elevated temperatures (or high temperature devices) are recognized herein. For example, some batteries operate at high temperatures (e.g., at least about 100° C. or 300° C.) and have reactive material vapors (e.g., reactive metal vapors, such as, for example, vapors of lithium, sodium, potassium, magnesium, or calcium) that may be well contained within the device. Other examples of high temperature reactive material devices include nuclear (e.g., fusion and / or fission) reactors that use molten salts or metals (e.g., molten sodium or lithium or molten alloys containing sodium or lithium) as coolants, devices for manufacturing semiconductors, heterogeneous reactors, and devices for producing (e.g., processing) and / or handling (e.g., transporting or storing) reactive materials (e.g., reactive chemicals such as, for example, chemicals with strong chemical reducing capabilities, or reactive metals such as, for example, lithium or sodium). Such devices may be sufficiently sealed from the external environment during use to prevent reactive material vapors from leaving the device (e.g., to prevent device failure, prolong device use, or to avoid adverse health effects on users or operators of such devices), and / or have a protective lining within the device to prevent corrosion of the container. Furthermore, the seals of these devices themselves may be protected from the effects of use in the presence of high temperature, reactive materials.

[0007] The present disclosure provides ceramic materials that can be used in high temperature devices and / or other devices, including, for example, reinforced ceramics for ballistic protection systems and devices (eg, ballistic protection armor).

[0008] The present disclosure provides seals and / or reactor vessel linings for energy storage devices and other devices having (e.g., containing or including) reactive materials (e.g., reactive metals) and operating at high temperatures (e.g., at least about 100° C. or 300° C.). The energy storage devices (e.g., batteries) can be used within a power grid or as part of a stand-alone system. The batteries can be charged from a power generation source for later discharge when there is a demand for power consumption.

[0009] In one aspect, the present disclosure provides a high temperature device comprising: a container comprising an inner cavity, wherein the inner cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.; a seal that seals the inner cavity of the container from an environment outside the container, wherein the seal comprises a ceramic component, and wherein the seal is exposed to the reactive material and the environment outside the container; a conductor that extends from the environment outside the container through the seal to the inner cavity of the container; and a first metal sleeve coupled to the conductor and the ceramic component, wherein the first metal sleeve is coupled to the ceramic component via a first braze joint comprising a first braze, and wherein the first braze comprises an alloy of silver and aluminum.

[0010] In some embodiments, the conductor is a negative current lead. In some embodiments, the device further comprises a negative current collector within the container, wherein the negative current collector is in contact with the reactive material and is attached to the negative current lead.

[0011] In some embodiments, the apparatus further comprises a second metal sleeve coupled to the ceramic component, wherein the second metal sleeve is coupled to the container or to a collar joined to the container, wherein the second metal sleeve is coupled to the ceramic component via a second braze joint comprising a second braze material, and wherein the second braze material comprises an alloy of silver and aluminum. In some embodiments, the alloy of silver and aluminum comprises a ratio of silver to aluminum less than or equal to about 19 to 1. In some embodiments, one or both of the first braze material and the second braze material further comprises a titanium braze alloy. In some embodiments, the titanium braze alloy comprises approximately 19-21 weight percent zirconium, 19-21 weight percent nickel, 19-21 weight percent copper, and the remaining weight percent comprises at least titanium.

[0012] In some embodiments, the device further comprises an internal braze disposed adjacent to the first braze joint, the second braze joint, or both the first braze joint and the second braze joint, wherein the internal braze is exposed to the inner cavity of the container. In some embodiments, the internal braze comprises a titanium braze alloy.

[0013] In some embodiments, the second metal sleeve is coupled to the container or the collar by a third brazing material. In some embodiments, the third brazing material comprises a nickel-based or titanium-based brazing material, and wherein the nickel-based brazing material comprises greater than or equal to about 70 weight percent nickel. In some embodiments, the nickel-based brazing material comprises a BNi-2 brazing material, a BNi-5b brazing material, or a BNi-9 brazing material.

[0014] In some embodiments, the first metal sleeve is coupled to the conductor by a fourth brazing material. In some embodiments, the fourth brazing material is a nickel-based brazing material, a titanium-based brazing material, or an alloy of silver and aluminum.

[0015] In some embodiments, the alloy of silver and aluminum further comprises a wetting agent. In some embodiments, the wetting agent comprises titanium. In some embodiments, the ceramic component comprises aluminum nitride. In some embodiments, the ceramic component further comprises greater than or equal to about 3 weight percent yttrium oxide. In some embodiments, the ceramic component further comprises from about 1% to about 4% yttrium oxide by weight.

[0016] In some embodiments, the first metal sleeve and the second metal sleeve comprise alloy 42, and the conductor or the ferrule comprises stainless steel. In some embodiments, the stainless steel comprises 304L stainless steel. In some embodiments, the thickness of the first metal sleeve and the second metal sleeve is less than or equal to about 0.020 inches.

[0017] In one aspect, the present disclosure provides an electrochemical cell comprising: a container comprising an inner cavity, wherein the inner cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.; a seal that seals the inner cavity of the container from an environment outside the container, wherein the seal comprises a ceramic component exposed to both the reactive material and the environment outside the container; a current lead extending from the inner cavity of the container through the seal to the environment outside the container; a first metal sleeve coupled to the current lead and the ceramic component; and a second metal sleeve coupled to the ceramic component and the container or to a collar joined to the container, wherein the ceramic component comprises a physical ion blocker on a surface of the ceramic component.

[0018] In some embodiments, the physical ion block is shaped to inhibit electromigration along the surface of the ceramic component. In some embodiments, the physical ion block is shaped to inhibit the formation of metal dendrites across the surface of the ceramic component. In some embodiments, the first metal sleeve and the second metal sleeve are coupled to the ceramic component by a first braze and a second braze, respectively. In some embodiments, the surface of the ceramic component is an exposed surface of the ceramic component between the first braze and the second braze, and wherein the physical ion block is shaped so that the shortest path from the first braze to the second braze along the exposed surface of the ceramic component includes a path segment that is at least partially away from both the first braze and the second braze.

[0019] In some embodiments, the first braze and the second braze each include an alloy of silver and aluminum. In some embodiments, the current lead is a negative current lead. In some embodiments, the physical ion block is attached to the surface of the ceramic component. In some embodiments, the physical ion block is disposed on an exposed surface of the ceramic component. In some embodiments, the physical ion block is an integral part of the ceramic component, wherein the physical ion block includes one or more protrusions that are part of the exposed surface of the ceramic component, and wherein the one or more protrusions extend from a reference surface of the ceramic component.

[0020] In some embodiments, the one or more protrusions include a plurality of protrusions defining a groove. In some embodiments, the one or more protrusions extend a distance greater than or equal to about 2 mm from the reference surface of the ceramic component. In some embodiments, the one or more protrusions include a long dimension and a short dimension, and wherein the long dimension defines a slope set at an angle substantially orthogonal to the reference surface of the ceramic component. In some embodiments, the one or more protrusions define a slope set at an acute angle relative to the reference surface of the ceramic component and facing a positive electric field source. In some embodiments, the one or more protrusions include a first portion extending from the reference surface of the ceramic component and a second portion defining a slope parallel to the reference surface of the ceramic component and extending toward a positive electric field source. In some embodiments, the positive electric field source is the body of the container that is electrically connected to a positive electrode.

[0021] In one aspect, the present disclosure provides a high temperature device comprising: a container comprising an inner cavity, wherein the inner cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200°C; a seal that seals the inner cavity of the container from an environment outside the container, wherein the seal comprises a ceramic component, and wherein the seal is exposed to both the reactive material and the environment outside the container; a conductor that extends from the environment outside the container through the seal to the inner cavity of the container; a metal sleeve coupled to the conductor and the ceramic component, wherein the metal sleeve is coupled to the ceramic component by a braze joint comprising a braze material, and wherein the braze material is formed of a material that is substantially non-reactive with air and that prevents air from diffusing into the container when the reactive material is maintained at a temperature of at least about 200°C for a period of at least about 1 day.

[0022] In some embodiments, the braze is ductile. In some embodiments, the device further comprises an internal braze, and wherein the internal braze contacts the reactive material and protects the braze from the reactive material. In some embodiments, the internal braze is an active metal braze. In some embodiments, the diffusion of air into the container is at most about 1×10 -8 Atmospheric pressure - cubic centimeters per second. In some embodiments, the brazing material is an alloy of at least two different metals.

[0023] In one aspect, the present disclosure provides a high temperature device comprising: a container having a chamber containing a reactive material, the reactive material comprising a gas portion and a liquid portion, the reactive material being maintained at a temperature of at least about 200°C; a seal that seals and isolates the chamber of the container from an environment external to the container, wherein the seal comprises a ceramic component exposed to the gas portion; a conductor that extends through the seal from the external environment of the container to the chamber of the container, wherein the conductor is electrically connected to the liquid portion; and a first shield connected to the conductor and disposed within the gas portion between the seal and the liquid portion.

[0024] In some embodiments, the first shield at least partially blocks the seal and the liquid portion from each other. In some embodiments, the first shield completely blocks the seal and the liquid portion from each other. In some embodiments, the first shield extends a distance from the conductor that is greater than or equal to about 1.5 times the width of the conductor. In some embodiments, the first shield is configured to increase the effective gas diffusion path from the liquid portion to the seal by greater than or equal to about 10% relative to the same high temperature device without the shield. In some embodiments, the first shield is configured to provide about 7 cm -1 or more effective gas diffusion paths from the liquid portion to the seal.

[0025] In some embodiments, the first shield is configured to increase the effective ion path length from the liquid portion to the seal by about 30% or more relative to an otherwise identical high temperature device without the shield. In some embodiments, the increase in effective ion diffusion path length is about 75% or more. In some embodiments, the first shield is configured to provide an effective ion diffusion path length of greater than or equal to about 1.5. In some embodiments, the first shield is configured to provide an effective ion diffusion path length of greater than or equal to about 2.

[0026] In some embodiments, the conductor is a negative current lead. In some embodiments, the device further comprises a second shield disposed between the first shield and the seal. In some embodiments, the first shield and the second shield comprise alternating raised and recessed portions, the alternating raised and recessed portions being shaped to create a diffusion path from the liquid portion to the seal having a length at least 1.5 times the width of the container. In some embodiments, the second shield is coupled to a wall of the chamber. In some embodiments, the first shield is in electrical contact with the negative current lead, and wherein the second shield is in electrical contact with the positive current lead.

[0027] In some embodiments, the device further comprises a second shield in electrical contact with the positive current lead and disposed between the first shield and the liquid portion. In some embodiments, the liquid portion generates vapor, and the second shield converts the vapor into a salt upon contact. In some embodiments, the inner surface of the container exposed to the gas portion comprises an ion-conductive membrane electrically connected to a positive current source, and the first shield is shaped so that the vapor flowing between the liquid portion and the seal flows along the inner surface. In some embodiments, the first shield comprises an edge at its periphery, the edge being shaped and positioned in the chamber to inhibit capillary flow of liquid from the liquid portion along a path from the liquid portion to the seal.

[0028] In one aspect, the present disclosure provides an electrochemical cell comprising: a container having a chamber containing a reactive material maintained at a temperature of at least about 200° C.; a seal that seals the chamber of the container from an environment external to the container, wherein the seal comprises a ceramic component exposed to the reactive material and a metal sleeve coupled to the ceramic component by a brazing material; and a current lead extending from the external environment of the container to the chamber of the container, wherein the current lead is in electrical contact with the reactive material, and wherein the current lead comprises a shoulder comprising the same material as the current lead, and wherein the shoulder couples the sleeve to the current lead.

[0029] In some embodiments, the current lead is a negative current lead. In some embodiments, the electrochemical cell further comprises a negative current collector within the chamber and attached to one end of the negative current lead. In some embodiments, the negative current lead comprises a cylindrical body extending through the seal and a threaded portion attaching the negative current lead to the negative current collector, and the negative current lead further comprises two parallel, substantially flat surfaces on opposite sides of one end of the negative current lead located outside the container. In some embodiments, the negative current collector comprises foam.

[0030] In some embodiments, the high temperature device is a battery, and wherein the battery comprises a negative electrode, a positive electrode, and a liquid electrolyte. In some embodiments, at least one of the negative electrode and the positive electrode is a liquid metal electrode. In some embodiments, the liquid electrolyte is a molten halide electrolyte.

[0031] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in the art through the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be appreciated, the present disclosure is capable of other and different embodiments, and several of its details can be modified in various readily understood aspects, all without departing from the present disclosure. Therefore, the drawings and description are to be considered illustrative rather than restrictive in nature. Summary of the invention

[0032] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The novel features of the present invention are particularly set forth in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by referring to the following detailed description and accompanying drawings (also referred to herein as "drawings" or "figures") which set forth illustrative embodiments in which the principles of the present invention are utilized, in which:

[0034] Figure 1 is a schematic diagram of an electrochemical cell (A) and an arrangement (e.g., a battery) of electrochemical cells (B and C);

[0035] Figure 2 is a schematic cross-sectional view of a housing having a conductor in electrical communication with a current collector through an aperture in the housing;

[0036] Figure 3 A seal design is shown having a ceramic component disposed between one or more metal sleeves;

[0037] Figure 4 An electrochemical cell containing reactive materials and including a seal including additional components to inhibit corrosion of the seal is illustrated;

[0038] Figure 5 An electrochemical cell having a shield configured to increase the effective gas diffusion path is shown;

[0039] Figure 6An electrochemical cell having a plurality of shields configured to further increase the diffusion path length is shown;

[0040] Figure 7 An electrochemical cell having a shield having a lip to inhibit flow and splashing of liquid toward a seal is illustrated;

[0041] Figure 8 An electrochemical cell having a shield configured to increase the effective ion diffusion path is shown;

[0042] Fig. 9 is an image of a monomer having a positively polarized shield disposed between a liquid portion and a negatively polarized shield;

[0043] Fig. 10A , Fig. 10B and Fig. 10C Different configurations of physical ion blocks are illustrated;

[0044] Fig.11A A negative current lead including a negative current lead (NCL) coupler is illustrated;

[0045] Fig. 11B shows a front view and a side view of a current lead including a pair of substantially flat parallel surfaces at one end;

[0046] Fig.12 A schematic drawing of a brazed ceramic seal is shown, wherein the material is thermodynamically stable with respect to the internal and external environments of the cell;

[0047] Fig.13 Seals are shown where the ceramic material and / or the brazing material are not thermodynamically stable with respect to the internal and external environments;

[0048] Fig.14 An example of a brazed ceramic seal is shown;

[0049] Fig.15 An example of a brazed ceramic seal is shown;

[0050] Fig.16 An example of a brazed ceramic seal is shown; and

[0051] Fig.17 An example of a brazed ceramic seal is shown; DETAILED DESCRIPTION

[0052] Although various embodiments of the present invention have been shown and described herein, it will be readily understood by those skilled in the art that such embodiments are provided by way of example only. Many variations, changes and substitutions may be envisioned by those skilled in the art without departing from the present invention. It should be understood that various alternatives to the embodiments of the present invention described herein may be adopted. It should be understood that different aspects of the present invention may be understood individually, collectively or in combination with one another.

[0053] As used herein, the term "metal-to-metal direct bonding" or "metal-to-metal direct joint" generally refers to an electrical connection that brings two metal surfaces into contact (eg, by forming a brazed joint or weld). In some examples, the metal-to-metal direct joint does not include a wire.

[0054] As used herein, the term "electronically" generally refers to a situation where electrons can easily flow between two or more components with less resistance. Components that are in electronic communication with each other may be in electrical communication with each other.

[0055] As used herein, the term "vertical" generally refers to the direction parallel to the force of gravity.

[0056] As used herein, the term "stable" to describe a material generally refers to a material that is thermodynamically stable, chemically stable, thermochemically stable, electrochemically stable, kinetically stable, or any combination thereof. A stable material may be substantially stable thermodynamically, chemically, thermochemically, electrochemically, and / or kinetically. A stable material may not be substantially reduced, eroded, or corroded chemically or electrochemically. Any aspects described in the present disclosure with respect to a stable, thermodynamically stable, or chemically stable material may also apply, at least in some configurations, to a thermodynamically stable, chemically stable, thermochemically stable, and / or electrochemically stable material.

[0057] Ceramic materials and seals for high temperature applications

[0058] The present disclosure provides a seal or corrosion-resistant lining for a high-temperature device. The device may be a high-temperature reactive material device containing / including one or more reactive materials. For example, the high-temperature device may contain reactive materials. In some cases, the device may be a high-temperature reactive metal device. The device may be, but is not limited to, for example, for the production and / or processing of reactive materials such as reactive metals (e.g., lithium, sodium, magnesium, aluminum, calcium, titanium and / or other reactive metals) and / or chemicals with strong chemical reduction capabilities (e.g., reactive chemicals), for semiconductor manufacturing, for nuclear reactors (e.g., nuclear fusion / fission reactors, using, for example, molten salts or metals such as molten sodium or lithium or molten sodium- or lithium-containing alloys as coolants), for non-uniform reactors, for chemical processing devices, for chemical transport devices, for chemical storage devices, or for batteries (e.g., liquid metal batteries). For example, some batteries operate at high temperatures (e.g., at least about 100° C. or 300° C.) and have reactive metal vapors (e.g., vapors of lithium, sodium, magnesium, aluminum, or calcium, etc.) that can be sufficiently contained within the battery to reduce failure. In some examples, such high temperature devices operate at, are heated to, and / or maintained at temperatures of at least about 100° C., 150° C., 200° C., 250° C., 300° C., 350° C., 400° C., 450° C., 500° C., 550° C., 600° C., 650° C., 700° C., 750° C., 800° C., 850° C., 900° C., or higher. At such temperatures, one or more components of the device may be in a liquid (or molten) or vapor state.

[0059] The device may include a ceramic material. The ceramic material may be used as a dielectric insulator in a device containing one or more reactive materials. The device may be operated at a temperature of, for example, at least about 300° C. or 400° C. The device may be associated with a nuclear fission or nuclear fusion reactor. The dielectric insulator may be part of a seal (e.g., a hermetic seal). The ceramic material may be used in a seal of a device containing reactive materials and operated at a temperature greater than about 300° C.

[0060] The seal may include a ceramic material (e.g., aluminum nitride (AlN)) in contact with a reactive material (e.g., a reactive metal or a molten salt) contained in the device. The ceramic material may be chemically resistant to the reactive material (e.g., a reactive material contained in the device, such as, for example, a reactive metal or a molten salt). The ceramic material may be chemically resistant to the reactive material when the device is operated at a high temperature (e.g., at least about 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 500°C, 600°C, 700°C, 800°C, or 900°C).

[0061] The seal may include an active metal braze joint disposed between the ceramic material and at least one of the metal ferrule / sleeve and the device. The active metal braze joint may include a metal species that chemically reduces the ceramic material (eg, titanium (Ti) or zirconium (Zr)).

[0062] The seal may surround a conductive feedthrough (and may electrically isolate the feedthrough from the housing of the device), a thermocouple, or a voltage sensor. For example, a ceramic material may be an insulator.

[0063] The seal may surround a conductive feedthrough (and may electrically isolate the feedthrough from the housing of the device), a thermocouple, or a voltage sensor. For example, the ceramic material may be an insulator. In some examples, the seal may be chemically resistant to reactive materials in the device at a temperature of at least about 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 500°C, 600°C, 700°C, 800°C, or 900°C. In some examples, the seal may be chemically resistant to reactive materials at such a temperature for at least about 6 months, 1 year, 2 years, 5 years, 10 years, 20 years, or more. In some examples, the device may be a high temperature reactive metal device, and the seal may be chemically resistant to materials in the device containing reactive metals. In one example, the seal may be resistant to lithium vapor at a temperature of at least about 300°C for at least about one year. The seal may retain reactive materials (e.g., vapors of reactive materials) in the device. For example, the seal may retain reactive metal vapors and / or molten salt vapors within the device.

[0064] Electrochemical cells, devices and systems

[0065] The present disclosure provides electrochemical energy storage devices (e.g., batteries) and systems. The energy storage device can be formed or provided within an energy storage system. The electrochemical energy storage device typically includes at least one electrochemical cell, also referred to herein as a "cell" and a "battery cell," sealed (e.g., hermetically sealed) within a housing. The cell can be configured to deliver electrical energy (e.g., electrons at an electric potential) to a load such as, for example, an electronic device, another energy storage device, or a power grid.

[0066] An electrochemical cell of the present disclosure may include a negative electrode, an electrolyte adjacent to the negative electrode, and a positive electrode adjacent to the electrolyte. The negative electrode may be separated from the positive electrode by an electrolyte. The negative electrode may be an anode during discharge. The positive electrode may be a cathode during discharge. The cell may include a negative electrode made of material 'A' and a positive electrode made of material 'B', represented as A||B. The positive electrode and the negative electrode may be separated by an electrolyte. The cell may also include a housing, one or more current collectors, and a seal (e.g., a high temperature electrical isolation seal).

[0067] In some examples, the electrochemical cell is a liquid metal battery cell. In some examples, the liquid metal battery cell may include a liquid electrolyte arranged between a liquid (e.g., molten) metal negative electrode and a solid, semi-solid, liquid (e.g., molten) metal, semi-metal and / or non-metal positive electrode. In some cases, the liquid metal battery cell has a molten alkaline earth metal (e.g., magnesium (Mg), calcium (Ca)) or alkali metal (e.g., lithium, sodium, potassium) negative electrode, an electrolyte and a molten metal positive electrode. The molten metal positive electrode may, for example, include one or more of tin (Sn), lead (Pb), bismuth (Bi), antimony (Sb), tellurium (Te) and selenium (Se). For example, the positive electrode may include liquid Pb, solid Sb, liquid or semi-solid Pb-Sb alloy or liquid Bi. The positive electrode may also include one or more transition metals or d-block elements (e.g., zinc (Zn), cadmium (Cd), and mercury (Hg)), alone or in combination with other metals, metalloids, or non-metals, such as, for example, Zn-Sn alloys or Cd-Sn alloys. In some examples, the positive electrode may include a metal or metalloid having a stable oxidation state (e.g., a metal having a single or single oxidation state). Any description of a metal or molten metal positive electrode herein, or any description of a positive electrode may refer to an electrode comprising one or more of a metal, a metalloid, and a non-metal. The positive electrode may include one or more of the listed material examples. In one example, the metal positive electrode may include lead and / or antimony. In some examples, the metal positive electrode may include an alkali metal and / or an alkaline earth metal alloyed in the positive electrode.

[0068] The electrolyte may include a salt (e.g., a molten salt) such as an alkali metal salt or an alkaline earth metal salt. The alkali metal salt or alkaline earth metal salt may be a halide such as a fluoride (F), chloride (Cl), bromide (Br), or iodide (I) of an active alkali metal or alkaline earth metal, or a combination thereof. In one example, the electrolyte (e.g., in a Type 1 or Type 2 chemistry) includes lithium chloride (LiCl). In some examples, the electrolyte may include sodium fluoride (NaF), sodium chloride (NaCl), sodium bromide (NaBr), sodium iodide (NaI), lithium fluoride (LiF), lithium chloride (LiCl), lithium bromide (LiBr), lithium iodide (LiI), potassium fluoride (KF), potassium chloride (KCl), potassium bromide (KBr), potassium iodide (KI), calcium fluoride (CaF2), calcium chloride (CaCl2), calcium bromide (CaBr2), calcium iodide (CaI2), strontium fluoride (SrF2), strontium chloride (SrCl2), strontium bromide (SrBr2), strontium iodide (SrI2), or any combination thereof. In some examples, the electrolyte includes magnesium chloride (MgCl2). Alternatively, the salt of the active alkali metal can be, for example, a non-chlorine halide, a diimide salt, a fluorosulfonyl-amine salt, a perchlorate, a hexafluorophosphate, a tetrafluoroborate, a carbonate, a hydroxide, a nitrate, a nitrite, a sulfate, a sulfite, or a combination thereof. In some cases, the electrolyte may include a mixture of salts (e.g., 25:55:20 mol% LiF:LiCl:LiBr, 50:37:14 mol% LiCl:LiF:LiBr, 34:32.5:33.5 mol% LiCl-LiBr-KBr, etc.). In some examples, the electrolyte contains about 30:15:55 mol% CaCl2:KCl:LiCl. In some examples, the electrolyte contains about 35:65 mol% CaCl2:LiCl. In some examples, the electrolyte contains about 24:38:39 wt% LiCl:CaCl2:SrCl2. In some examples, the electrolyte comprises at least about 20 wt% CaCl2, 20 wt% SrCl2, and 10 wt% KCl. In some examples, the electrolyte comprises at least about 10 wt% LiCl, 30 wt% CaCl2, 30 wt% SrCl2, and 10 wt% KCl. The electrolyte may exhibit low (e.g., minimal) electronic conductivity. For example, the electrolyte may have an electron migration number (i.e., the percentage of charge (electrons and ions) attributed to the migration of electrons) of less than or equal to about 0.03% or 0.3%.

[0069] In some cases, the negative electrode and / or the positive electrode of the electrochemical energy storage device is in a liquid state at the operating temperature of the energy storage device. In order to maintain the (one or more) electrodes in a (one or more) liquid state, the battery cell can be heated to any suitable temperature. In some examples, the battery cell is heated to and / or maintained at a temperature of about 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, 475°C, 500°C, 550°C, 600°C, 650°C or about 700°C. The battery cell can be heated to and / or maintained at a temperature of at least about 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, 475°C, 500°C, 550°C, 600°C, 650°C, 700°C, 800°C or 900°C. In such a case, the negative electrode, electrolyte and / or positive electrode may be in a liquid state (or molten state). In one example, the negative electrode and electrolyte are in a liquid state, and the positive electrode is in a solid or semi-solid state. In some cases, the battery cell is heated to between about 200°C and 600°C, 500°C and 550°C, or 450°C and 575°C.

[0070] In some embodiments, the electrochemical cell or energy storage device may be at least partially or completely self-heating. For example, the battery may be sufficiently insulated, charged, discharged, and / or conditioned at a sufficient rate and / or cycled for a sufficient percentage of time to allow the system to generate sufficient heat through the inefficiencies of the cycling operation to maintain the cell at a given operating temperature (e.g., a cell operating temperature above the freezing point of at least one of the liquid components) without applying additional energy to the system.

[0071] The electrochemical cells of the present disclosure may be adapted to cycle between a charging (or energy storage) mode and a discharging mode. In some examples, the electrochemical cells may be fully charged, partially charged, or partially or fully discharged.

[0072] A cell may have a voltage. A charge cutoff voltage (CCV) may refer to the voltage at which a cell is fully charged or substantially fully charged, such as the voltage cutoff limit used in a battery when cycling in a constant current mode. An open circuit voltage (OCV) may refer to the voltage of a cell (e.g., fully or partially charged) when the cell is disconnected from any circuit or external load (i.e., when no current flows through the cell). As used herein, a voltage or cell voltage may refer to the voltage of a cell (e.g., in any state of a charging condition or a charge / discharge condition). In some cases, a voltage or cell voltage may be an open circuit voltage. In some cases, a voltage or cell voltage may be a voltage during a charging process or during a discharging process. The voltage of the present disclosure may be employed or represented relative to a reference voltage, such as a ground voltage (0 volts (V)) or a voltage of opposite electrodes in an electrochemical cell.

[0073] The present disclosure provides monomers of type 1 and type 2, which can vary and be defined based on the composition of active components (e.g., negative electrode, electrolyte and positive electrode), and can vary based on the operating mode of the monomer (e.g., low voltage mode vs. high voltage mode). The monomer may include a material configured for use in the type 2 operating mode. The monomer may include a material configured for use in the type 1 operating mode. In some cases, the monomer may operate in both the high voltage (type 2) operating mode and the low voltage (type 1) operating mode. For example, a monomer having a positive electrode material and a negative electrode material generally configured for use in the type 1 mode may operate in the type 2 operating mode. The monomer may cycle between the type 1 operating mode and the type 2 operating mode. The monomer may be initially charged (or discharged) to a given voltage (e.g., 0.5V to 1V) in the type 1 mode, and then charged (and then discharged) to a higher voltage (e.g., 1.5V to 2.5V or 1.5V to 3V) in the type 2 mode. In some cases, a cell operating in Type 2 mode may operate at a voltage between electrodes that may exceed the voltage of a cell operating in Type 1 mode. In some cases, a Type 2 cell chemistry may operate at a voltage between electrodes that may exceed the voltage of a Type 1 cell chemistry operating in Type 1 mode. A Type 2 cell may operate in Type 2 mode.

[0074] In one example of a type 1 cell, cations formed at the negative electrode during discharge can migrate into the electrolyte. At the same time, the electrolyte can provide cations of the same kind (e.g., cations of the negative electrode material) (e.g., Sb, Pb, Bi, Sn, or any combination thereof) to the positive electrode, which can reduce the cations to uncharged metal species and alloy with the positive electrode. In some examples, different cation species in the electrolyte can be co-deposited onto the positive electrode (e.g., Ca 2+ (Ca2+ ) and lithium + (Li + ) is deposited onto Sb and forms (one or more) Ca-Li-Sb alloys). In the discharge state, the negative electrode of the negative electrode material (e.g., lithium (Li), sodium (Na), potassium (K), Mg, Ca) can be (e.g., partially or completely) depleted. During the charging process, the alloy on the positive electrode can decompose to produce one or more different types of cations of the negative electrode material that migrate into the electrolyte (e.g., Li + 、Na + , K + Mg 2+ , Ca 2+ ). The electrolyte, in turn, can provide cations (e.g., cations of the negative electrode material) to the negative electrode, where the cations accept one or more electrons from the external circuit and are converted back to neutral metal species, which recharges the negative electrode to provide the cell in a charged state. In some examples, different cation species in the electrolyte can be co-deposited onto the negative electrode during charging. Type 1 cells can operate in a pressure-bounce manner, in which entry of one or a group of cations into the electrolyte results in release of the same cation or the same group of cation species from the electrolyte.

[0075] In one example of a type 2 cell, the electrolyte contains cations of the negative electrode material (e.g., Li + 、Na + , K + Mg 2+ , Ca 2+ ), and the positive electrode comprises a positive electrode material (e.g., Sb, Pb, Sn, Zn, Hg). During discharge, cations of the negative electrode material from the electrolyte accept one or more electrons (e.g., from the negative current collector) to form a negative electrode comprising the negative electrode material. In some examples, the negative electrode material is liquid and wets into the foam (or porous) structure of the negative current collector. In some examples, the negative current collector may not include a foam (or porous) structure. In some examples, the negative current collector may include a metal, such as tungsten (W) (e.g., to avoid corrosion of Zn), tungsten carbide (WC) or molybdenum (Mo). The negative current collector does not contain an iron-nickel alloy (Fe-Ni) foam. At the same time, the positive electrode material from the positive electrode emits electrons (e.g., to the positive current collector) and dissolves into the electrolyte as cations of the positive electrode material (e.g., Sb 3+ , Pb 2+ Sn 2+ 、Zn 2+ , Hg 2+). The concentration of cations of the positive electrode material can vary with vertical proximity within the electrolyte (e.g., as a function of distance above the positive electrode material) based on the atomic weight and diffusion kinetics of the cation material in the electrolyte. In some examples, cations of the positive electrode material are enriched in the electrolyte near the positive electrode.

[0076] In some embodiments, negative electrode material may not be provided when assembling a cell operable in Type 2 mode. For example, a Li||Pb cell or an energy storage device including (one or more) such cells may be assembled in a discharged state with a Li salt electrolyte and a Pb or Pb alloy (e.g., Pb-Sb) positive electrode (i.e., Li metal may not be included during assembly).

[0077] Although the electrochemical cells of the present disclosure have been described, in some examples, when operating in Type 1 mode or Type 2 mode, other operating modes are possible. Type 1 mode or Type 2 mode are provided as examples and are not intended to limit the various operating modes of the electrochemical cells disclosed herein.

[0078] In some cases, the electrochemical cell includes a liquid metal negative electrode (e.g., sodium (Na) or lithium (Li)), a liquid (e.g., LiF-LiCl-LiBr, LiCl-KCl, or LiCl-LiBr-KBr) or solid ion conductive electrolyte (e.g., ″-alumina ceramic), and a solid, liquid, or semi-solid positive electrode (e.g., a solid matrix or particle bed impregnated with a liquid or molten electrolyte). Such a cell can be a high temperature battery. One or more such cells can be provided in an electrochemical energy storage device. The negative electrode can include an alkali metal or an alkaline earth metal, such as, for example, lithium, sodium, potassium, magnesium, calcium, or any combination thereof. The positive electrode and / or electrolyte can include a liquid chalcogen or a molten chalcogen-halogen compound (e.g., an elemental, ionic, or other form of sulfur (S), selenium (Se), or tellurium (Te)), the molten salt includes a transition metal halide (e.g., Ni, Fe, chromium (Cr), manganese (Mn), or a molten salt. , cobalt (Co) or vanadium (V) halides, such as, for example, nickel chloride (NiCl3) or iron chloride (FeCl3), solid transition metals (e.g., particles of Ni, Fe, Cr, Mn, Co or V), sulfur, one or more metal sulfides (e.g., FeS2, FeS, NiS2, CoS2, or any combination thereof), liquid or molten alkali halide metal salts (e.g., including aluminum (Al), Zn or Sn) and / or other (e.g., supporting) compounds (e.g., NaCl, NaF, NaBr, NaI, KCl, LiCl or other alkali metal halides, bromide salts, elemental zinc, zinc-chalcogen or zinc-halogen compounds, or metal main group metals or oxygen scavengers (such as, for example, aluminum or transition metal-aluminum alloys)), or any combination thereof. The solid ion conductive electrolyte may include a beta alumina (e.g., ″-alumina) ceramic capable of conducting sodium ions at elevated temperatures or high temperatures. In some cases, the solid state ionically conductive electrolyte operates above about 100°C, 150°C, 200°C, 250°C, 300°C, or 350°C.

[0079] In one example, an electrochemical cell in a charged state includes a negative electrode containing calcium, an electrolyte containing CaCl2, and a positive electrode containing antimony. The operating temperature of the cell may be lower than about 600°C, 550°C, 500°C, 450°C, 400°C, 350°C, 300°C, 250°C, or 200°C. In some examples, the cell may have an operating temperature of at least about 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, 500°C, or higher. The positive electrode or cathode in a charged state may contain solid antimony and / or solid antimony alloy, and may not contain any liquid metal. The negative electrode or anode in a charged state may contain lithium and / or magnesium metal. Under normal operating (e.g., charging, discharging) conditions, the negative electrode may remain in a liquid or semi-solid state.

[0080] Any aspects of the present disclosure described with respect to the cathode may also be applicable to the anode, at least in some configurations. Similarly, in alternative configurations one or more battery electrodes and / or the electrolyte may not be liquid. In further examples, at least one battery electrode may be a solid, a gel, or a paste. In addition, in some examples, the electrode and / or the electrolyte may not contain metal. Aspects of the present disclosure are applicable to various energy storage devices / energy conversion devices and are not limited to liquid metal batteries.

[0081] Battery and case

[0082] The electrochemical cell of the present disclosure may include a housing that can be suitable for various purposes and operations. The housing may include one or more monomers. The housing may be configured to electrically couple an electrode to a switch that can be connected to an external power source and an electrical load. The monomer housing may, for example, include a conductive current feed-through conductor (e.g., a current lead rod) electrically coupled to the first pole of the switch and / or another monomer housing, and a conductive container cover electrically coupled to the second pole of the switch and / or another monomer housing. The monomer may be arranged in the cavity of the container. The first of the electrodes of the monomer (e.g., a positive electrode) may contact the end wall of the container and be electrically coupled thereto. The second of the electrodes of the monomer (e.g., a negative electrode) may contact a conductive feed-through body or conductor (e.g., a negative current lead) on a container cover (collectively referred to herein as a "monomer cover assembly", "cover assembly" or "cap assembly") and be electrically coupled thereto. An electrically insulating seal (e.g., a bonded ceramic ring) can electrically isolate the negative potential portion of the cell from the positive electrical portion of the cell (e.g., electrically insulating a negative current lead from a positive current lead or electrically insulating a positively polarized current lead from a negatively polarized cell cover / cell housing). In one example, the negative current lead and the container cover (e.g., a cell cap) can be electrically isolated from each other, wherein a dielectric sealant material can be placed between the negative current lead and the cell cap. Alternatively, the housing includes an electrically insulating sheath (e.g., an alumina sheath) or a corrosion-resistant and electrically conductive sheath or crucible (e.g., a graphite sheath or crucible). In some examples, the housing and / or container can be a battery housing and / or container.

[0083] The monomer can have any monomer and seal configuration disclosed herein. For example, the active monomer material can be kept in a sealed steel / stainless steel container with a high temperature seal on the monomer cover. The current lead (e.g., a negative current lead rod) can pass through the monomer cover (and be sealed to the monomer cover by a dielectric high temperature seal) and be connected to a porous current collector (e.g., a negative current collector, such as a metal foam) suspended in the electrolyte. In some examples, the monomer can use a graphite sheath, coating, crucible, surface coating or lining (or any combination thereof) on the inner wall of a monomer crucible (e.g., a container). In some examples, the monomer may not use a graphite sheath, coating, crucible, surface coating or lining on the inner wall of a monomer crucible (e.g., a container).

[0084] The monomer can have a set of dimensions. In some examples, the monomer can be greater than or equal to about 4 inches wide, 4 inches deep and 2.5 inches high. In some examples, the monomer can be greater than or equal to about 8 inches wide, 8 inches deep and 2.5 inches high. In some examples, the height and width of the monomer can be greater than the depth of the monomer, and can be referred to as a "prismatic" monomer geometry, where the seal is located on the top horizontal surface of the monomer. The width of the prismatic monomer geometry can be at least about 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches or more inches, the height is at least about 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches or more inches, and the depth is less than about 8 inches, 6 inches, 4 inches, 2 inches or less inches. In some examples, the prismatic monomer geometry has a width of about 4 inches, a height of about 6 inches and a depth of about 2 inches. In some examples, the prismatic monomer geometry has a width of about 6 inches, a height of about 6 inches and a depth of about 2 inches. In some examples, the prismatic unibody geometry has a width of about 6 inches, a height of about 6 inches, and a depth of about 3 inches. In some examples, the prismatic unibody geometry has a width of about 8 inches, a height of about 8 inches, and a depth of about 2 inches. In some examples, the prismatic unibody geometry has a width of about 8 inches, a height of about 8 inches, and a depth of about 3 inches. In some examples, the prismatic unibody geometry has a width of about 9 inches, a height of about 9 inches, and a depth of about 2 inches. In some examples, the prismatic unibody geometry has a width of about 9 inches, a height of about 9 inches, and a depth of about 3 inches. In some examples, any given dimension (e.g., height, width, or depth) of an electrochemical cell can be at least about 1 inch, 2 inches, 2.5 inches, 3 inches, 3.5 inches, 4 inches, 4.5 inches, 5 inches, 5.5 inches, 6 inches, 6.5 inches, 7 inches, 7.5 inches, 8 inches, 8.5 inches, 9 inches, 9.5 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, or 20 inches. In one example, a cell (e.g., each cell) can have dimensions greater than or equal to about 4 inches by 4 inches by 2 inches. In some examples, a cell (e.g., each cell) can have dimensions greater than or equal to about 8 inches by 8 inches by 2.5 inches. In some examples, a cell can have an energy storage capacity greater than or equal to about 50 watt-hours. In some examples, the battery can have an energy storage capacity of at least about 200 watt-hours.

[0085] The positive electrode may be electrically connected to the positive current collector. In some embodiments, the positive electrode may be electrically connected to the housing. In some embodiments, the positive electrode may include antimony. In some embodiments, the positive electrode may include an antimony alloy. In some embodiments, the positive electrode may be a solid metal electrode. In some embodiments, the solid metal positive electrode may be a flat plate configuration. Alternatively or additionally, the solid metal positive electrode may include particles. The particles may include particles, flakes, needles, or any combination thereof of a solid material. In some embodiments, the positive electrode may be solid antimony. Solid antimony may be a flat plate configuration. Alternatively or additionally, solid antimony may be particles including particles, flakes, needles, or any combination thereof of a solid material. The solid metal positive electrode particles may include a size of at least about 0.001 mm, at least about 0.01 mm, at least about 0.1 mm, at least about 0.25 mm, at least about 0.5 mm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 5 mm, or more. In some embodiments, the electrolyte is located on top of the positive electrode. Alternatively or additionally, the positive electrode may be immersed in the electrolyte or surrounded by the electrolyte.

[0086] The electrochemical cell may be arranged in the housing so that the average flow path of the ions is substantially perpendicular to the plane of the container lid (e.g., when the lid faces upward, the ions flow vertically between the negative electrode and the positive electrode). The configuration may include a negative electrode included in a negative electrode current collector suspended in a cavity of the housing by a negative current lead. In this configuration, the width of the negative electrode current collector may be greater than the height. The negative electrode may be partially or completely immersed in a molten salt electrolyte. A gaseous headspace may exist above the negative electrode (i.e., between the negative electrode and the container lid). The molten salt electrolyte may be between the negative electrode and the positive electrode and separate them. The positive electrode may be located at or near the bottom of the cavity (i.e., opposite to the container lid). The positive electrode may include a solid slab geometry or may include solid material particles. The positive electrode may be located below the electrolyte or may be immersed or surrounded by the electrolyte. During discharge, ions can flow from the negative electrode to the positive electrode with an average flow path perpendicular to and away from the container lid. During charging, ions can flow from the positive electrode to the negative electrode with an average flow path perpendicular to the container lid and toward the container lid.

[0087] The electrochemical cell can be arranged with the housing so that the average flow path of the ions is substantially parallel to the plane of the container lid (e.g., when the lid faces up, the ions flow horizontally between the negative electrode and the positive electrode). In some examples, the electrochemical cell includes a negative electrode included in a negative electrode current collector suspended in a cavity of the housing by a negative current lead. In this configuration, the height of the negative electrode current collector may be greater than the width. The negative electrode may be partially or completely immersed in a molten salt electrolyte. There may be a gaseous head space between the negative electrode and the container lid. In some embodiments, the negative electrode may be immersed and covered by a molten electrolyte, and the gaseous head space may be between the electrolyte and the container lid. The positive electrode may be positioned between the bottom of the cavity and the container lid along the sidewall of the housing. The positive electrode may be positioned along a portion of the inner sidewall or cover one or more of the entire inner sidewalls of the cavity. The positive electrode may cover at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90% or more of the area of ​​the sidewall.

[0088] Based on the design requirements of the battery, the cross-sectional geometry of the cell or battery can be circular, oval, square, rectangular, polygonal, curved, symmetrical, asymmetrical, or any other composite shape. In some examples, the cell or battery is axially symmetrical, with a circular or square cross-section. The components of the cell or battery (e.g., the negative electrode current collector) can be arranged in an axisymmetric manner within the cell or battery. In some cases, one or more components can be arranged asymmetrically, such as, for example, offset from the center of the axis.

[0089] One or more electrochemical cells ("cells") may be arranged in groups. Examples of electrochemical cell groups include modules, packages, cores, CEs, and systems.

[0090] Modules can include monomers (e.g., monomers connected together on a substantially horizontal packaging plane) that are attached together in parallel, for example, by mechanically connecting the monomer housing of a monomer to the monomer housing of an adjacent monomer. In some examples, modules can include monomers that are attached together in series, for example, by mechanically connecting the monomer housing of a monomer to a current lead rod protruding from the seal of an adjacent monomer. In some examples, the monomers are connected to each other by a joining feature that is a part of the monomer body and / or connected to the monomer body (e.g., an ear piece protruding from the main part of the monomer body). Modules can include multiple monomers in parallel or in series. Modules can include any number of monomers, for example, at least about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or more monomers. In some examples, modules contain at least about 4, 9, 12 or 16 monomers. In some examples, the module can store greater than or equal to about 700 watt-hours of energy and / or deliver at least about 175 watts of power. In some examples, the module can store at least about 1080 watt-hours of energy and / or deliver at least about 500 watts of power. In some examples, the module can store at least about 1080 watt-hours of energy and / or deliver at least about 200 watts (e.g., greater than or equal to about 500 watts) of power. In some examples, the module can include a single cell.

[0091] The package can include modules attached by different electrical connections (e.g., vertically). The package can include any number of modules, for example, at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or more modules. In some examples, the package includes at least about 3 modules. In some examples, a package can store at least about 2 kWh of energy and / or deliver at least about 0.4 kW (e.g., at least about 0.5 kW or 1.0 kW) of power. In some examples, a package can store at least about 3 kWh of energy and / or deliver at least about 0.75 kW (e.g., at least about 1.5 kW) of power. In some examples, the package includes at least about 6 modules. In some examples, the package can store greater than or equal to about 6 kilowatt-hours of energy and / or deliver at least about 1.5 kilowatts (eg, greater than or equal to about 3 kilowatts) of power. In some examples, the modules are connected together in a series connection into a package.

[0092] The core can include multiple modules or packages attached by different electrical connections (e.g., by series connection and / or parallel connection). The core can include any number of modules or packages, for example, at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 45, 50 or more packages. In some examples, the core also includes a mechanical system, an electrical system and a thermal system that allow the core to store and return electrical energy efficiently in a controlled manner. In some examples, the core includes at least about 12 packages. In some examples, the core can store at least about 25 kilowatt-hours of energy and / or deliver at least about 6.25 kilowatts of power. In some examples, the core includes at least about 36 packages. In some examples, the core can store at least about 200 kilowatt-hours of energy and / or deliver at least about 40, 50, 60, 70, 80, 90, 100, 200, 500, 1000 kilowatts or more of power.

[0093] A "core enclosure" (CE) may include a plurality of cores attached by different electrical connections (e.g., by series and / or parallel connections). A CE may include any number of cores, for example, at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or more cores. In some examples, a CE includes a core connected in parallel with an appropriate bypass electronic circuit so that one core can be disconnected while continuing to allow other cores to store and return energy. In some examples, a CE includes at least 4 cores. In some examples, a CE is capable of storing at least about 100 kWh of energy and / or delivering a power greater than or equal to about 25 kW. In some examples, a CE includes 4 cores. In some cases, a CE is capable of storing about 100 kWh of energy and / or delivering a power greater than or equal to about 25 kW. In some examples, the CE is capable of storing greater than or equal to about 400 kWh of energy and / or delivering at least about 80 kW of power, e.g., greater than or equal to about 80, 100, 120, 140, 160, 180, 200, 250, 300, 500, 1000, or more kW or more.

[0094] The system may include multiple cores or CEs attached by different electrical connections (e.g., by series and / or parallel). The system may include any number of cores or CEs, for example, at least about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or more cores. In some examples, the system includes 20 CEs. In some examples, the system is capable of storing greater than or equal to about 2 megawatt-hours of energy and / or delivering at least about 400 kilowatts (e.g., about or at least about 500 kilowatts or 1000 kilowatts) of power. In some examples, the system includes 5 CEs. In some examples, the system is capable of storing greater than or equal to about 2 MWh of energy and / or delivering at least about 400 kW of power, e.g., at least about 400, 500, 600, 700, 800, 900, 1,000, 1,200, 1,500, 2,000, 2,500, 3,000, or 5,000 kW of power or more.

[0095] A group of cells (e.g., cores, CEs, systems, etc.) with a given energy capacity and power capacity (e.g., a CE or system capable of storing a given amount of energy) can be configured to deliver at least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95%, or about 100% of a given (e.g., rated) power level. For example, while a 1000kW system may also be able to operate at 500kW, a 500kW system may not be able to operate at 1000kW. In some examples, a system (e.g., a CE or system capable of storing a given amount of energy) with a given energy capacity and power capacity can be configured to deliver less than about 100%, 110%, 125%, 150%, 175%, or 200% of a given (e.g., rated) power level, etc. For example, a system can be configured to provide more than its rated power capacity for a period of time that is less than the time it would take to expend its energy capacity at the power level being provided (e.g., providing power greater than the system's rated power for a period of time that corresponds to less than approximately 1%, 10%, or 50% of its rated energy capacity).

[0096] A battery may include one or more electrochemical cells connected in series and / or in parallel. A battery may include any number of electrochemical cells, modules, packages, cores, CEs, or systems. A battery may undergo at least one charge / discharge or discharge / charge cycle ("cycle").

[0097] The battery may include one or more electrochemical cells. (One or more) cells may include a housing. Individual cells may be electrically coupled in series and / or in parallel with each other. In a series connection, the positive terminal of a first cell is connected to the negative terminal of a second cell. In a parallel connection, the positive terminal of a first cell may be connected to the positive terminal of a second cell and / or (one or more) additional cells. Similarly, cell modules, packaging packages, cores, CEs, and systems may be connected in series and / or in parallel in the same manner as described for the cells.

[0098] Reference will now be made to the drawings, wherein like reference numerals refer to like components throughout. It should be understood that the drawings and features therein are not necessarily drawn to scale.

[0099] refer to Figure 1 , an electrochemical cell (A) is a unit including an anode and a cathode. The cell may include an electrolyte and be sealed in a housing as described herein. In some examples, the electrochemical cells may be stacked (B) to form a battery (i.e., a grouping of one or more electrochemical cells). The cells may be arranged in parallel, in series, or in parallel and in series (C). In addition, as described in more detail elsewhere herein, the cells may be arranged in groups (e.g., modules, packages, cores, CEs, systems, or any other group including one or more electrochemical cells). In some examples, such groups of electrochemical cells may allow a given number of cells to be controlled or regulated together at a group level (e.g., to coordinate or replace the regulation / control of a single cell).

[0100] The electrochemical cells of the present disclosure (e.g., type 1 cells operating in type 2 mode, type 1 cells operating in type 1 mode, or type 2 cells) may be capable of storing a reasonably large amount of energy (e.g., a considerable amount of energy), accepting ("absorbing") input thereof, and / or releasing it. In some cases, the cells are capable of storing, absorbing, and / or releasing greater than or equal to about 1 watt-hour (Wh), 5Wh, 25Wh, 50Wh, 100Wh, 250Wh, 500Wh, 1 kilowatt-hour (kWh), 1.5kWh, 2kWh, 3kWh, 5kWh, 10kWh, 15kWh, 20kWh, 30kWh, 40kWh, or 50kWh. It should be recognized that the amount of energy stored in the electrochemical cell and / or battery may be less than the amount of energy absorbed into the electrochemical cell and / or battery (e.g., due to inefficiencies and losses). The cells may have such energy storage capacity when operated at any current density herein.

[0101] The monomer may be capable of providing at least about 10 milliamperes per square centimeter (mA / cm 2 )、20mA / cm 2 、30mA / cm2 , 40mA / cm 2 , 50mA / cm 2 、60mA / cm 2 , 70mA / cm 2 、80mA / cm 2 、90mA / cm 2 , 100mA / cm 2 , 200mA / cm 2 、300mA / cm 2 , 400mA / cm 2 , 500mA / cm 2 、600mA / cm 2 , 700mA / cm 2 、800mA / cm 2 , 900mA / cm 2 , 1A / cm 2 , 2A / cm 2 、3A / cm 2 , 4A / cm 2 , 5A / cm 2 or 10A / cm 2 The current density is provided based on the effective cross-sectional area of ​​the electrolyte and the cross-sectional area is the area orthogonal to the net flow direction of ions through the electrolyte during the charge or discharge process. In some cases, the monomer can be capable of operating with a direct current (DC) efficiency of at least about 10%, 20%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 90%, 95%, etc. In some cases, the monomer can be capable of operating with a charge efficiency (e.g., Coulombic charge efficiency) of at least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 85%, 90%, 95%, 98%, 99%, 99.5%, 99.9%, 99.95%, 99.99%, etc.

[0102] In the charged state, the electrochemical cells of the present disclosure (e.g., type 1 cells operating in type 2 mode, type 1 cells operating in type 1 mode, or type 2 cells) can have (or can operate at) a voltage of at least about 0V, 0.1V, 0.2V, 0.3V, 0.4V, 0.5V, 0.6V, 0.7V, 0.8V, 0.9V, 1.0V, 1.1V, 1.2V, 1.3V, 1.4V, 1.5V, 1.6V, 1.7V, 1.8V, 1.9V, 2.0V, 2.1V, 2.2V, 2.3V, 2.4V, 2.5V, 2.6V, 2.7V, 2.8V, 2.9V, or 3.0V. In some examples, the cell can have an open circuit voltage (OCV) of at least about 0.2 V, 0.3 V, 0.4 V, 0.5 V, 0.6 V, 0.7 V, 0.8 V, 0.9 V, 1.0 V, 1.1 V, 1.2 V, 1.3 V, 1.4 V, 1.5 V, 1.6 V, 1.7 V, 1.8 V, 1.9 V, 2.0 V, 2.1 V, 2.2 V, 2.3 V, 2.4 V, 2.5 V, 2.6 V, 2.7 V, 2.8 V, 2.9 V, or 3.0 V. In one example, the cell has an open circuit voltage greater than about 0.5 V, 1 V, 2 V, or 3 V. In some examples, the charge cutoff voltage (CCV) of the cell in the charged state is from greater than or equal to about 0.5 V to 1.5 V, 1 V to 3 V, 1.5 V to 2.5 V, 1.5 V to 3 V, or 2 V to 3 V. In some examples, the charge cutoff voltage (CCV) of the cell is at least about 0.5 V, 0.6 V, 0.7 V, 0.8 V, 0.9 V, 1.0 V, 1.1 V, 1.2 V, 1.3 V, 1.4 V, 1.5 V, 1.6 V, 1.7 V, 1.8 V, 1.9 V, 2.0 V, 2.1 V, 2.2 V, 2.3 V, 2.4 V, 2.5 V, 2.6 V, 2.7 V, 2.8 V, 2.9 V, or 3.0 V. In some examples, the voltage of the cell in a charged state (eg, operating voltage) is between approximately 0.5V and 1.5V, 1V and 2V, 1V and 2.5V, 1.5V and 2.0V, 1V and 3V, 1.5V and 2.5V, 1.5V and 3V, or 2V and 3V.The cell can provide such voltage(s) (e.g., voltage, OCV, and / or CCV) when operated for up to and beyond about 10 cycles, 20 cycles, 30 cycles, 40 cycles, 50 cycles, 100 cycles, 200 cycles, 300 cycles, 400 cycles, 500 cycles, 600 cycles, 700 cycles, 800 cycles, 900 cycles, 1,000 cycles, 2,000 cycles, 3,000 cycles, 4,000 cycles, 5,000 cycles, 10,000 cycles, 20,000 cycles, 50,000 cycles, 100,000 cycles, or 1,000,000 or more cycles (also referred to herein as "charge / discharge cycles").

[0103] In some examples, the limiting factor of the number of cycles may depend, for example, on the housing and / or seal, unlike the chemical processes of the negative electrode, electrolyte, and / or positive electrode. The limitation in the cycle may not be determined by the electrochemical process, but by the degradation of the inactive components of the monomer (such as the container or seal). The monomer can be operated without significantly reducing the capacity. In some cases, the operating service life of the monomer may be limited by the life of the container, seal, and / or cap of the monomer. During the operation of the monomer at the operating temperature, the monomer may have a negative electrode, electrolyte, and positive electrode in a liquid state (or molten state).

[0104] The electrochemical cells of the present disclosure may have a response time of any suitable value (e.g., suitable for responding to disturbances in the power grid). In some cases, the response time is less than or equal to about 100 milliseconds (ms), 50 ms, 10 ms, 1 ms, etc. In some examples, the response time is at most about 100 ms, 50 ms, 10 ms, 1 ms, etc.

[0105] A cell may be hermetically or non-hermetically sealed. Also, in a group of cells (e.g., a battery), each cell may be hermetically or non-hermetically sealed. If a cell is not hermetically sealed, a group of cells or a battery (e.g., several cells in series or in parallel) may be hermetically sealed.

[0106] The seal can be made hermetic by one or more methods. For example, the seal can withstand relatively high compressive forces (e.g., greater than about 1,000 psi or 10,000 psi) between the container lid and the container to provide a seal in addition to electrical isolation. Alternatively, the seal can be bonded by welding points, solder joints, or other chemical bonding materials that join the associated monolithic components to the insulating sealant material.

[0107] In one example, the cell housing includes a conductive container, a container aperture, and a conductor in electrical communication with a current collector. The conductor can pass through the container aperture and can be electrically isolated from the conductive container. The housing can be capable of hermetically sealing a cell capable of storing at least about 10Wh of energy.

[0108] Figure 2 A battery comprising an electrically conductive casing 201 and a conductor 202 in electrical communication with a current collector 203 is schematically illustrated. Figure 2 The battery may be a cell of the energy storage device. The conductor may be electrically isolated from the housing and may protrude through the housing through an aperture in the housing so that when the first cell is stacked with the second cell, the conductor of the first cell is in electrical communication with the housing of the second cell.

[0109] In some examples, the cell includes a negative current collector, a negative electrode, an electrolyte, a positive electrode, and a positive current collector. The negative electrode can be part of the negative current collector. Alternatively, the negative electrode is separated from the negative current collector, but otherwise maintains electronic communication with the negative current collector. The positive electrode can be part of the positive current collector. Alternatively, the positive electrode can be separated from the positive current collector, but otherwise maintains electronic communication with the positive current collector.

[0110] The cell may include an electronically conductive shell and a conductor in electronic communication with a current collector. The conductor protrudes through the shell through an aperture in the shell and may be electronically isolated from the shell.

[0111] The single housing may include a conductive container and a conductor in electrical communication with the current collector. The conductor may protrude through the housing and / or the container through an aperture in the container and may be electrically isolated from the container. When the first housing and the second housing are stacked, the conductor of the first housing may contact the container of the second housing.

[0112] In some cases, the area of ​​the aperture through which the conductor protrudes from the housing and / or container is small relative to the area of ​​the housing and / or container. The ratio of the area of ​​the aperture to the area of ​​the container and / or housing can be less than or equal to about 0.5, 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, 0.01, 0.005, or 0.001 (e.g., less than about 0.1).

[0113] The housing can enclose a cell capable of storing, receiving and / or releasing any suitable amount of energy, as described in more detail elsewhere herein. For example, the housing can enclose a cell capable of storing, receiving and / or releasing less than about 100Wh, about 100Wh, greater than about 100Wh, or at least about 10Wh or 25Wh of energy.

[0114] Characteristics and properties of seals

[0115] Seals can be important components of high temperature systems (e.g., liquid metal batteries) containing reactive materials. Provided herein is a method for selecting a material suitable for forming a seal and a method for designing a suitable seal for a system (e.g., such as a liquid metal battery) containing reactive liquid metal or liquid metal vapor and / or (one or more) reactive molten salt or reactive molten salt vapor (e.g., based on the selection of these materials and considerations of thermal properties, mechanical properties, and electrical properties). The seal can also be used as a part of an electrically isolated feedthrough connected to a vessel containing reactive liquid metal or reactive metal vapor, for applications such as fusion reactors containing molten or high pressure Li vapor in addition to energy storage or other applications involving liquid sodium, potassium, magnesium, calcium, and / or lithium. Use of stable ceramics and conductive materials can also be suitable for applications with reactive gases, such as those used in semiconductor material processing or device manufacturing.

[0116] The seal may be electrically insulating and gas-tight (e.g., hermetic). The seal may be made of a material that is not attacked by liquid and vapor phases of system / vessel components (e.g., monomeric components), such as, for example, molten sodium (Na), molten potassium (K), molten magnesium (Mg), molten calcium (Ca), molten lithium (Li), Na vapor, K vapor, Mg vapor, Ca vapor, Li vapor, or any combination thereof. The method identifies seals including aluminum nitride (AlN) or silicon nitride (Si3N4) ceramics and active alloy braze joints (e.g., Ti, Fe, Ni, B, Si, or Zr alloy based) as being thermodynamically stable with most reactive metal vapors, thereby allowing for the design of seals that are not significantly attacked by metals or metal vapors.

[0117] In some embodiments, the seal can physically separate the current lead (e.g., a negative electrode current collector such as a metal rod extending into the cell cavity) from the body of the cell (e.g., the cell (also referred to herein as the "container") and the lid) of the opposite polarization (e.g., positive polarization). The seal can act as an electrical insulator between these cell components and hermetically isolate the active cell components (e.g., liquid metal electrodes, liquid electrolytes, and vapors of these liquids). In some examples, the seal prevents external elements from entering the cell (e.g., moisture, oxygen, nitrogen, and other contaminants that may adversely affect the performance of the cell). Some examples of general seal specifications are listed in Table 1. Such specifications (e.g., properties and / or metrics) may include, but are not limited to, airtightness, electrical insulation, durability, coulombic efficiency (e.g., charging efficiency or round-trip efficiency), DC-DC efficiency, discharge time, and capacity decay rate.

[0118] Table 1: Examples of common seal specifications

[0119]

[0120]

[0121] The seal can be hermetic, for example, to a degree quantified by a helium (He) leak rate (e.g., a leak rate from a device filled with He under operating conditions (e.g., at operating temperature, operating pressure, etc.). In some examples, the helium (He) leak rate can be less than about 1×10 -6 Atmospheric pressure cubic centimeter per second (atm cc / s), 5×10 -7 atm cc / s, 1×10 -7 atm cc / s, 5×10 -8 atm cc / s or 1×10 -8 atm cc / s. In some examples, the He leakage rate is equivalent to the total leakage rate of He leaving the system (e.g., cell, seal). In some examples, if one atmosphere of He pressure is applied across the sealed interface, then the He leakage rate is equivalent to the total leakage rate of He, as determined by the actual He pressure / concentration difference across the sealed interface and the measured He leakage rate.

[0122] The seal can provide any suitable low helium leak rate. In some examples, the seal provides a helium leak rate of not greater than or equal to about 1 x 10 at a temperature (e.g., a storage temperature of the monomer, an operating temperature of the monomer, and / or a temperature of the seal) greater than or equal to about -25°C, 0°C, 25°C, 50°C, 200°C, 350°C, 450°C, 550°C, or 750°C. -10 , 1x10 -9 , 1x10 -8 , 1x10 -7 , 5x10 -7 , 1x10 -6 , 5x10 -6 , 1x10 -5 or 5x10 -5Atmosphere-cubic centimeters per second (atm-cc / s) helium leak rate. The seal can provide such a helium leak rate when the electrochemical cell has been operated (e.g., at rated capacity) for, for example, a period of at least about 1 hour, 12 hours, 1 day, 2 days, 3 days, 4 days, 5 days, 1 week, 2 weeks, 3 weeks, 1 month, 6 months, 1 year, 2 years, 5 years, 10 years, 20 years, or more. In some examples, the seal provides such a helium leak rate when the electrochemical cell has been operated for at least about 350 charge / discharge cycles (or cycles), 500 cycles, 1,000 cycles, 3,000 cycles, 10,000 cycles, 50,000 cycles, 75,000 cycles, or 150,000 cycles.

[0123] In one example, the seal is substantially non-reactive to air and prevents air from diffusing into the container when the reactive material is maintained at a temperature of at least about 200° C., 250° C., 300° C., 350° C., 400° C., 450° C., 500° C., or more. The seal can prevent air from diffusing into the container for at least about 1 hour, 12 hours, 1 day, 2 days, 3 days, 4 days, 5 days, 1 week, 2 weeks, 3 weeks, 1 month, 6 months, 1 year, 2 years, 5 years, 10 years, 20 years, or more. The air diffusion into the container can be up to about 1×10 -4 , 1x10 -5 , 1x10 -6 , 1x10 -7 , 1x10 -8 , 1x10 -9 , 1x10 -10 or less than atmospheric pressure - cubic centimeters per second.

[0124] The seal can electrically isolate the conductor from the conductive housing. The degree of electrical isolation can be quantified by measuring the impedance across the seal. In some examples, at any operating, static or storage temperature, the impedance across the seal is greater than or equal to about 0.05 kilo-ohms (kOhm), 0.1 kOhm, 0.5 kOhm, 1 kOhm, 1.5 kOhm, 2 kOhm, 3 kOhm, 5 kOhm, 10 kOhm, 50 kOhm, 100 kOhm, 500 kOhm, 1,000 kOhm, 5,000 kOhm, 10,000 kOhm, 50,000 kOhm, 100,000 kOhm, or 1,000,000 kOhm. In some examples, the impedance across the seal is less than about 0.1 kOhm, 1 kOhm, 5 kOhm, 10 kOhm, 50 kOhm, 100 kOhm, 500 kOhm, 1,000 kOhm, 5,000 kOhm, 10,000 kOhm, 50,000 kOhm, 100,000 kOhm, or 1,000,000 kOhm at any operating, quiescent, or storage temperature. The seal can provide electrical isolation when the electrochemical cell has been operated, for example, for a period of at least about 1 month, 6 months, 1 year, or longer. In some examples, the seal provides electrical isolation when the electrochemical cell has been operated for at least about 350 charge / discharge cycles (cycles), 500 cycles, 1,000 cycles, 3,000 cycles, 10,000 cycles, 50,000 cycles, 75,000 cycles, 150,000 cycles. The seal can provide electrical isolation when the electrochemical cell has been operated for a period of at least about 1, 5, 10, 20, 50, or 100 years. In some examples, the seal provides electrical isolation when the electrochemical cell has been operated for greater than or equal to about 350 charge / discharge cycles.

[0125] The seal can be durable. In some examples, the seal can maintain integrity for at least 1 month, 2 months, 6 months, 1 year, 2 years, 5 years, 10 years, 15 years, 20 years or more. The seal can have such properties and / or measurements under operating conditions.

[0126] In some examples, a battery or device including a seal can have a Coulombic efficiency of at least about 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.8%, 99.9% or more (e.g., at a current density of about 20 mA / cm 2 , 200mA / cm 2 or 2,000mA / cm 2In some examples, a battery or device including a seal can have a DC-DC efficiency of at least about 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or more (e.g., at a current density of about 200 mA / cm 2 or 220mA / cm 2 In some examples, a battery or device including a seal can have a discharge time of at least about 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, or more (e.g., at a current density of about 200 mA / cm 2 or 220mA / cm 2 In some examples, a battery or device including a seal can have a discharge time between about 4 hours and 6 hours, 2 hours and 6 hours, 4 hours and 8 hours, or 1 hour and 10 hours (e.g., at a current density of about 200 mA / cm 2 or 220mA / cm 2 In some examples, a battery or device including a seal can have a capacity fade rate (e.g., discharge capacity fade rate) of less than about 10% / cycle, 5% / cycle, 1% / cycle, 0.5% / cycle, 0.1% / cycle, 0.08% / cycle, 0.06% / cycle, 0.04% / cycle, 0.02% / cycle, 0.01% / cycle, 0.005% / cycle, 0.001% / cycle, 0.0005% / cycle, 0.0002% / cycle, 0.0001% / cycle, 0.00001% / cycle, or less. The capacity fade rate can provide a measure of the change (decrease) in discharge capacity as "% per cycle" (e.g., as % per charge / discharge cycle).

[0127] In some examples, the seal allows the electrochemical cell to be implemented at one or more given operating conditions (e.g., operating temperature, temperature cycling, voltage, current, internal gas pressure, internal pressure, vibration, etc.). Some examples of operating conditions are described in Table 2. Such operating conditions can include, but are not limited to, metrics such as operating temperature, idle temperature, temperature cycling, voltage, current, internal gas pressure, external gas pressure, internal pressure, vibration, and service life, for example.

[0128] Table 2: Examples of operating conditions for monomers

[0129]

[0130]

[0131] In some examples, the operating temperature (e.g., the temperature experienced by the seal during operation) is at least about 100°C, 200°C, 300°C, 400°C, 500°C, 600°C, 700°C, 800°C, 900°C, or higher. In some examples, the temperature experienced by the seal during operation is between about 440°C and 550°C, between 475°C and 550°C, between 350°C and 600°C, or between 250°C and 650°C. In one example, an operating temperature of about 400°C to about 500°C, about 450°C to about 550°C, about 450°C to about 500°C, or about 500°C to about 600°C, or an operating temperature of at least about 200°C (e.g., suitable for a cell chemistry that can operate at as low as 200°C) can be achieved. In some examples, the temperature experienced by the seal can be about equal to the operating temperature of an electrochemical cell or a high temperature device (e.g., an energy storage device). In some examples, the temperature to which the seal is subjected can be different from the operating temperature of the electrochemical cell or the high temperature device (e.g., different by at least less than or equal to about 1°C, 5°C, 10°C, 20°C, 50°C, 100°C, 150°C, 200°C, etc.). In one example, the electrochemical cell includes a reactive material maintained at a temperature of at least about 200°C (e.g., the operating temperature of the cell), and the temperature of the seal is at least about 200°C (e.g., the same as the operating temperature of the cell or different from the operating temperature of the cell). In some examples, the operating temperature of the seal can be lower or higher than the operating temperature of the electrochemical cell or the high temperature device.

[0132] The chemical stability of materials (e.g., cell cover assembly materials, one or more adhesive sealing materials, etc.) may be considered (e.g., to ensure the durability of the seal during all possible temperatures that the system may reach). The seal may be exposed to one or more different atmospheres, including inside the cell (internal atmosphere) and in the open air (external atmosphere). For example, the seal may be exposed to typical air components containing moisture, as well as to potential corrosive active materials in the cell. In some embodiments, an airtight seal is provided. An airtight sealed battery or battery housing can prevent inappropriate amounts of air, oxygen, nitrogen, and / or water from leaking or otherwise entering the battery. An airtight sealed battery or battery housing can prevent inappropriate amounts of one or more gases (e.g., air or any (one or more) components thereof, or other types of surrounding atmospheres or any (one or more) components thereof) from leaking or otherwise entering the battery around the battery. In some examples, an airtight sealed cell or cell housing can prevent gas or metal / salt vapor (e.g., helium, argon, negative electrode vapor, electrolyte vapor) from leaking from the cell.

[0133] A hermetically sealed cell or cell housing can prevent an undue amount of air, oxygen, and / or water from entering the cell (e.g., an amount that is sufficient to prevent the cell from being exposed to air at a rate of at least about 100 mA / cm2 for at least about 1, 2, 5, 10, or 20 years). 2 The battery is charged and discharged such that the battery maintains at least about 80% of its energy storage capacity and / or maintains a round-trip coulombic efficiency of at least about 90% per cycle). In some cases, when the battery is in contact with air at a pressure that is at least about (or less than about) 0 atmospheres (atm), 0.1 atm, 0.2 atm, 0.3 atm, 0.4 atm, 0.5 atm, 0.6 atm, 0.7 atm, 0.8 atm, 0.9 atm, or 0.99 atm higher than the internal pressure of the battery, or at least about (or less than about) 0.1 atm, 0.2 atm, 0.5 atm, or 1 atm lower than the internal pressure of the battery, and at a temperature of about 400° C. to about 700° C., the rate at which oxygen, nitrogen, and / or water vapor is transferred into the battery is less than about 0.25 milliliters (mL) per hour, 0.02 mL per hour, 0.002 mL per hour, or 0.0002 mL per hour. In some cases, when the battery is in contact with air at a pressure greater than or equal to about 0.5 atm, 1 atm, 1.5 atm, 2 atm, 2.5 atm, 3 atm, 3.5 atm, or 4 atm less than the internal pressure of the battery and at a temperature of about 400° C. to about 700° C., the rate at which the metal vapor, molten salt vapor, or inert gas is transferred out of the battery is less than 0.25 mL per hour, 0.02 mL per hour, 0.002 mL per hour, or 0.0002 mL per hour. In some examples, the number of moles of oxygen, nitrogen, or water vapor that leaks into the cell over a given period of time (e.g., at least about 1 month period, 6 month period, 1 year period, 2 year period, 5 year period, 10 year period, or more) is less than about 10%, 5%, 3%, 1%, 0.5%, 0.1%, 0.05%, or 0.5% of the number of moles of active material (e.g., active metal material) in the cell.

[0134] The seal can meet one or more specifications including, but not limited to: electrical insulation and airtightness, ability to operate continuously over the service life at operating temperatures, thermal cycling capability, sufficiently high conductivity of the conductor (e.g., negative current lead), a configuration that does not protrude excessively from the body of the cell, an inner surface that is chemically stable with liquids and vapors of active components, an outer surface that is stable in air, the ability to avoid arcing at high potentials, etc.

[0135] Materials, chemical compatibility and coefficients of thermal expansion

[0136] The materials and features of the seals herein can be configured to achieve suitable material (e.g., chemical, mechanical, thermal) compatibility. Material compatibility can include, for example, appropriate matching of coefficient of thermal expansion (CTE), suitable Young's modulus properties (e.g., low Young's modulus metal materials), and / or suitable ductility properties (e.g., one or more components with high ductility). The seals can incorporate structural features that can compensate for CTE mismatches.

[0137] Materials can be selected to achieve low CTE mismatch between various (e.g., paired) seal materials and / or housing (e.g., monolithic cover and / or body) materials. Materials can be selected to achieve low stress (e.g., stress due to CTE mismatch) at (one or more) joints between various (e.g., paired) seal materials and / or housing materials. The joints between various seal materials and / or housing materials can be of a given type (e.g., ceramic to metal or metal to metal). In one example, the ceramic material has a CTE that appropriately (e.g., substantially) matches the CTE of the monolithic cover or body, thereby reducing or minimizing (one or more) stresses (e.g., (one or more) stresses at one or more ceramic to metal joints between the ceramic material and the monolithic cover or body). In some examples, the CTE of the ceramic material is appropriately (e.g., substantially) different from the CTE of the monolithic cover or body. In this case, a metal collar or sleeve can be used that has a better CTE match or has one or more other properties that reduce stress in the ceramic to metal joint. The metal ferrule or sleeve can move CTE stress from the ceramic joint (e.g., from the ceramic-to-metal joint between the ceramic and the metal ferrule or sleeve) to the monolithic cover or body joint (e.g., to the metal-to-metal joint between the metal ferrule or sleeve and the monolithic cover or body). The CTE of the ceramic material can appropriately (e.g., substantially) match the CTE of the metal ferrule or sleeve. The CTE of the ceramic material can appropriately (e.g., substantially) be different from the CTE of the metal ferrule or sleeve. For example, by using a ductile metal ferrule or sleeve (e.g., containing at least about 95% or 99% Ni) and / or by using a ductile brazing material (e.g., containing at least about 95% or 99% Ag, Cu, or Ni), (one or more) ceramic-to-metal seal joint stresses can be reduced. The ductile brazing material can be used to reduce (one or more) stresses at the ceramic-to-metal joint between the ceramic and the monolithic cover or body or to reduce (one or more) stresses at the ceramic-to-metal joint between the ceramic and the metal ferrule or sleeve.

[0138] The seal can be made of any suitable material (e.g., so that the seal forms an airtight seal and electrical isolation). In some examples, the seal includes a ceramic material and a brazing material. The ceramic material can have a CTE that matches the housing material so that the electrochemical cell maintains suitable airtight and / or electrical insulation properties during operation and / or startup of the battery. The ceramic material can have a CTE that matches the CTE of the brazing material and / or the top of the cell (e.g., a cover or cap, or any component of the cell cover assembly) or the body. In some examples, the CTE of the ceramic material, the brazing material, and the top or body of the cell may not be identically matched, but may be close enough to minimize stress during the brazing operation and subsequent thermal cycles in operation. In some examples, the CTE of the ceramic material may not be close enough to the CTE of the top or body of the cell (e.g., in some cases resulting in an unstable and / or unreliable ceramic-to-metal joint that may lose its non-leakage properties). The seal may include a collar (e.g., a thin metal collar) or a sleeve (e.g., to overcome the CTE mismatch between the ceramic material and the cell cover or the cell body). The collar or sleeve can be a metal collar or sleeve. The collar or sleeve can be brazed to the ceramic (e.g., via a brazing material) and joined to the cell cover and / or current lead, which protrudes through the cell cover and enters the battery cavity. Suitable collar or sleeve materials and / or designs can be selected to reduce the stress generated at the ceramic to metal joint (e.g., by reducing CTE mismatch), increase the stress generated at the collar or sleeve to the cell cover or body joint (e.g., by increasing CTE mismatch), or a combination thereof. The seal can include features that reduce the CTE mismatch between the ceramic and the cell cover and / or the current lead rod. Any aspects of the present disclosure described about the cell top or body (e.g., CTE, joint stress, configuration and / or formation, etc.) can be equally applicable to the cell top and body at least in some configurations. Any aspects of the present disclosure described about the cell top can be equally applicable to the cell body at least in some configurations, and vice versa.

[0139] The CTE of the metal ferrule or sleeve may be at least about 5 μm / m / °C, 6 μm / m / °C, 7 μm / m / °C, 8 μm / m / °C, 9 μm / m / °C, 10 μm / m / °C, 11 μm / m / °C, 12 μm / m / °C, 13 μm / m / °C, 14 μm / m / °C, 15 μm / m / °C, 16 μm / m / °C, 17 μm / m / °C, 18 μm / m / °C, 19 μm / m / °C or 20 μm / m / °C. The metal ferrule or sleeve may have a CTE of less than or equal to about 20 μm / m / ° C., 19 μm / m / ° C., 18 μm / m / ° C., 17 μm / m / ° C., 16 μm / m / ° C., 15 μm / m / ° C., 14 μm / m / ° C., 13 μm / m / ° C., 12 μm / m / ° C., 11 μm / m / ° C., 10 μm / m / ° C., 9 μm / m / ° C., 8 μm / m / ° C., 7 μm / m / ° C., 6 μm / m / ° C., or 5 μm / m / ° C. In some examples, the metal ferrule or sleeve includes Zr and has a CTE of less than or equal to about 7 μm / m / ° C. In some examples, the metal ring or sleeve includes Ni (e.g., at least about 95% or 99% Ni, or at least about 40% Ni and at least about 40% Fe by weight) and has a CTE greater than or equal to about 6μm / m / °C, 7μm / m / °C, 8μm / m / °C, 9μm / m / °C, 10μm / m / °C, 11μm / m / °C, 12μm / m / °C, 13μm / m / °C, 14μm / m / °C, 15μm / m / °C, 16μm / m / °C, 17μm / m / °C, 18μm / m / °C, 19μm / m / °C, or 20μm / m / °C. The metal ferrule or sleeve may include greater than or equal to about 5%, 10%, 15%, 20%, 25%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 99% Ni (e.g., by weight). The metal ferrule or sleeve may comprise a Ni composition in combination with greater than or equal to about 5%, 10%, 15%, 20%, 25%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 99% Fe (by weight).Such Ni or Ni-Fe compositions (e.g., alloys) may contain one or more other elements (e.g., C, Co, Mn, P, S, Si, Cr and / or Al) in individual or combined concentrations less than or equal to about 1%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.15%, 0.1%, 0.09%, 0.08%, 0.07%, 0.06%, 0.05%, 0.04%, 0.03%, 0.025%, 0.01%, or 0.005%. In some examples, the metal ferrule or sleeve includes greater than or equal to about 50.5% Ni, greater than or equal to about 48% Fe, and less than or equal to about 0.60% Mn, 0.30% Si, 0.005% C, 0.25% Cr, 0.10% Co, 0.025% P, and / or 0.025% S (e.g., Alloy 52). In some examples, the metal ferrule or sleeve includes greater than or equal to about 41% Ni, greater than or equal to about 58% Fe, and less than or equal to about 0.05% C, 0.80% Mn, 0.40% P, 0.025% S, 0.30% Si, 0.250% Cr, and / or 0.10% Al (e.g., Alloy 42). In some examples, the metal ferrule or sleeve comprises an Fe alloy having between about 17.5% and 19.5% Cr, between about 0.10% and 0.50% Ti, between about 0.5% and 0.90% Nb, less than or equal to about 1% Ni, 1% Si, 1% Mn, 0.04% Phosphorus, 0.03% Nitrogen, 0.03% Sulfur and / or 0.03% Carbon, and the balance Fe (e.g., 18CrCb ferritic stainless steel). Such an Fe alloy (e.g., 18CrCb ferritic stainless steel) may have a CTE of about 8ppm / K, 9ppm / K, 10ppm / K, 11ppm / K, or 12ppm / K. In some examples, the metal ferrule or sleeve comprises an Fe alloy having between about 17.5% and 18.5% Cr, between about 0.10% and 0.60% Ti, between about 0.3% and 0.90% Nb, less than about 1% Si, 1% Mn, 0.04% Phosphorus, 0.015% Sulfur and / or 0.03% Carbon, and the balance Fe (e.g., 441 grade stainless steel). Such an Fe alloy (e.g., 441 grade stainless steel) may have a CTE of about 9ppm / K, 10ppm / K, 11ppm / K, 12ppm / K, 13ppm / K, or 14ppm / K.In some examples, the metal ferrule or sleeve comprises a Ni alloy having at least about 72% Ni, between about 14% and 17% Cr, between about 6% and 10% Fe, and less than about 0.15% C, 1% Mn, 0.015% S, 0.50% Si, and / or 0.5% Cu (e.g., Inconel 600). Such a Ni alloy (e.g., Inconel 600) may have a CTE of about 12ppm / K, 13ppm / K, 14ppm / K, 15ppm / K, 16ppm / K, or 17ppm / K. In some examples, the metal ferrule or sleeve comprises a Ni alloy having less than about 0.05% C, 0.25% Mn and / or 0.002% S, less than or equal to about 0.20% Si, 15.5% Cr, 8% Fe and / or 0.1% Cu, and the balance Ni and Co (e.g., ATI Alloy 600). Such a Ni alloy (e.g., ATI Alloy 600) may have a CTE of about 12 ppm / K, 13 ppm / K, 14 ppm / K, 15 ppm / K, 16 ppm / K, or 17 ppm / K. In some examples, the metal ferrule or sleeve includes greater than or equal to about 67% Ni, less than about 2% Co, 0.02% C, 0.015% B, 0.35% Cu, 1.0% W, 0.020% P and / or 0.015% S, between about 14.5% and 17% Cr, between about 14% and 16.5% Mo, between about 0.2% and 0.75% Si, between about 0.30% and 1.0% Mn, between about 0.10% and 0.50% Al, between about 0.01% and 0.10% La, and less than or equal to about 3% Fe (e.g., Hastelloy S). Such an alloy (e.g., Hastelloy S) may have a CTE of about 12 ppm / K, 13 ppm / K, 14 ppm / K, 15 ppm / K, 16 ppm / K, or 17 ppm / K. The metal ferrule or sleeve may have the aforementioned CTE values ​​for use in temperature ranges between, for example, about 25°C to 400°C, 20°C to 500°C, 25°C to 500°C, 25°C to 600°C, 25°C to 900°C, or 25°C to 1000°C.

[0140] The seal may include one or more brazing materials (e.g., the same or different brazing materials at different joints when a metal collar or sleeve is used, or one brazing material when a ceramic material is directly joined to a monolithic cover or body). The CTE of the brazing material may be at least about 3 micrometers per meter per degree Celsius (μm / m / °C), 4 μm / m / °C, 5 μm / m / °C, 6 μm / m / °C, 7 μm / m / °C, 8 μm / m / °C, 9 μm / m / °C, 10 μm / m / °C, 11 μm / m / °C, 12 μm / m / °C, 13 μm / m / °C, 14 μm / m / °C, 15 μm / m / °C, 16 μm / m / °C, 17 μm / m / °C, 18 μm / m / °C, 19 μm / m / °C, or 20 μm / m / °C. The CTE of the brazing material may be less than or equal to approximately 3 micrometers per meter per degree Celsius (μm / m / °C), 4 μm / m / °C, 5 μm / m / °C, 6 μm / m / °C, 7 μm / m / °C, 8 μm / m / °C, 9 μm / m / °C, 10 μm / m / °C, 11 μm / m / °C, 12 μm / m / °C, 13 μm / m / °C, 14 μm / m / °C, 15 μm / m / °C, 16 μm / m / °C, 17 μm / m / °C, 18 μm / m / °C, 19 μm / m / °C or 20 μm / m / °C. The brazing material may have a CTE value for use in a temperature range of, for example, about 25°C to 400°C, 20°C to 500°C, 25°C to 500°C, 25°C to 600°C, 25°C to 900°C, or 25°C to 1000°C.

[0141] The stress(s) of the ceramic to metal joint can be reduced by using a brazing material that is appropriately (e.g., sufficiently) ductile. The ductile brazing material can include silver (Ag), copper (Cu), and / or nickel (Ni). The brazing material can include, for example, at least about 95% or 99% Ag (e.g., by weight), at least about 95% or 99% Cu (e.g., by weight), or at least about 95% or 99% Ni (e.g., by weight). The brazing material can include any suitable ductile brazing material described herein. The ductile brazing material may have a yield strength of less than or equal to about 10 MPa, 20 MPa, 30 MPa, 40 MPa, 50 MPa, 60 MPa, 70 MPa, 80 MPa, 90 MPa, 100 MPa, 150 MPa, 200 MPa, 250 MPa, 300 MPa, 350 MPa, 400 MPa, 450 MPa, 500 MPa, 600 MPa, 700 MPa, 800 MPa, 900 MPa, or 1000 MPa. The brazing material may have such a yield strength at a temperature, for example, greater than or equal to about 25° C., 400° C., 500° C., 600° C., 700° C., 800° C., 900° C., 1000° C., or 1100° C. In some examples, the brazing material may be coated (e.g., Ni coated).

[0142] The seal may include one or more metallized materials (e.g., metallized powders). The CTE of the metallized material (e.g., after forming the metallized layer) may be at least about 3 μm / m / °C, 4 μm / m / °C, 5 μm / m / °C, 6 μm / m / °C, 7 μm / m / °C, 8 μm / m / °C, 9 μm / m / °C, 10 μm / m / °C, 11 μm / m / °C, 12 μm / m / °C, 13 μm / m / °C, 14 μm / m / °C, 15 μm / m / °C, 16 μm / m / °C, 17 μm / m / °C, 18 μm / m / °C, 19 μm / m / °C, or 20 μm / m / °C. The CTE of the metallization material (e.g., after forming the metallization layer) may be less than or equal to approximately 3 micrometers per meter per degree Celsius (μm / m / °C), 4 μm / m / °C, 5 μm / m / °C, 6 μm / m / °C, 7 μm / m / °C, 8 μm / m / °C, 9 μm / m / °C, 10 μm / m / °C, 11 μm / m / °C, 12 μm / m / °C, 13 μm / m / °C, 14 μm / m / °C, 15 μm / m / °C, 16 μm / m / °C, 17 μm / m / °C, 18 μm / m / °C, 19 μm / m / °C, or 20 μm / m / °C. The metallization material may have a CTE value for, for example, a temperature range between about 25°C and 400°C, 20°C and 500°C, 25°C and 500°C, 25°C and 600°C, 25°C and 900°C, or 25°C and 1000°C. The Young's modulus of the metallization material may be less than about 50 gigapascals (GPa), 75 GPa, 100 GPa, 150 GPa, or 500 GPa. The metallization material may have a Young's modulus value for, for example, a temperature of 25°, 300°C, 400°C, 500°C, 600°C, 900°C, or 1000°C. The metallization material may be chemically stable in air and / or when exposed to reactive materials in the device at a temperature greater than or equal to about 200°C, 300°C, 400°C, 500°C, 600°C, 900°C, or 1000°C.

[0143] The seal can include a ceramic material and a brazing material. In some examples, the ceramic material is stable (e.g., thermodynamically stable) when in contact with (e.g., not chemically reacting with) one or more reactive materials (e.g., reactive liquid metals or reactive liquid metal vapors, such as, for example, molten lithium, lithium vapor, or calcium metal). In some examples, the ceramic material (e.g., AlN, Nd2O3) is stable when in contact with air (or other types of external atmospheres). In some examples, the ceramic material is stable with molten salts, is substantially not attacked by the molten salts (e.g., the material may have a slight surface reaction, but will not develop into degradation or attack of the bulk material), and does not substantially dissolve into the molten salts. Examples of ceramic materials include, but are not limited to, aluminum nitride (AlN), beryllium nitride (Be3N2), boron nitride (BN), calcium nitride (Ca3N2), silicon nitride (Si3N4), aluminum oxide (Al2O3), beryllium oxide (BeO), calcium oxide (CaO), cerium oxide (CeO2 or Ce2O3), erbium oxide (Er2O3), lanthanum oxide (La2O3), magnesium oxide (MgO), neodymium oxide (Nd2O3), samarium oxide (Sm2O3), scandium oxide (Sc2O3), ytterbium oxide (Yb2O3), yttrium oxide (Y2O3), zirconium oxide (ZrO2), yttria partially stabilized zirconium oxide (YPSZ, yttriapartially stabilized zirconium oxide) zirconia), boron carbide (B4C), silicon carbide (SiC), titanium carbide (TiC), zirconium carbide (ZrC), titanium diboride (TiB2), chalcogenides, quartz, glass, or any combination thereof. The ceramic material can be electrically insulating (e.g., the ceramic material can have a dielectric constant greater than about 10 2 Ohm-cm, 10 4 Ohm-cm, 10 6 Ohm-cm, 10 8 Ohm-cm, 10 10 Ohm-cm, 10 12 Ohm-cm, 10 14 Ohm-cm or 10 16 The CTE of the ceramic material can be (e.g., substantially) similar to (e.g., less than or equal to about 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50% different from) the CTE of stainless steel (e.g., grade 430 stainless steel, 441 stainless steel, or 18CrCb ferritic stainless steel) or a nickel alloy (e.g., an alloy containing greater than or equal to about 50% Ni and greater than or equal to about 48% Fe, such as, for example, Alloy 52).

[0144] In some examples, the brazing material includes one or more brazing components, so that at least one brazing component has a low solubility in the reactive material, the reactive material has a low solubility in at least one brazing component, the brazing component does not react with the reactive material at the operating temperature of the device (e.g., does not form an intermetallic alloy with it), and / or the brazing component melts above the operating temperature of the device. The reactive material can be, for example, a reactive metal. In some examples, the brazing material includes at least one brazing component with a low solubility in the reactive metal. In some examples, the reactive metal has a low solubility in the brazing component. In some examples, the brazing component does not form an intermetallic alloy with the reactive metal at the operating temperature of the device. In some examples, the brazing component and / or the brazing material melts above the operating temperature of the device. In some examples, (one or more) brazing components may include Ti, Ni, Y, Re, Cr, Zr, and / or Fe, and the reactive metal may include lithium (Li) and / or calcium (Ca).

[0145] Examples of brazing component materials include, but are not limited to, aluminum (Al), beryllium (Be), copper (Cu), chromium (Cr), iron (Fe), manganese (Mn), molybdenum (Mo), nickel (Ni), niobium (Nb), rubidium (Rb), scandium (Sc), silver (Ag), tantalum (Ta), rhenium (Te), titanium (Ti), vanadium (V), yttrium (Y), zirconium (Zr), phosphorus (P), boron (B), carbon (C), silicon (Si), or any combination thereof. In some cases, the ceramic material includes aluminum nitride (AlN) and the brazing material includes titanium (Ti). In some examples, the brazing material includes a mixture of two or more materials (e.g., 3 materials). The materials can be provided in any proportion. For example, the brazed joint can include 3 materials in a ratio of about 30:30:40 or 40:40:20 (e.g., in weight-%, atomic-%, molar-%, or volume-%). In some examples, the brazing material includes a mixture of titanium, nickel, copper, and / or zirconium. In some cases, the brazed joint includes at least about 20, 30, or 40 weight-% titanium, at least about 20, 30, or 40 weight-% nickel, and at least about 20, 30, 40, 50, or 60 weight-% zirconium. In some cases, the brazed joint includes less than about 20, 30, or 40-weight-% titanium, less than about 20, 30, or 40 weight-% nickel, and less than about 20, 30, 40, 50, or 60 weight-% zirconium. In some cases, the brazed joint includes about 18% Ti, about 60% Zr, about 22% Ni (e.g., on a weight-%, atomic-%, molar-%, or volume-% basis). In some cases, the braze material includes at least about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or more weight-%, atomic-%, mole-%, or volume-% of titanium, nickel, or zirconium (or any other brazing material herein). In some examples, the braze material includes about 19-21 weight percent (wt%) Zr, 19-21 wt% Ni, 19-21 wt% Cu, and the remainder mainly includes Ti or is entirely Ti (i.e., "TiBraze 200"). In some examples, the braze material includes about 61-63 wt% Zr, 19-21 wt% Ni, and the remainder mainly includes Ti or is entirely Ti (i.e., "TiZrNi" braze material). In some examples, the braze material comprises about 29-31 wt % Ni, with the remainder primarily or entirely Ti (ie, a "TiNi-70" braze material). In some examples, the braze material comprises at least about 10 wt % or 15 wt % Ti (ie, a "Ti braze alloy").In some cases, the brazing material contains less than or equal to about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or more weight-%, atomic-%, molar-%, or volume-% of titanium, nickel or zirconium (or any other brazing material herein). In some examples, the brazing material contains greater than about 70wt%, greater than about 74wt%, greater than about 78wt%, greater than about 82wt%, greater than about 86wt%, greater than about 90wt%, greater than about 94wt%, or more nickel. In some examples, the brazing material contains between about 70wt% and 80wt%, between about 70wt% and 90wt%, between about 70wt% and 95wt%, between about 80wt% and 90wt%, or between about 80wt% and 95wt% nickel. In some examples, the brazing material comprises nickel between about 82wt% and 94wt%. In some cases, the brazing material comprises greater than or equal to about 70wt% Ni (hereinafter referred to as "BNi brazing material"). In some cases, the brazing material comprises greater than or equal to about 82% Ni, and less than or equal to about 7% Cr, 3% Fe, 4.5% Si, 3.2% B and / or 0.06% C (e.g., BNi-2 brazing material). In some cases, the brazing material comprises greater than or equal to about 82% Ni, and less than or equal to about 15% Cr, 4.0% B and / or 0.06% C (e.g., BNi-9 brazing material). In some cases, the brazing material comprises greater than or equal to about 82% Ni, and less than or equal to about 15% Cr, 7.3% Si, 0.06% C and / or 1.4% B (e.g., BNi-5b brazing material). In some cases, the brazing material comprises yttrium, chromium or rhenium, and nickel. In some examples, the brazing material comprises silver (Ag) and aluminum (Al), and may also comprise titanium. The brazing material may comprise silver to aluminum (Ag:Al) in a ratio of about 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 11:1, 12:1, 13:1, 14:1, 15:1, 16:1, 17:1, 18:1, 19:1, 20:1, 25:1 or more. In some examples, the brazing material comprises a ratio of about 19:1 Ag:Al by weight or volume (e.g., about 95wt% Ag to about 5wt% Al), and may also comprise other additives, such as Ti.

[0146] To facilitate bonding a ceramic material to a metal ferrule or sleeve using certain brazing materials (e.g., inactive brazing materials), a layer comprising a metal (also referred to herein as a "metallization layer" and a "pre-metallization layer") may be first applied to the ceramic material via a pre-metallization step (e.g., the metallization layer may be applied to the ceramic material by a coating process). For example, a metallization layer having a controlled layer thickness may be applied to the ceramic material by sputter coating or by high temperature heat treatment in a vacuum or controlled atmosphere (e.g., Ar or N2 and H2 gases) (e.g., sintering the metallization layer to the ceramic material) without bonding the metal ferrule or sleeve to the brazing material. The pre-metallization step may enable, for example, a subsequent brazing step to bond the pre-metallized ceramic surface to a metal ferrule or sleeve by using a brazing material that may not be directly bonded to the ceramic material (e.g., the brazing material may not be bonded to a ceramic material without a metallization layer).

[0147] The metallization layer may include a metallization material (also referred to herein as a "premetallization material"). As described in more detail elsewhere herein, the metallization material may include one or more metals and / or non-metallic materials (e.g., one or more metals, ceramics, silica glass, etc.). Applying the metallization material may result in the formation of one or more premetallization layers. (One or more) sublayers may be formed in one step (e.g., a processing step using a single metallization material may result in the formation of two sublayers) or may be produced by multiple processing steps (e.g., multiple processing steps using different metallization materials). The metallization material may include a brazing material. For example, at least a portion (e.g., some portions) of a brazing material (e.g., yttrium, titanium, or aluminum) may be applied as a metallization material via a premetallization step. In some cases, the premetallization material may be referred to as a premetallization brazing material. The metallization material may be different from the brazing material. In some cases, the material may be referred to as a metallization material rather than a brazing material. For example, when a metal coating is applied as a powder and the powder is bonded to a ceramic, the powder may be referred to as a metallization powder rather than a brazing powder. Such terms may distinguish between brazing materials (e.g., powders) that may melt to the ceramic and / or metal during heat treatment, and metallization materials that may effectively sinter to the ceramic during heat treatment and may not melt (e.g., may not fully melt) during heat treatment.

[0148] In some embodiments, the ceramic-to-metal brazed joint may be formed by a metallization process followed by a brazing process. In some embodiments, the metallization step may not be included, and the ceramic-to-metal brazed joint may be formed directly by an active brazing step (eg, using a Ti-containing braze material).

[0149] The ceramic material may include AlN. The ceramic material may include a main ceramic material (e.g., AlN) and one or more secondary ceramic materials (e.g., Y2O3, SiC, or a combination thereof). The ceramic material may be formed substantially or entirely of a main ceramic material. The ceramic material may include various levels of (one or more) secondary ceramic materials. For example, the ceramic material may include a first secondary ceramic material and a second secondary ceramic material. The ceramic material may include a first secondary ceramic material (e.g., Y2O3) having a concentration greater than or equal to about 3wt%. As an alternative, the ceramic material may include a first secondary ceramic material (e.g., Y2O3) having a concentration less than about 3wt%. The ceramic material may include a combination of a first secondary ceramic material and at least a second secondary ceramic material (e.g., SiC), the concentration of the second secondary ceramic material being greater than or equal to about 25wt% (or 25 volume-%) (also referred to herein as "v%, "vol%, " and "volume percentage"). In some examples, the ceramic material may include AlN as a main ceramic material, and about 1wt% to 5wt% Y2O3 as a second ceramic material.

[0150] The brazing joint may be an inert brazing joint or an active brazing joint. An inert brazing joint may melt and wet a ceramic material or wet a ceramic material having a metallization layer deposited thereon. Copper and silver are examples of inert brazing joints. An active brazing joint may react with a ceramic (e.g., chemically reducing the metal component of the ceramic (e.g., reducing Al from AlN)). In some examples, an active brazing material may include a metal alloy having an active metal species such as titanium (Ti) or zirconium (Zr) that reacts with a ceramic material (e.g., AlN+Ti→Al+TiN or AlN+Zr→Al+ZrN or 2Nd2O3+3Ti→4Nd+3TiO2). An active brazing joint may also include one or more inert components (e.g., Ni). (One or more) inert components may, for example, reduce the melting point of the brazing joint and / or improve the chemical stability of the brazing joint. In some cases, an active metal brazing joint bead-like rises on the ceramic and / or does not wet the ceramic.

[0151] The seal can be welded or brazed to the conductive housing, the cell (housing) cover and / or the conductor. In some examples, the conductive housing and / or the conductor include 400 series stainless steel, 300 series stainless steel, nickel, steel or any combination thereof. In some examples, the conductive housing and / or the conductor include low carbon stainless steel, such as 304L stainless steel (304L SS), for example. Low carbon stainless steel (e.g., 304L SS) can also be used in the metal collar and / or sleeve of the seal. In some examples, the sleeve includes alloy 42, and the collar and the conductor include low carbon stainless steel (e.g., 304L SS) and / or steel (e.g., low carbon steel). In some examples, the conductor includes a Ni coating (e.g., nickel-plated low carbon steel). In some examples, low carbon stainless steel can reduce undesirable chemical reactions with reactive materials in the cell.

[0152] In some examples, the sleeve or collar material may include, for example, 304 stainless steel, 304L stainless steel, 430 stainless steel (430SS), 410 stainless steel, alloy 42, alloy 52, and nickel-cobalt iron alloy. In some examples, the sleeve or collar assembly may include a coating, such as a Ni coating (e.g., alloy 42 coated with Ni). The brazing material may include, for example, nickel-100, molybdenum (Mo), and tungsten (W). The ceramic material may include, for example, aluminum nitride (AlN), aluminum oxide (Al2O3), boron nitride (BN) oriented parallel to the grain orientation, boron nitride (BN) oriented perpendicular to the grain orientation, yttrium oxide (Y2O3), and yttrium oxide partially stabilized zirconia (YPSZ).

[0153] In some examples, the conductive component of the seal includes a metal having a low CTE (e.g., less than about 1 ppm / °C, 2 ppm / °C, 3 ppm / °C, 4 ppm / °C, 5 ppm / °C, 6 ppm / °C, 7 ppm / °C, 8 ppm / °C, 9 ppm / °C, 10 ppm / °C, 11 ppm / °C, 12 ppm / °C, or 15 ppm / °C), a low Young's modulus (e.g., less than about 0.1 Gpa, 0.5 Gpa, 1 Gpa, 10 Gpa, 50 Gpa, 100 Gpa, 150 Gpa, 200 GPa, or 500 GPa), a high ductility (e.g., an ultimate strength greater than about 100%, 200%, 300%, 400%, or 500% of a yield strength), or any combination thereof. In some examples, the ultimate strength may be greater than about 50%, 100%, or 200% of a material's yield strength to provide it with sufficient ductility. In some examples, the conductive component does not include a conductive ceramic. Low CTE, low Young's modulus and / or high ductility component properties can result in low stress concentrations in the ceramic. Low Young's modulus component properties can result in less stress generated between components having different CTE values ​​(e.g., for a given CTE mismatch between two materials being bonded together, if at least one material has a low Young's modulus, the tension generated by the CTE difference can cause the material with the low Young's modulus to "stretch," resulting in relatively less stress between the two materials. Low CTE, low Young's modulus and / or high ductility component properties can reduce the likelihood of failure (e.g., due to reduced stress concentrations and / or less stress generated). Metals that meet these specifications (in addition to corrosion resistance to internal and external monomer environments) can include, for example, zirconium (Zr), high zirconium content alloys, tungsten (W), titanium (Ti), nickel (Ni) and / or molybdenum (Mo).

[0154] In some embodiments, the seal comprises a ceramic, one or more brazing materials and one or more metal collars. For example, two metal collars may be bonded to the ceramic, one on each side of the ceramic. Each such metal collar may also be bonded to (one or more) additional metal collars. Thus, a composite metal collar comprising two or more metal collars may be created. In some examples, the composite metal collar comprises at least two metal collars, wherein at least one metal collar comprises a material suitable for bonding (e.g., using a type of brazing material) to the ceramic and at least one metal collar comprises a material suitable for bonding to another component of the seal or monomer (e.g., using another type of brazing material). The two metal collars may also be bonded (e.g., using another type of brazing material). In some cases, at least a portion (e.g., all) of the brazing materials used to bond the metal collars of the seal to each other and / or to other parts of the monomer may be of the same type. In some examples, at least a portion or all of the brazing materials may be of different types. In addition, one or more metal collars may be welded instead of brazed, or welded and brazed. The seal may comprise one or more composite metal collars. In some examples, the seal includes at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20 or more individual metal ferrules. In one example, the seal includes 3 or 4 individual metal ferrules that form two composite metal ferrules. In some examples, at least a portion of the individual metal ferrules can include the same material. For example, metal ferrules that include the same material can be used to join the metal ferrules to similar materials (e.g., similar single housing or conductor materials).

[0155] In some examples, the seal includes a ceramic, a brazing material, a first (e.g., thin) metal collar, and / or a second metal collar. The first metal collar can be brazed to the ceramic and the second metal collar can be brazed to the first metal collar. In some examples, the first metal collar is a low CTE material such as alloy 42, zirconium (Zr), or tungsten (W) and the second metal collar is an iron alloy such as steel, stainless steel, 300 series stainless steel (e.g., 304L stainless steel), or 400 series stainless steel (e.g., 430 stainless steel). In some examples, the first metal collar is less than about 2 microns (μm), 5μm, 10μm, 20μm, 50μm, 100μm, 150μm, 250μm, 500μm, 1,000μm, 1,500μm, or 2,000μm thick.

[0156] In some examples, the seal includes a ceramic, a brazing material, a first metal collar, a second metal collar, and a third metal collar. The first metal collar can be bonded to a portion of the ceramic, and the second metal collar can be bonded to the first metal collar. The third metal collar can be bonded to different parts of the ceramic so that the first metal collar and the third metal collar are separated by an electrically insulating ceramic material. The junctions between the first metal collar and the ceramic and between the third metal collar and the ceramic can be airtight. In some examples, the seal also includes a fourth metal collar bonded to the third metal collar (for example, the first metal collar is bonded to a portion of the ceramic, the second metal collar is bonded to the first metal collar, the third metal collar is bonded to another portion of the ceramic and the fourth metal collar is bonded to the third metal collar). The brazing material for bonding the first metal collar to the second metal collar can include or be similar to any brazing material composition described herein. The first metal collar or the second metal collar can be bonded (for example, using a brazing composition similar to any brazing composition described herein, or welding) to the monolithic cover. The third metal ferrule may be bonded to the fourth metal ferrule or directly to the negative current lead (eg, brazed using any of the brazing compositions of the present disclosure).

[0157] Figure 33 is a cross-section of a radially symmetrical example of a seal 300 including a ceramic component 305. The ceramic component may include, for example, aluminum nitride (AlN). In some examples, the ceramic component may include yttrium oxide (Y2O3). In one example, the ceramic component includes about 3 weight percent or more of yttrium oxide. In some examples, the ceramic component includes about 1 percent to about 4 percent of yttrium oxide. The ceramic component 305 is joined to a first metal sleeve (e.g., nickel-plated alloy 42) 310 via a first metal-to-ceramic joint (e.g., brazing material) 355. The seal also includes a second metal sleeve (e.g., Ni-plated alloy 42) 340 joined to the ceramic component 305 via a second metal-to-ceramic joint (e.g., first brazing alloy) 315. The first metal-to-ceramic joint 355 and the second metal-to-ceramic joint 315 may include, for example, a first brazing alloy of silver and aluminum (Ag-Al). The first metal-to-ceramic joint 355 and the second metal-to-ceramic joint 315 may include a first brazing alloy and an internal brazing alloy. The first braze alloy can be exposed to an environment outside the container (e.g., ambient air), and the internal braze alloy can be exposed to an internal environment of the container (e.g., high temperature reactive materials). The first braze alloy can include a ductile material. The first braze material can be an alloy of at least two different metals. The first braze alloy can have a silver-to-aluminum ratio of less than 19 to 1; for example, the first braze alloy can contain about 95% or less silver. The first braze alloy can also include a wetting agent. For example, the wetting agent can include titanium or titanium hydride. In some examples, the wetting agent can be provided as a metallization layer of the first braze alloy. For example, the metal sleeves 310 and 340 can be brazed to the outer surface of the ceramic component.

[0158] The first metal-to-ceramic joint 355 and / or the second metal-ceramic joint 315 may also include an internal brazing alloy. The internal brazing alloy may be located at or near the inner surface of the first metal-to-ceramic joint 355 and / or the second metal-to-ceramic joint 315. The internal brazing alloy may be more chemically stable than the first brazing alloy. The internal brazing material may be an alloy of at least two different metals. The internal brazing alloy may include a brittle material. The internal brazing alloy may be an active metal brazing material. When exposed to a reactive metal material inside a sealed container (e.g., a high-temperature battery cell), the internal brazing alloy may be stable. The internal brazing alloy may form a protective barrier between the reactive material and the first brazing alloy. The first brazing alloy may be exposed to the air outside the sealed container, and a barrier may be provided between the ambient air and the internal brazing alloy. The internal brazing alloy may include a Ni-based brazing alloy (e.g., BNi-2, BNi-7, BNi-9) or a Ti brazing alloy (e.g., TiBraze 200, TiZrNi, TiNi-70). The bottom metal-to-ceramic joint 315 can include a first brazing alloy of silver and aluminum, and the top metal-to-ceramic joint 355 can include both a first brazing alloy of silver and aluminum (e.g., about 95% Ag and 5% Al) and an internal brazing alloy of a Ti brazing alloy (e.g., TiBraze 200). The internal brazing alloy can be exposed to reactive materials (e.g., reactive metal vapors and / or salt vapors and / or liquids) in the sealed container and can be unexposed to air outside the sealed container. The first brazing alloy in the top metal-to-ceramic joint 355 can be exposed to air outside the sealed container without being exposed to reactive materials in the sealed container. In some examples, the bottom metal-to-ceramic joint 315 can also include a first brazing alloy and an internal brazing alloy (as described above for joint 355).

[0159] The first metal sleeve 310 is joined to a conductor (e.g., a current lead, such as a negative current lead) 350 via a first metal-to-metal joint (e.g., a solder, a braze) 345. The conductor may comprise a low carbon stainless steel, such as 304L stainless steel, for example, or a low carbon steel or Ni alloy (e.g., Ni 201). The second metal sleeve 340 is joined to a metal collar (e.g., 304L SS) 320 via a second metal-to-metal joint (e.g., a solder, a braze) 325. The metal collar 320 is joined to a container (e.g., at a cell cap comprising, for example, 304L SS) 330 via a third metal-metal joint (e.g., a solder, a braze) 335. The seal surrounds a chamber 360 of the container, which may contain reactive materials, such as reactive liquids and gases of an electrochemical cell, for example.

[0160] The metal-to-metal joint may include a BNi braze containing 70 wt % or more Ni; for example, a BNi-2, BNi-5b or BNi-9 braze, a titanium-based braze alloy (e.g., TiBraze 200), TiZrNi, TiNi-70, a silver-aluminum braze alloy (e.g., an alloy having a 19:1 Ag:Al ratio), a silver alloy, an aluminum alloy, an alloy containing at least silver, and / or an alloy containing at least aluminum. In some embodiments, the second metal-to-metal joint comprises a BNi braze or a titanium-based braze alloy (e.g., TiBraze 200). In some embodiments, the first metal-to-metal joint and the second metal-to-metal joint comprise a BNi braze or a Ti braze alloy. In some embodiments, each metal-to-metal joint comprises a BNi braze, a Ti braze alloy, and / or an Ag-Al braze alloy. In some examples, the metal collar 320 is welded to the container or integrally formed as part of the container.

[0161] Although described as metal sleeves, in some embodiments, one or both of the metal sleeves 310 and 340 can be provided as metal collars. Figure 3 The seals illustrated in the figure can include a variety of materials. In one example, the ceramic component 305 includes Al2O3 ceramic, the joints 315 and 355 include Cu-Ag brazing material, and the metal sleeves 310 and 340 include Fe-Ni alloy (e.g., Fe-Ni sleeves or collars). In one example, the ceramic component 305 includes AlN ceramic, the joints 315 and 355 include copper brazing material with a metallization layer containing nickel plating, and the metal sleeves 310 and 340 include nickel metal (e.g., Ni metal sleeves or collars). In one example, the ceramic component 305 includes AlN ceramic, the joints 315 and 355 include Cr-Ni brazing material with a metallization layer, and the metal sleeves 310 and 340 include nickel metal (e.g., Ni metal sleeves or collars).

[0162] The seal 300 may be incorporated into the electrochemical cell 400, optionally with a Figure 4Additional feature combinations illustrated. The electrochemical cell 400 includes a container including a lid 330 and a can 430. The container contains reactive materials that are maintained at an elevated temperature (e.g., greater than 200° C.) during operation. The reactive materials include an electrolyte 410 (e.g., a salt) in contact with a positive electrode 420 (e.g., Pb-Sb, Bi, Sb, or FeS2) and a negative electrode 440 (e.g., Li, Na, Mg, Ca). A negative current collector 450 (e.g., foam) connects the negative electrode to a negative current lead 350 that extends through the seal 300 to the external environment. A liner 460 (e.g., a graphite crucible) may be provided between the can 430 and the active cell assembly (e.g., the electrolyte 410 and the positive electrode 420).

[0163] The seal 300 may include Figure 4 Multiple features illustrated. In one example, the ceramic assembly 305 comprises an AlN ceramic, the joints 315 and 355 comprise an Al-Ag braze activated with Ti, TiH2 and / or a Ti braze alloy, and the metal sleeves 310 and 340 comprise an Alloy 42 metal alloy having a nickel layer on its surface (e.g., a nickel-plated Alloy 42 metal sleeve). The thickness of the metal sleeve assemblies 310 and 340 can be less than about 0.030 inches. In some examples, the thickness of the metal sleeve is less than or equal to about 0.025 inches, 0.02 inches, 0.015 inches, 0.01 inches, or less. In some examples, the thickness of the metal sleeve is between about 0.01 inches and 0.015 inches, between about 0.01 inches and 0.02 inches, or between about 0.01 inches and 0.025 inches. In one example, the ceramic assembly includes a physical ion blocking feature 1000 (as further described below) that can prevent or inhibit the formation of metal dendrites along the ceramic surface. In one example, the current lead 350 (e.g., the negative current lead) comprises a Ni alloy, steel (e.g., mild steel), or stainless steel (e.g., 304L SS alloy) and includes a stainless steel (e.g., 304LSS) metal collar 320. The current lead 350 may include features such as a shoulder that is an integral part of the current lead and serves as a surface for brazing the top metal sleeve 310. The top metal-to-metal joint 345 between the current lead 350 and the top metal sleeve 310 may comprise an Ag-Al braze (e.g., ~95% Ag and ~5% Al), may comprise a Ni-based braze alloy (e.g., BNi-9 braze), or may comprise, for example, a Ti-based braze alloy (e.g., TiBraze 200). The bottom metal-to-metal joint 325 between the bottom metal sleeve 340 and the metal ferrule 320 may comprise an Ag-Al braze (e.g., ~95% Ag and ~5% Al) or may comprise a Ni-based braze alloy (e.g., BNi-9 braze) or a Ti braze alloy (e.g., TiBraze 200), for example.

[0164] The container of the monomer may include a gas portion between the liquid portion and the seal. In some examples, reactive materials from the liquid portion may evaporate into the gas portion, eventually contacting the seal. In addition, liquid and / or ions may flow from the negative electrode along the surface of the negative current lead to the seal. When particles of the reactive material contact the seal, these processes may cause undesirable corrosion. Therefore, a shield 500 may be provided to inhibit the flow of vapor, liquid and / or ions from the liquid portion to the seal.

[0165] Figure 5 An electrochemical cell including a shield 500 is illustrated, and the shield 500 is shaped to inhibit or block the flow of steam from the liquid portion to the seal. The shield 500 extends into the gas portion between the liquid portion and the seal. In order to make the steam flow from the liquid portion at the bottom of the image (e.g., at a point near the center) to the seal at the top, the steam can flow outward along the path, around the shield, then inward toward the center, and rise to the top of the seal. The path is illustrated by path 510, path 520, path 530 and path 540 respectively. The shield can partially or completely block and / or block the seal and the liquid portion from being separated from each other. On the contrary, if there is no shield, the gas flows directly upward along path 550, and then the path 540 is shared to the seal. The latter path can provide less impedance to the gas flow, as discussed in more detail below.

[0166] By allowing a small gap between the shield and the surrounding wall, the shield can force the gas to flow along a narrow path in each segment; generally, the width of the path can be assigned as a parameter w, which can have a variable value (for example, in some cases, w is less than or equal to about 1 cm, or less than or equal to about 2 mm, or less than or equal to about 1 mm). The amount of gas flowing along an infinitesimal distance dL in one of the paths can be proportional to the cross-sectional area through which the path flows. The smaller the area, the more restricted the gas flow; in addition, the longer the length of the gas flow, the more its flow may be slowed. The shield can extend from the conductor. The shield can extend from the conductor for a distance greater than or equal to about 1 times, 1.5 times, 2 times, 3 times, 4 times, 5 times or more of the conductor width. In some examples, the shield extends from the conductor to an infinitesimal distance of the container wall.

[0167] The extent to which gas flow is restricted to a longer path due to the shroud can be estimated by a parameter called the "effective gas diffusion path," or EGDP. EGDP can be defined as the integral of the path between two points (e.g., from the liquid to the seal) along the reverse cross-sectional area through which gas can flow. For example, on path 510 in a circularly symmetric cell, at radius r from the center and with a path width w, the area can be estimated as the circumference of a circle of width w times radius r. Under the assumption of radially symmetric cell / shroud geometry, the infinitesimal EGDP can be approximated by And it can be obtained by integrating on each path Estimate the complete EGDP. The units of EGDP are 1 / length, and larger EGDP values ​​may correspond to longer effective distances that vapor can flow. For example, given a path from the inner radius r1 of the current wire to the outer radius r2 of the tank and back (approximate paths 510, 520, and 530, where path 520 is at radius r2 along length L), the EGDP for the portion of the path from the liquid to the seal may be estimated as (Ignore the second-order terms, such as O(w 2 )) Performing a similar integration for path 550 traveling a distance L upward in the annular region between r1 and r2 yields EGDP as This may be a significantly smaller value than with the shield. The path 540 within the seal is common to both configurations and therefore may be ignored. For example, the shield may increase the EGDP from the liquid portion to the seal by greater than or equal to about 10%, about 15%, about 20%, about 30%, or about 50% relative to the same monomer without the shield. For example, a Figure 5 A simple shield such as the one depicted in Figure 2 can reduce the EGDP of a monomer from about 6.35 cm -1 Increase to about 7.30cm -1 In some examples, the EGDP from the liquid portion to the seal is at least about 1 cm -1 , 2cm -1 , 3cm -1 , 4cm -1 , 5cm -1 、6cm -1 、7cm -1 or greater. In one example, the EGDP from the liquid portion to the seal is 7 cm -1 or larger.

[0168] Further increases in EGDP can be achieved using more sophisticated shroud designs. For example, Figure 6A cell is illustrated that includes a more complex shield system that includes multiple shields. A first shield 502 is connected to the negative current lead in the center, and a second shield 504 is connected to the wall of the cell container that is joined to the lid. Both shields include multiple alternating raised and recessed portions to provide a longer and tortuous path from the liquid portion to the seal. For example, the path can be S-shaped. For example, such a path can have a length greater than or equal to about 1.2 times, 1.5 times, 1.7 times, 2 times, 3 times, or 5 times the width of the container.

[0169] The shields provided herein can be shaped to provide additional benefits. For example, Figure 7 A shield 506 is shown including a lip 508 at its end. The lip is shaped to inhibit the flow of liquid from the liquid portion to the seal (e.g., liquid along a solid surface, such as by capillary forces, splashing or spreading). For example, liquids having moderate surface wetting angles may be prevented or blocked from flowing around the edge of the shield.

[0170] The shield can also provide protection against ion flow along the surface of the negative current conductor to the seal. For example, Figure 8 A shield is illustrated that is configured to increase the effective ion diffusion path (EIDP) for ions traveling from the liquid portion at the bottom of the image to the seal at the top. A first path 514 along the surface of the shield and the negative current lead to the seal is compared to a second path 516 along the surface of the negative current lead. The EIDP can be defined as a dimensionless parameter that is given by the integral of the path between two points (e.g., from the liquid to the seal) along the reverse perimeter through which a particle flowing along the path along the surface can flow. For example, when flowing along a radial path from the center of a circle to its perimeter, the infinitesimal EIDP can be approximated by where r is the radius of the circle. Then, the complete integral will be on the path if Figure 8 In the case where the distance from the liquid portion to the seal is L, the radius of the current lead is r1, the radius of the shield is r2, and assuming circular symmetry, the EIDP of path 516 is approximately and the EIDP of path 514 is the same value plus approximately Additional shields can further increase the EIDP by causing ions to flow back and forth repeatedly. For example, a shield or multiple shields in such a system can provide an EIDP increase of greater than or equal to about 30%, about 40%, about 50%, about 70%, about 75%, about 80%, about 90%, or 100% compared to the same system without shields. In some examples, the effective ion diffusion path length is increased by about 75% or more. For example, the EIDP with shields can be greater than or equal to about 1, about 1.5, about 2, about 3, about 4, or about 5. In one example, a monomer without shields has an EIDP of 1.17 and the same monomer with shields as shown has an EIDP of 1.60. In a second example, multiple shields are provided, resulting in an EIDP of 2.24. More complex structures, such as Figure 6 The S-shaped structure can provide a further increase in EIDP.

[0171] An additional feature that may be provided by the shields disclosed herein is cathodic protection. Figure 4 , shield 500 blocks the steam from the liquid part 410 from traveling along a straight path to the seal 300. Instead, the steam is directed to the outer edge of the container, adjacent to the wall 430 of the tank. The wall 430 of the tank can be electrically connected to the positive electrode. Therefore, the atomic metal vapor from the liquid part can be oxidized by contacting the positive current source with the wall. The wall can include an ion conductive membrane (e.g., containing salts from electrolytes and / or previous vapor-wall interactions) so that the liquid metal atoms can be oxidized into salts when in contact with the wall. For example, the ion conductive membrane can conduct ions between the wall and the liquid part. These interactions can inhibit the active metal atoms from flowing to the seal from the liquid part. The shield configured to guide the steam along the conductive container wall, particularly in close proximity (e.g., about 5mm or less), and extending a distance (e.g., about 1cm or longer), can enhance this effect.

[0172] Fig. 9 A configuration including multiple shields is illustrated, wherein a first shield 522 is attached to the negative current lead, and a second shield 524 is disposed between the first shield 522 and the liquid portion 526, the second shield 524 being in contact with the positive current lead. To reach the seal at the top of the image, the vapor may pass through the second shield 524, which serves to oxidize the reactive metal vapor into less reactive salt ions, thereby reducing seal corrosion.

[0173] The ceramic portion of the seal may include measures to reduce the flow of metal species, including electromigration of metal ions from the brazing material along the surface of the ceramic component. The seal may include a ceramic component having a tubular structure. The tubular structure may have any cross-sectional geometry, including but not limited to circular, elliptical, triangular, square, rectangular or polygonal. In some embodiments, the ceramic component is annular or "ring-shaped". The inner dimensions of the tubular structure may be greater than or equal to the outer dimensions of the current lead, so that the ceramic component can surround the current lead (for example, the ceramic component can be a ring that fits the outer surface of the current lead). The ceramic component may be in partial contact with the outer surface of the current lead, may be in partial contact, or may not be in contact. The seal may be formed by brazing a metal sleeve to the top and bottom of the outer surface of the ceramic component (for example, the surface of the ceramic component that is not exposed to the reactive material in the sealed container), forming a first brazing joint and a second brazing joint. Alternatively or additionally, the first braze joint and the second braze joint may be formed by brazing a metal sleeve to the top and bottom of the inner surface of the ceramic component, by brazing to the inner top edge and the outer top edge of the ceramic component, by brazing to the inner bottom edge and the outer bottom edge of the ceramic component, or by brazing a metal sleeve to the top edge and the bottom edge of the ceramic component. The first braze joint and the second braze joint may surround the ceramic component and form a closed and airtight seal along the outer surface of the ceramic component. The braze joint may hide or cover a portion of the outer surface of the ceramic component. A portion of the ceramic component between the first braze joint and the second braze joint may not be covered by the first braze joint and the second braze joint and may be exposed to the surrounding environment. The surrounding environment may be any environment outside the monomer. For example, the exposed surface of the ceramic component between the first braze joint and the second braze may be outside the monomer without contacting the reactive vapor or reactive material in the monomer. The ceramic component exposed to the surrounding environment may have a surface extending from the first braze joint to the second braze joint and surrounding the current lead. The ceramic component may or may not be in contact with the current lead. In some examples, the surface of the ceramic component extending between the first braze joint and the second braze joint is smooth (e.g., the surface may include a linear intercept between the first braze joint and the second braze joint) and can provide a minimum surface area when compared to other possible surfaces that intercept both the first braze joint and the second braze joint. In some examples, the surface of the ceramic component extending between the first braze joint and the second braze joint has a protrusion that increases the area of ​​the exposed surface of the ceramic component. The protrusion can be defined as one or more features extending away from (e.g., at least partially orthogonal to) a theoretical or imaginary smooth surface (e.g., a reference surface) extending between the first braze joint and the second braze joint of the seal.In some embodiments, a protrusion may also be defined as one or more features that extend at least partially away from both the first braze joint and the second braze joint of the seal.

[0174] Under some operating conditions, some brazing materials can allow metal ions to flow across the surface of the ceramic component, which can result in an undesirable short circuit, for example, due to the formation of metal dendrites when the ions reach the far electrode and are reduced to a neutral metal. As this process is repeated, the dendrites can grow across the surface of the ceramic component, eventually forming a metallic connection between oppositely polarized conductors, resulting in a short circuit. To inhibit this, physical ion blocks can be provided on the exposed surfaces of the ceramic component and / or integrated into the design of the ceramic component. For example, Figure 4The seal 300 illustrates a physical ion blocker 1000, which includes a plurality of protrusions on an extended surface substantially perpendicular to a reference surface extending between a first braze joint and a second braze joint. The protrusions may be formed by one or more exposed surfaces of a ceramic component, the exposed surface being substantially parallel to, substantially perpendicular to, and / or at an acute angle to the reference surface extending from the first braze joint to the second braze joint. The plurality of protrusions may each include a first surface portion, a second surface portion, and / or a third surface portion. The first surface portion may extend away from an exposed surface of the ceramic component, the exposed surface of the ceramic component being perpendicular to, substantially perpendicular to, or at an angle to the reference surface of the ceramic component extending from the first braze joint to the second braze joint. For example, the protrusion may be angled to be less than or equal to about 20 degrees compared to a right angle, less than or equal to about 5 degrees compared to a right angle, or less than or equal to about 1 degree compared to a right angle. The second surface portion may be parallel to, substantially parallel to, or at a defined slope relative to the reference surface of the ceramic component extending from the first braze joint to the second braze joint. The third surface portion may extend toward the reference surface of the ceramic component. The electric field vector may be parallel to the reference surface and directed from the first ceramic to the metal brazing joint to the second ceramic to the metal brazing joint. One of the ceramic to metal brazing joints may be electrically connected to the positive electrode. In the absence of a protrusion, ions may be pulled by the electric field between the brazing material of the positively polarized sleeve (e.g., 340) and the brazing material of the negatively polarized sleeve (e.g., 310). The protrusion may cause the ions traveling along the exposed surface of the ceramic component to move perpendicular to or at least partially resist the electric field, thereby slowing down or stopping the advancement of the ions. Although two protrusions are illustrated, more or less protrusions may also be used, such as a single protrusion (e.g., surrounding the outer perimeter of the ceramic component), or three or more such protrusions. The ceramic component and the protrusion may be a single component (i.e., the ceramic component and the protrusion may be a continuous material). Alternatively or additionally, the protrusion may be a plurality of components adhered together and / or bonded to the ceramic component by welding, brazing, ceramic glue or cement or other bonding methods. In some examples, the lengths or angles of the protrusions may be different from each other. The protrusions may extend from the first brazed joint to the reference surface of the ceramic component of the second brazed joint by a distance greater than or equal to about 0.5 millimeters (mm), 1 mm, 2 mm, 3 mm, 4 mm, 6 mm, 8 mm, 10 mm, or more.

[0175] Fig. 10A , Fig. 10B and 10C Various ceramic components including physical ion blocks are illustrated. Fig. 10A , Fig. 10B and 10C Radially symmetric two-dimensional cross-sections of a ceramic component including a physical ion block are illustrated, with the radial symmetry line passing vertically through the center of each image. Fig. 10A A ceramic component 1010 including a physical ion block 1012 is illustrated. The physical ion block 1012 includes angled protrusions to form voids or recesses 1014 that are oriented downwardly in the direction of the positive side of the electric field 1016. When ions traveling along the surface reach the physical ion blocker in the direction of the electric field 1016, they are redirected in a direction having a vector component opposite to the electric field vector, as shown by the reverse arrow 1018. Thus, the path from the bottom to the top first approaches the top, then reverses the process, and then resumes motion to the top. Because the motion is in the opposite direction of the electric field, the positive ions will be effectively opposed by the field, thereby inhibiting electromigration. Fig. 10B Another embodiment is shown in which a ceramic component 1020 includes a physical ion blocker 1022 having a protrusion at an acute angle to the surface of the ceramic component and forming an inclined groove 1024 (downward) generally toward the source of the positive electric field. The angled groove (or gap) provides a similar effect to the parallel groove 1014, in that ions moving along the surface above the groove can at least partially travel along the surface of the ceramic component against the perpendicular electric field. Fig. 10C A third example is shown in which a ceramic component 1030 includes a physical ion blocker 1032 that includes a protrusion defining a recess 1034 that defines an inclined surface that is substantially perpendicular to the surface of the ceramic component. As shown here, the physical ion blocker can be formed as an integral part of the ceramic component or integrated with the ceramic component. Alternatively, the physical ion blocker can be attached to the ceramic component.

[0176] Improvements to the current leads (e.g., negative current leads) are Fig.11A As shown in the figure. Fig.11A Two embodiments of a negative current lead (NCL) including a coupler for joining to a metal sleeve are illustrated. In a first embodiment 1810, a coupler 1815 is provided as a separate piece that is attached (e.g., welded) to the NCL. In a second embodiment 1820, a coupler 1825 is provided as an integral part of the NCL, forming a shoulder to which a sleeve can be joined (e.g., brazed or welded).

[0177] Fig. 11B Additional features that may be included in current leads such as NCLs are illustrated. In some embodiments, an NCL may be provided that includes a uniform cylindrical top. Such a top may be difficult to constrain, for example, when attaching a negative current collector on the opposite side of the NCL (e.g., to a threaded connector), or when making other attachments to the NCL. In order to more effectively constrain the NCL, a pair of substantially flat parallel surfaces may be provided at the ends of the NCL. Fig. 11BSuch features are illustrated, as shown in front view 1830 and side view 1840. By breaking the cylindrical symmetry, these surfaces provide effective gripping points, such as by a wrench, for example. This allows torque to be applied to rotate or stabilize the NCL when adjusting the cell or NCL or when attaching other components (e.g., negative current collector).

[0178] In some examples, the brazed ceramic seal includes a subassembly. The subassembly may include an insulating ceramic bonded to one or more (e.g., two) flexible spring-shaped or accordion-like components (herein referred to as metal sleeves). After the subassembly is manufactured, the sleeve may be brazed or welded to other monomer components such as negative current leads, monomer covers, and / or collars bonded (welded) to the monomer covers. Alternatively, all joints may be created on a complete cap assembly by brazing (e.g., if the tolerance limit is tight enough). The chemical compatibility between the brazing material and the atmosphere to which the material is exposed and the thermal robustness during high temperature operation and thermal cycling may be evaluated during the design of the subassembly. In some cases, the ceramic material is aluminum nitride (AlN) or silicon nitride (Si3N4), and the brazing material is a titanium alloy, a nickel alloy doped with titanium, a zirconium alloy, or a nickel alloy doped with zirconium. In some cases, the ceramic material is aluminum nitride (AlN), and the brazing material is a silver aluminum alloy.

[0179] Fig.12 A schematic diagram of a brazed ceramic seal having a material that is thermodynamically stable with respect to the internal 1205 and / or external 1210 environment of a cell is shown. Such a material may not include a coating. Various materials may have mismatched CTEs, which may be accommodated using one or more geometric features or structural features 1215 (e.g., flexible metal elbows, fins, or folds). One end of the feature 1215 that accommodates the CTE may be welded to a cell housing 1220 (e.g., 400 series stainless steel) and the other end may be brazed 1225 to a first metallized surface 1230 of a ceramic material 1235. The ceramic material 1235 may be, for example, aluminum nitride (AlN), boron nitride (BN), or yttrium oxide (Y2O3) as described herein. The ceramic material may be brazed to a current collector (conductive feedthrough) 1240 via a brazed joint 1245. The brazed joint 1245 may, for example, contain iron (Fe), nickel (Ni), titanium (Ti), or zirconium (Zr). The brazed joint 1245 may be in contact with a second metallized surface of a ceramic 1250 (eg, titanium or titanium nitride). Several layers of material placed adjacent to each other may result in a CTE gradient that may mitigate the mismatch.

[0180] Fig.13A seal is shown where the ceramic and / or braze material is thermodynamically stable with respect to the interior 1205 and exterior 1210 environments. In some cases, a coating may be applied to the interior 1305 and / or exterior 1310 of the seal or inclusion assembly.

[0181] Fig.14 , Fig.15 , Fig.16 and Fig.17 Further examples of brazed ceramic seals are shown.In some examples, the seal extends a greater distance above the housing. Fig.14 An example of a seal on a cell is shown, which may advantageously not include a coating, not include a CTE mismatch adaptation feature, and / or provide enhanced structural stability to resist vibration and mechanical forces during operation, manufacturing, or transportation. In this example, the housing 1405 can be sealed to separate the current collector 1410. This arrangement can hermetically seal the interior 1415 of the cell to separate the exterior 1420 of the cell. The components of the seal can be arranged vertically and can include a first solder joint 1425, a ceramic 1435, a first metallized surface 1430 of the ceramic, a second solder joint 1440, and a second metallized surface 1445 of the ceramic.

[0182] Fig.15 A seal 1520 is shown that can provide structural stability to resist vibration and mechanical forces during operation, manufacturing and transportation. In this example, a CTE adaptation feature 1505 is disposed between the housing 1510 and the current collector 1515. The seal 1520 can include a ceramic and two brazed joints in contact with the metallized surface of the ceramic. In some examples, the seal is coated on the inner side 1525 and / or the outer side 1530. In some examples, the coating (one or more) can include yttrium oxide (Y2O3).

[0183] Fig.16 A seal 1610 is shown with a secondary mechanical load bearing component 1605. In some cases, the load bearing component is electrically insulating. In some cases, the load bearing component does not form a hermetic seal. The seal 1610 (e.g., comprising a ceramic, two brazed joints in contact with a metallized surface of the ceramic, etc.) can hermetically seal the cell housing 1615 to separate the current collector 1620.

[0184] Fig.17An example of a secondary auxiliary seal 1705 is shown (e.g., in the event of a failure of the primary seal 1710). The secondary seal can fall onto and / or bond to the primary seal in the event of a failure of the primary seal. In some examples, the secondary seal includes a glass that melts and becomes flowable in the event of a failure of the primary seal. The molten secondary seal can pour down onto the failed primary seal and block the leak. In some examples, seal 1705 and / or seal 1710 can be axisymmetric (e.g., annular around a vertical axis passing through the aperture in the monolithic cover).

[0185] The devices, systems and methods of the present disclosure may be combined with or modified by other devices, systems and / or methods, such as, for example, U.S. Pat. No. 3,663,295 (“STORAGE BATTERY ELECTROLYTE”), U.S. Pat. No. 3,775,181 (“LITHIUM STORAGE CELLS WITH A FUSED ELECTROLYTE”), U.S. Pat. No. 8,268,471 (“HIGH-AMPERAGE ENERGY STORAGE DEVICE WITH LIQUID METAL NEGATIVE ELECTRODE AND METHODS”), U.S. Pat. Publication No. 2011 / 0014503 (“ALKALINE EARTH METAL ION BATTERY”), U.S. Pat. Publication No. 2011 / 0014505 (“LIQUID ELECTRODE BATTERY”), U.S. Pat. Publication No. 2012 / 0104990 (“ALKALI METAL ION BATTERY WITH BIMETALLIC ELECTRODE”), U.S. Patent Publication No. 2014 / 0099522 (“LOW-TEMPERATURE LIQUID METAL BATTERIES FOR GRID-SCALEDSTORAGE”), and PCT Application No. PCT / US2016 / 021048 (“CERAMIC MATERIALS AND SEALS FOR HIGHTEMPERATURE REACTIVE MATERIAL DEVICES”), each of which is incorporated herein by reference in its entirety.

[0186] The energy storage device of the present disclosure can be used in grid-scale scenarios or stand-alone use scenarios. The energy storage device of the present disclosure can be used in some cases to power vehicles such as scooters, motorcycles, cars, trucks, trains, helicopters, airplanes, and other mechanical equipment such as robots.

[0187] It should be understood that the terms used herein are for the purpose of describing specific embodiments and are not intended to limit the scope of the present invention. It should be noted that the singular forms "a", "an", and "the" as used herein include plural referents unless the context clearly dictates otherwise. In addition, unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present invention belongs.

[0188] The present invention provides embodiments including but not limited to the following:

[0189] 1. A high temperature device, comprising:

[0190] a container comprising an interior cavity, wherein the interior cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.;

[0191] a seal that seals the interior cavity of the container from an environment external to the container, wherein the seal comprises a ceramic component, and wherein the seal is exposed to the reactive material and the environment external to the container;

[0192] a conductor extending from the environment external to the container through the seal to the interior cavity of the container; and

[0193] A first metal sleeve is coupled to the conductor and the ceramic assembly, wherein the first metal sleeve is coupled to the ceramic assembly through a first braze joint comprising a first braze material, and wherein the first braze material comprises an alloy of silver and aluminum.

[0194] 2. The high temperature device of embodiment 1, wherein the conductor is a negative current lead.

[0195] 3. The high temperature device according to embodiment 2, further comprising a negative current collector within the container, wherein the negative current collector is in contact with the reactive material and is attached to the negative current lead.

[0196] 4. The high temperature device according to embodiment 1 further includes a second metal sleeve coupled to the ceramic component, wherein the second metal sleeve is coupled to the container or coupled to a collar that is joined to the container, wherein the second metal sleeve is coupled to the ceramic component through a second brazing joint containing a second brazing material, and wherein the second brazing material contains an alloy of silver and aluminum.

[0197] 5. The high temperature device of embodiment 1 or 4, wherein the alloy of silver and aluminum comprises a ratio of silver to aluminum less than or equal to about 19 to 1.

[0198] 6. The high temperature device according to embodiment 5, wherein one or both of the first brazing material and the second brazing material further comprises a titanium brazing alloy.

[0199] 7. The high temperature device according to embodiment 4 further comprises an internal brazing material disposed adjacent to the first brazing joint, the second brazing joint, or both the first brazing joint and the second brazing joint, wherein the internal brazing material is exposed to the inner cavity of the container.

[0200] 8. The high temperature device of embodiment 7, wherein the internal brazing material comprises a titanium brazing alloy.

[0201] 9. The high temperature device of embodiment 8, wherein the titanium brazing alloy comprises approximately 19-21 weight percent zirconium, 19-21 weight percent nickel, 19-21 weight percent copper, and the remaining weight percent comprises at least titanium.

[0202] 10. The high temperature device according to embodiment 4, wherein the second metal sleeve is coupled to the container or the collar by a third brazing material.

[0203] 11. The high temperature device according to embodiment 10, wherein the third brazing material comprises a nickel-based or titanium-based brazing material, and wherein the nickel-based brazing material comprises greater than or equal to about 70 weight percent nickel.

[0204] 12. The high temperature device according to embodiment 11, wherein the nickel-based brazing material comprises BNi-2 brazing material, BNi-5b brazing material or BNi-9 brazing material.

[0205] 13. The high temperature device of embodiment 11, wherein the first metal sleeve is coupled to the conductor by a fourth brazing material.

[0206] 14. The high temperature device according to embodiment 13, wherein the fourth brazing material is a nickel-based brazing material, a titanium-based brazing material, or an alloy of silver and aluminum.

[0207] 15. The high temperature device of embodiment 1, wherein the alloy of silver and aluminum further comprises a wetting agent.

[0208] 16. The high temperature device of embodiment 15, wherein the wetting agent comprises titanium.

[0209] 17. The high temperature device of embodiment 1, wherein the ceramic component comprises aluminum nitride.

[0210] 18. The high temperature device of embodiment 17, wherein the ceramic component further comprises greater than or equal to about 3 weight percent yttrium oxide.

[0211] 19. The high temperature device of embodiment 17, wherein the ceramic component further comprises about 1% to about 4% by weight of yttrium oxide.

[0212] 20. The high temperature device of embodiment 4, wherein the first metal sheath and the second metal sheath comprise Alloy 42.

[0213] 21. The high temperature device of embodiment 20, wherein the conductor or the ferrule comprises stainless steel, and wherein the stainless steel comprises 304L stainless steel.

[0214] 22. The high temperature device of embodiment 20, wherein the thickness of the first metal sheath and the second metal sheath is less than or equal to about 0.020 inches.

[0215] 23. An electrochemical monomer comprising:

[0216] a container comprising an interior cavity, wherein the interior cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.;

[0217] a seal that seals the interior cavity of the container from an environment external to the container, wherein the seal includes a ceramic component that is exposed to both the reactive material and the environment external to the container;

[0218] a current lead extending from the interior cavity of the container through the seal to the environment outside the container;

[0219] a first metal sleeve coupled to the current lead and the ceramic assembly; and

[0220] a second metal sleeve coupled to the ceramic assembly and the container or to a collar engaged to the container,

[0221] The ceramic component includes a physical ion blocker on a surface of the ceramic component.

[0222] 24. The electrochemical cell of embodiment 23, wherein the physical ion block is shaped to inhibit electromigration along the surface of the ceramic component.

[0223] 25. The electrochemical cell of embodiment 23, wherein the physical ion block is shaped to inhibit the formation of metal dendrites across the surface of the ceramic component.

[0224] 26. The electrochemical cell of embodiment 23, wherein the first metal sheath and the second metal sheath are coupled to the ceramic component by first and second brazing materials, respectively.

[0225] 27. An electrochemical cell according to embodiment 26, wherein the surface of the ceramic component is an exposed surface of the ceramic component between the first braze and the second braze, and wherein the physical ion blocker is formed so that the shortest path from the first braze to the second braze along the exposed surface of the ceramic component includes a path segment that is at least partially away from both the first braze and the second braze.

[0226] 28. The electrochemical cell of embodiment 26, wherein the first brazing material and the second brazing material each comprise an alloy of silver and aluminum.

[0227] 29. The electrochemical cell of embodiment 23, wherein the current lead is a negative current lead.

[0228] 30. The electrochemical cell of embodiment 23, wherein the physical ion block is attached to the surface of the ceramic component.

[0229] 31. The electrochemical cell of embodiment 23, wherein the physical ion block is disposed on an exposed surface of the ceramic component.

[0230] 32. An electrochemical cell according to embodiment 31, wherein the physical ion block is an integral part of the ceramic component, wherein the physical ion block includes one or more protrusions that are part of the exposed surface of the ceramic component, and wherein the one or more protrusions extend from a reference surface of the ceramic component.

[0231] 33. The electrochemical cell of embodiment 32, wherein the one or more protrusions comprise a plurality of protrusions defining a recess.

[0232] 34. The electrochemical cell of embodiment 32, wherein the one or more protrusions extend a distance greater than or equal to about 2 mm from the reference surface of the ceramic component.

[0233] 35. The electrochemical cell of embodiment 32, wherein the one or more protrusions include a long dimension and a short dimension, and wherein the long dimension defines a slope that is disposed at an angle substantially orthogonal to the reference surface of the ceramic component.

[0234] 36. The electrochemical cell of embodiment 32, wherein the one or more protrusions define a sloped surface disposed at an acute angle relative to the reference surface of the ceramic component and facing toward a positive electric field source.

[0235] 37. An electrochemical cell according to embodiment 32, wherein the one or more protrusions include a first portion and a second portion, the first portion extending from the reference surface of the ceramic component and the second portion defining a slope parallel to the reference surface of the ceramic component and extending toward a positive electric field source.

[0236] 38. The electrochemical cell of embodiment 37, wherein the positive electric field source is the body of the container in electrical communication with a positive electrode.

[0237] 39. A high temperature device comprising:

[0238] a container comprising an interior cavity, wherein the interior cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.;

[0239] a seal that seals the interior cavity of the container from an environment external to the container, wherein the seal comprises a ceramic component, and wherein the seal is exposed to both the reactive material and the environment external to the container;

[0240] a conductor extending from the environment external to the container through the seal to the interior cavity of the container;

[0241] a metal sleeve coupled to the conductor and the ceramic assembly, wherein the metal sleeve is coupled to the ceramic assembly via a braze joint comprising a braze material, and wherein the braze material is formed of a material that is substantially non-reactive with air and prevents diffusion of air into the container when the reactive material is maintained at a temperature of at least about 200° C. for a period of at least about 1 day.

[0242] 40. The high temperature device of embodiment 39, wherein the brazing material is ductile.

[0243] 41. The high temperature device according to embodiment 39 further includes an internal brazing material, and wherein the internal brazing material contacts the reactive material and protects the brazing material from the reactive material.

[0244] 42. The high temperature device of embodiment 41, wherein the internal brazing material is an active metal brazing material.

[0245] 43. The high temperature device according to embodiment 39, wherein the diffusion of air into the container is at most about 1×10 -8 Atmospheric pressure - cubic centimeters per second.

[0246] 44. The high temperature device according to embodiment 40, wherein the brazing material is an alloy of at least two different metals.

[0247] 45. The high temperature device of embodiment 1 or 39, wherein the high temperature device is a battery, and wherein the battery comprises a negative electrode, a positive electrode, and a liquid electrolyte.

[0248] 46. ​​A high temperature device according to embodiment 45, wherein at least one of the negative electrode and the positive electrode is a liquid metal electrode.

[0249] 47. A high temperature device according to embodiment 45, wherein the liquid electrolyte is a molten halide electrolyte.

[0250] 48. The electrochemical cell of embodiment 23, wherein the electrochemical cell is a battery, and wherein the battery comprises a negative electrode, a positive electrode, and a liquid electrolyte.

[0251] 49. The electrochemical cell according to embodiment 48, wherein at least one of the negative electrode and the positive electrode is a liquid metal electrode.

[0252] 50. The electrochemical cell according to embodiment 48, wherein the liquid electrolyte is a molten halide electrolyte.

[0253] Although preferred embodiments of the present invention have been shown and described herein, it will be readily understood by those skilled in the art that such embodiments are provided by way of example only. Those skilled in the art will now appreciate that many variations, changes and substitutions may be made without departing from the present invention. It should be understood that in the practice of the present invention, various alternatives to the embodiments of the present invention described herein may be employed. The following claims are intended to define the scope of the present invention, and therefore encompass methods and structures within the scope of these claims and their equivalents.

Claims

1. A high temperature device, comprising: a container comprising an interior cavity, wherein the interior cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.; a seal that seals the interior cavity of the container from an environment external to the container, wherein the seal comprises a ceramic component, and wherein the seal is exposed to the reactive material and the environment external to the container; a conductor extending from the environment external to the container through the seal to the interior cavity of the container; as well as A first metal sleeve is coupled to the conductor and the ceramic assembly, wherein the first metal sleeve is coupled to the ceramic assembly through a first braze joint comprising a first braze material, and wherein the first braze material comprises an alloy of silver and aluminum.

2. The high temperature device of claim 1, wherein the conductor is a negative current lead. 3 . The high temperature device of claim 2 , further comprising a negative current collector within the container, wherein the negative current collector is in contact with the reactive material and is attached to the negative current lead.

4. The high temperature device of claim 1 , further comprising a second metal sleeve coupled to the ceramic component, wherein the second metal sleeve is coupled to the container or to a collar joined to the container, wherein the second metal sleeve is coupled to the ceramic component via a second braze joint comprising a second braze material, and wherein the second braze material comprises an alloy of silver and aluminum.

5. The high temperature device of claim 1 or 4, wherein the alloy of silver and aluminum comprises a ratio of silver to aluminum less than or equal to about 19 to 1. 6 . The high temperature device according to claim 5 , wherein one or both of the first brazing material and the second brazing material further comprises a titanium brazing alloy.

7. The high temperature device according to claim 4, further comprising an internal braze material disposed adjacent to the first braze joint, the second braze joint, or both the first braze joint and the second braze joint, wherein the internal braze material is exposed to the inner cavity of the container.

8. The high temperature device of claim 7, wherein the internal brazing material comprises a titanium brazing alloy.

9. An electrochemical monomer comprising: a container comprising an interior cavity, wherein the interior cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.; a seal that seals the interior cavity of the container from an environment external to the container, wherein the seal includes a ceramic component that is exposed to both the reactive material and the environment external to the container; a current lead extending from the interior cavity of the container through the seal to the environment outside the container; a first metal sleeve coupled to the current lead and the ceramic assembly; as well as a second metal sleeve coupled to the ceramic assembly and the container or to a collar engaged to the container, The ceramic component includes a physical ion blocker on a surface of the ceramic component.

10. A high temperature device comprising: a container comprising an interior cavity, wherein the interior cavity comprises a reactive material, and wherein the reactive material is maintained at a temperature of at least about 200° C.; a seal that seals the interior cavity of the container from an environment external to the container, wherein the seal comprises a ceramic component, and wherein the seal is exposed to both the reactive material and the environment external to the container; a conductor extending from the environment external to the container through the seal to the interior cavity of the container; a metal sleeve coupled to the conductor and the ceramic assembly, wherein the metal sleeve is coupled to the ceramic assembly via a braze joint comprising a braze material, and wherein the braze material is formed of a material that is substantially non-reactive with air and prevents diffusion of air into the container when the reactive material is maintained at a temperature of at least about 200° C. for a period of at least about 1 day.

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