Construction of electrode and battery assembly for metal-air

Abstract

According to one aspect, an electrochemical cell may include a container, at least two anode assembly entities, at least two oxygen evolution electrode (OEE) entities, and a gas diffusion electrode (GDE). In the container, the GDE may be placed between the at least two OEE entities and a mirrored row of the at least two anode assembly entities.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the priority benefit of U.S. Provisional Patent Application 63 / 373,287, filed on August 23, 2022, the entire content of which is incorporated herein by reference. Background of the Invention

[0003] Energy storage technologies are playing an increasingly important role in the power grid. These energy storage assets provide smoothing to better match power generation and demand on the grid. The services provided by energy storage devices are beneficial to the power grid on multiple time scales (from milliseconds to years). Today, there are energy storage technologies that can support time scales from milliseconds to hours, but there is a need to improve the availability, reliability, and / or resilience of energy storage systems while reducing their costs. Summary of the Invention

[0004] According to one aspect, an electrochemical cell may include: a container, at least two anode assembly entities, at least two oxygen evolution electrodes (OEE) entities, and a gas diffusion electrode (GDE), wherein, within the container, the GDE is placed between mirror image arrangements of the at least two OEE entities and the at least two anode assembly entities.

[0005] In some embodiments, from one side of the container to the other side of the container, the mirror image arrangement may include a first anode assembly entity, a first OEE entity, the GDE, a second OEE entity, and a second anode assembly entity.

[0006] In certain embodiments, from one side of the container to the other side of the container, the mirror image arrangement may include a first OEE entity, a first anode assembly entity, the GDE, a second anode assembly entity, and a second OEE entity.

[0007] In some embodiments, the electrochemical cell may further include an electrolyte placed within the container, wherein the at least two anode assembly entities, the at least two OEE entities, and the gas diffusion electrode are each at least partially immersed in the electrolyte within the container.

[0008] In certain embodiments, the container may include a lid that includes nested grooves, bellows, flange seals, thermowelded joints, and / or laser welded joints.

[0009] In some embodiments, the GDE may define an air channel between two faces of the GDE.

[0010] In some embodiments, the GDE can be a three-edge-sealed bipolar electrode, the bipolar electrode including two electrode sheets and a flow field therebetween. For example, the flow field can include a stack of foams with different porosities, filter felt strips, serpentine channels, folded channels, or combinations thereof. Additionally or alternatively, the flow field can mechanically and electrically separate the two faces of the bipolar electrode. Additionally or alternatively, the electrochemical cell can include a spacer material bag, one or more standoffs, and / or an electrode support that supports the at least two anode assembly entities, the GDE, and the at least two OEE entities in the container.

[0011] In some embodiments, the container can include an electronic structure that provides distributed electrode switching.

[0012] In certain embodiments, the container can include a cell demisting structure and / or a flame arrester structure associated with the headspace of the container.

[0013] In some embodiments, the at least two anode assembly entities can include metal stamping sheets.

[0014] In certain embodiments, the at least two anode assembly entities, the at least two OEE entities, and the GDE can each be restricted to prevent relative movement with respect to each other in the container.

[0015] In some embodiments, the outer wall of the container can be formed by the at least two anode assembly entities.

[0016] In certain embodiments, the container can include a plurality of ribbed structures on the outer wall of the container, the plurality of ribbed structures being spaced apart from each other to define a plurality of channels between consecutive ribbed structures. For example, the plurality of channels can have different heights ranging from a smaller height at the bottom of the container to a larger height at the top of the container. Additionally or alternatively, the container can be formed of blow-molded high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), polypropylene (PP), or polyethylene terephthalate (PET).

[0017] In some embodiments, the container can be a bag physically supported by a module into which the electrochemical cell can be inserted.

[0018] In some embodiments, the electrochemical cell can further include a spacer, where the spacer is a sheet placed between one of the OEE entities and the GDE, and / or between one of the OEE entities and one of the anode assembly entities. As an example, the sheet can be supported on one of the OEE entities.

[0019] In some embodiments, the electrochemical cell can be an iron-air battery cell, a zinc-air battery cell, and / or a lithium-air battery cell. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a system block diagram of a power generation system according to multiple embodiments.

[0021] Figure 2 is a system block diagram of a power generation system according to multiple embodiments.

[0022] Figure 3 is a schematic diagram of an electrochemical cell assembly.

[0023] Figure 4A is a perspective view of an external portion of an electrochemical cell.

[0024] Figure 4B is Figure 4A an exploded view of an internal portion of the electrochemical cell of

[0025] Figure 4C is Figure 4A a schematic diagram of the electrode arrangement of the electrochemical cell shown in

[0026] Figure 4D a schematic diagram of the electrode arrangement of an electrochemical cell, the electrode arrangement including respective anode assemblies between respective oxygen evolution electrodes (OEEs) on each side of a gas diffusion electrode.

[0027] Figure 5A is a schematic diagram of a module including a plurality of electrochemical cell entities, the schematic diagram showing the height (z-dimension) of the plurality of electrochemical cell entities looking down in a top view and the plurality of electrochemical cells arranged in multiple rows from the front to the back of the module, the depth dimension of each of the plurality of electrodes being parallel to the side-to-side dimension of the module such that the plurality of electrochemical cells form a square footprint within the module.

[0028] Figure 5B is a schematic diagram of a module including a plurality of electrochemical cell entities, the schematic diagram showing the height (z-dimension) of the plurality of electrochemical cell entities looking down in a top view and the plurality of electrochemical cells arranged in multiple rows from side to side of the module, the depth dimension of each of the plurality of electrodes being perpendicular to the side-to-side dimension of the module such that the plurality of electrochemical cells form a rectangular footprint within the module.

[0029] Figure 5CSchematic diagram of a module including a plurality of electrochemical cell entities, the schematic diagram showing the height (z-dimension) of the plurality of electrochemical cell entities looking down from a top view, the plurality of electrochemical cells arranged in a single row, and the depth dimension of the plurality of electrochemical cells being perpendicular to the side-to-side dimension of the module, such that the plurality of electrochemical cells form a rectangular occupied space within the module.

[0030] Figure 5D Schematic diagram of a module including a plurality of electrochemical cell entities, the schematic diagram showing the height (z-dimension) of the plurality of electrochemical cell entities looking down from a top view, the plurality of electrochemical cells arranged in multiple rows along the side-to-side direction, and the depth dimension of each of the plurality of electrodes being perpendicular to the side-to-side dimension of the module, such that the plurality of electrochemical cells form a square occupied space of the module.

[0031] Figure 6A Perspective view of the housing of one or more module entities of FIG. 5.

[0032] Figure 6B Is Figure 6A Perspective view of the housing of, shown in a state after removing the door panel.

[0033] Figure 6C Is Figure 6A Perspective view of the lower structure of the housing of.

[0034] Figure 7A Schematic diagram of a top-down view of the housing, showing an auxiliary area located within the housing and co-located with a plurality of module entities.

[0035] Figure 7B Schematic diagram of a top-down view of a system including a housing, each housing supporting a plurality of module entities, and each housing being supported by a shared auxiliary area.

[0036] Figure 7C Schematic diagram of a top view of a system including a housing, each housing having an auxiliary area, and each housing being connected to a shared auxiliary area.

[0037] Figures 8A to 8E Schematic diagram of an exemplary layout of a plurality of module entities within the housing.

[0038] Figures 9A to 9F Schematic diagram of an exemplary layout of a plurality of module entities within the housing.

[0039] Figures 10A to 10E Schematic diagram of an exemplary layout of a plurality of module entities within the housing.

[0040] Figure 11A Is Figure 4A Schematic diagram of a top view of the sealing channel of the lid of the electrochemical cell of.

[0041] Figure 11B Is Figure 11A A schematic cross-sectional view of the sealing channel in the lid shown in the figure, the cross-section being taken along line 11B-11B in Figure A.

[0042] Figure 11C Is Figure 4A A schematic view of the bellows seal of the lid of the electrochemical cell of

[0043] Figure 12A Is Figure 4A A front view of a part of the air electrode of the electrochemical cell of

[0044] Figure 12B Is along Figure 12A A close-up perspective view of a part of the air electrode in the area of detail 12B in

[0045] Figures 13A to 13B Is a schematic view of an exemplary process for press-fitting an air flow field during the electrode sealing lamination process.

[0046] Figure 14 Is a schematic view of an exemplary method for inserting a flow field into a pre-formed double-sided sealed electrode to form an electrode.

[0047] Figure 15A Is a schematic view of a low-pressure, highly uniform flow field of a porous medium for an electrochemical cell electrode.

[0048] Figure 15B Shows the simulation results of the flow field along the long and narrow active area of the electrode, the flow field being formed by two symmetrically opposed filter felts with a tapered geometry to balance the pressure drop from the electrode inlet to the outlet.

[0049] Figure 15C Is a schematic view of the flow field along the long and narrow active area of the electrode, the flow field being formed by vertically fed and laterally positioned porous medium strips to control and distribute the air flow.

[0050] Figure 15D Shows the simulation results of the flow field along the long and narrow active area of the electrode, the flow field being formed by horizontal meandering channels of different heights.

[0051] Figure 15E Shows the simulation results of the flow field along the long and narrow active area of the electrode, the flow field being formed by vertical meandering channels with a vertical inlet feed extending from the top to the bottom of the flow field.

[0052] Figure 15F Is a schematic view of the long and narrow active area of the electrode including an accordion-fold increasing in height from top to bottom to form a flow field.

[0053] Figure 15GSchematic of a long and narrow active area of an electrode including a stepped structure with increasing spacing from the top to the bottom of the electrode.

[0054] Figure 16 Perspective view of a module including multiple electrochemical cell entities separated by bags, where structural support is provided at the module level.

[0055] Figure 17 Schematic of a cathode including a separator.

[0056] Figure 18A Is Figure 4A Perspective view of an electrochemical cell, showing a top-down cross-section A-A of the electrochemical cell along Figure 4A the electrochemical cell.

[0057] Figure 18B Is Figure 4A Top-down view of a cross-section of an electrochemical cell, the cross-section taken along Figure 18A A-A in

[0058] Figure 19 Schematic of various aspects of an electrode support for fixing an electrochemical cell electrode.

[0059] Figure 20A Schematic of various aspects of separating two electrodes with a mesh separator.

[0060] Figure 20B Schematic of various aspects of separating two electrodes with a corrugated separator.

[0061] Figure 21 Schematic of a method for reducing ohmic drop along the height of an electrode and improving current uniformity in the electrode plane according to multiple embodiments.

[0062] Figure 22 Schematic of a method for anode current collection.

[0063] Figure 23A Top view of an electrode switch control device including a single centralized switch on a printed circuit board.

[0064] Figures 23B to 23D Schematic of various aspects of an electrode switch control device including multiple switches in parallel and distributed along the width of an electrochemical cell on a printed circuit board.

[0065] Figures 24A to 25H Schematic of various aspects of cell defogging, fire blocking, and hydrogen management according to multiple embodiments.

[0066] Figures 26A to 26C Schematic of various aspects of an anode assembly.

[0067] Figures 27A to 27D are schematic views of various aspects of the lid and container sealing.

[0068] Figure 28 are schematic views of various aspects of the anode operating as a main structural component of an electrochemical cell.

[0069] Figure 29 is a schematic view of the anode used as a container of an electrochemical cell.

[0070] Figure 30 is a schematic view of the thermal management of a module using forced air cooling between electrochemical cells.

[0071] Figure 31 are schematic views of various aspects of the container of an electrochemical cell.

[0072] Figure 32 shows various aspects of an exemplary blow molded battery container according to multiple embodiments.

[0073] Figure 33 shows through Figure 32 the computational fluid dynamics / finite element analysis simulation results of the air flow through the blow molded battery container.

[0074] Figure 34 is a perspective view of a container provided with curved channels.

[0075] Figure 35 is a schematic view of continuous air flow through an electrochemical cell module.

[0076] Figure 36 is a schematic view of a parallel flow configuration of stacked container entities arranged in rows within a module. DETAILED DESCRIPTION

[0077] Multiple embodiments will be described in detail with reference to the accompanying drawings. Where possible, the same reference numerals will be used throughout the figures to refer to the same or similar parts. References to specific examples and embodiments are for illustrative purposes only and are not intended to limit the scope of the claims. The following description of the embodiments is not intended to be limiting, but rather to enable those skilled in the art to make and use these embodiments or combinations thereof.

[0078] The various embodiments of the systems, devices, technologies, methods, activities, and operations described in this specification can be used for a variety of other activities and other fields beyond those described herein. Additionally, for example, these embodiments can be used in conjunction with: other devices or activities that may be developed in the future; and existing devices or activities that can be partially modified based on the teachings of this specification. Furthermore, the various embodiments and examples described in this specification can be used together (in whole or in part), and can be used in a variety of different combinations. Thus, the configurations provided in the various embodiments of this specification can be used together. For example, according to the disclosure provided herein, the components of an embodiment having A, A', and B and the components of an embodiment having A", C, and D can be used together in a variety of combinations, such as A, C, D and A, A", C, and D, etc. Therefore, the scope of this disclosure should not be limited to the specific embodiments, the configurations or arrangements set forth in the specific embodiments, examples, or the embodiments of the specific figures.

[0079] Embodiments of the present disclosure can include systems, methods, and devices for an electrochemical energy storage system, such as a metal-air battery system. The systems and methods of the various embodiments can provide the construction and configuration of the electrodes and / or cell components of a metal-air battery system.

[0080] The various embodiments can provide devices and / or methods for long-duration and ultra-long-duration low-cost energy storage (including for multi-day energy storage). As used herein, unless otherwise expressly stated, the terms "long-duration" and / or "ultra-long-duration" and similar such terms shall be given their broadest possible meaning, including an energy storage time of 8 hours or longer, such as an energy storage time of 8 hours, an energy storage time of 8 hours to 20 hours, an energy storage time of 20 hours, an energy storage time of 20 hours to 24 hours, an energy storage time of 24 hours, an energy storage time of 24 hours to one week, an energy storage time of one week to one year (e.g., for example, several days to several weeks to several months), etc., and can encompass long-duration energy storage (LODES) systems. Additionally, unless otherwise expressly stated, the terms "long-duration" and "ultra-long-duration" "energy storage battery" (including "electrochemical battery") and similar such terms shall be given their broadest possible meaning; including an electrochemical battery that can be configured to store energy over a time span of several days, several weeks, or several quarters, such as an electrochemical battery sometimes referred to as a multi-day energy storage (MDS) battery. By definition, the term "duration" represents the ratio of the energy to the power of an energy storage system. For example, a system with a rated energy of 24 MWh and a rated power of 8 MW has a duration of 3 hours; a system with a rated energy of 24 MWh and a rated power of 1 MW has a duration of 24 hours. Physically, this can be interpreted as the operating time of the energy storage system at its maximum power.

[0081] Generally, in one embodiment, a long-duration energy storage battery can be a long-duration electrochemical battery. Generally, such a long-duration electrochemical battery can store electrical power generated by a power generation system provided that: (i) the energy source or fuel for power generation is available, abundant, inexpensive, and combinations and variations thereof; (ii) when the power requirement or electrical demand of the power grid, customer, or other user is less than the amount of electrical power generated by the power generation system, the price paid for providing such electrical power to the power grid, customer, or other user is less than the economic efficiency point of generating such electrical power (e.g., the cost of power generation exceeds the market price of the electrical power), and combinations and variations thereof; and (iii) combinations and variations of (i) and (ii) and other reasons. Then, such electrical power stored in the long-duration electrochemical battery can be delivered to the power grid, customer, or other user when it is affordable or when there is other need. For example, an electrochemical battery can be configured to store energy generated by a solar cell during summer months when there is ample sunlight and solar power generation exceeds the grid demand, and release the stored energy during winter months when sunlight may be insufficient to meet the grid demand.

[0082] Multiple embodiments can provide devices and / or methods for a bulk energy storage system (e.g., a long-duration energy storage (LODES) system (e.g., a multi-day energy storage (MDS) system), a short-duration energy storage (SDES) system, etc.). As an example, multiple embodiments can provide the configuration and control of a battery bank (e.g., a battery bank for a LODES system) for a bulk energy storage system.

[0083] Although multiple examples are discussed with reference to Li-ion and / or Fe-air, the discussion of Li-ion and / or Fe-air is only used as an example, and multiple embodiments include other combinations and arrangements of storage technologies that can replace the exemplary solar + Li-ion + Fe-air discussion herein. For example, various metal-air storage technologies can be used as battery banks in multiple embodiments, such as zinc-air, lithium-air, sodium-air, etc.

[0084] As used herein, the term "module" can refer to a unit electrochemical cell string (e.g., a battery bank string). Multiple modules (or multiple units or electrochemical cells) can be connected together to form a battery bank string.

[0085] Unless the context otherwise indicates or clearly states, any element recited in the singular shall be understood to be intended to cover embodiments including one or more such elements, and the separate recitation of "one or more" is generally omitted for clarity and readability. Thus, for example, reciting a LODES system 104 shall be understood to include one or more LODES systems, etc.

[0086] Figure 1is a system block diagram of a power generation system 101 according to multiple embodiments. The power generation system 101 can be a power plant including a power source 102, a LODES system 104 (e.g., a multi-day energy storage (MDS) system), and an SDES system 160. As an example, the power source 102 can include a renewable power source, a non-renewable power source, a combination of a renewable power source and a non-renewable power source, etc. Examples of the power source 102 include wind turbines, solar generators, geothermal generators, nuclear generators, etc. The LODES system 104 can include electrochemical cells (e.g., one or more battery packs). The battery packs of the LODES system 104 can be any type of battery pack, such as rechargeable secondary batteries, refuellable primary batteries, a combination of primary batteries and secondary batteries, etc. The battery pack chemistry can be any suitable chemistry, such as Al, AlCl 3 、Fe、FeO x (OH) y 、Na x S y 、SiO x (OH) y 、AlO x (OH) y 、metal-air and / or any suitable type of battery pack chemistry. The SDES system 160 can include one or more electrochemical cells (e.g., one or more battery packs). The battery packs of the SDES system 160 can be any type of battery pack, such as rechargeable secondary batteries, refuellable primary batteries, a combination of primary batteries and secondary batteries, etc. The battery pack chemistry can be any suitable chemistry, such as Li ions, Na ions, NiMH, Mg ions and / or any suitable type of battery pack chemistry.

[0087] In multiple embodiments, the operation of the power source 102 can be controlled by the first control system 106. The first control system 106 can include an engine, a pump, a fan, a switch, a relay, or any other type of device that can control the power generation of the power source 102. In multiple embodiments, the operation of the LODES system 104 can be controlled by the second control system 108. The second control system 108 can include an engine, a pump, a fan, a switch, a relay, or any other type of device that can control the discharging and / or storing of electricity in the LODES system. In multiple embodiments, the operation of the SDES system 160 can be controlled by the third control system 158. The third control system 158 can include an engine, a pump, a fan, a switch, a relay, or any other type of device that can control the discharging and / or storing of electricity in the SDES system 160. The first control system 106, the second control system 108, and the third control system 158 can each be connected to the power plant controller 112. The power plant controller 112 can monitor the overall operation of the power generation system 101, generate control signals, and send control signals to the first control system 106, the second control system 108, and the third control system 158 to control the operation of the power source 102, the LODES system 104, and / or the SDES system 160.

[0088] In power generation system 101, power source 102, LODES system 104, and SDES system 160 can each be connected to power control device 110. Power control device 110 can be connected to power grid 115 or other transmission facilities. Power control device 110 can include switches, inverters (e.g., AC to DC inverters, DC to AC inverters, etc.), relays, power electronics, and any other type of device that can control the flow of power to / from power source 102, LODES system 104, SDES system 160, and / or power grid 115. Additionally or alternatively, power generation system 101 can include transmission facility 130 that connects power generation, transmission, and the power generation system 101 to power grid 115. As an example, transmission facility 130 can be connected between power control device 110 and power grid 115 such that power can flow between power generation system 101 and power grid 115. Transmission facility 130 can include transmission lines, distribution lines, cables, switches, relays, transformers, and any other type of device that can support the flow of power between power generation system 101 and power grid 115. Power control device 110 and / or transmission facility 130 can be connected to power plant controller 112. Power plant controller 112 can monitor and control the operation of power control device 110 and / or transmission facility 130, e.g., via a plurality of control signals. As an example, power plant controller 112 can control power control device 110 and / or transmission facility 130 to supply power from power source 102 to power grid 115, supply power from LODES system 104 to power grid 115, supply power from power source 102 and LODES system 104 to power grid 115, supply power from power source 102 to LODES system 104, supply power from power grid 115 to LODES system 104, supply power from SDES system 160 to power grid 115, supply power from power source 102 and SDES system 160 to power grid 115, supply power from power source 102 to SDES system 160, supply power from power grid 115 to SDES system 160, supply power from SDES system 160 and LODES system 104 to power grid 115, and / or supply power from power source 102, SDES system 160, and LODES system 104 to power grid 115. In multiple embodiments, power source 102 can selectively charge LODES system 104 and / or SDES system 160, and LODES system 104 and / or SDES system 160 can selectively discharge to power grid 115. In this way, the energy generated by power source 102 (e.g., renewable energy, non-renewable energy, etc.) can be output from LODES system 104 and / or SDES system 160 to power grid 115 at some time after generation.

[0089] In various embodiments, the power plant controller 112 can communicate with a network 120 (e.g., a 3G network, a 4G network, a 5G network, a core network, the Internet, combinations thereof, etc.). Using the connection to the network 120, the power plant controller 112 can exchange data with the network 120 and with devices connected to the network 120 (such as the power plant management system 121 or any other device connected to the network 120). The power plant management system 121 can include one or more computing devices, such as the computing device 124 and the server 122. The computing device 124 and the server 122 can be directly connected to each other and / or connected by being connected to the network 120. The various connections of the power plant controller 112 and the devices of the power plant management system 121 to the network 120 can be wired connections and / or wireless connections.

[0090] In various embodiments, the computing device 124 of the power plant management system 121 can provide a user interface that facilitates providing user-defined inputs to the power plant management system 121 and / or the power generation system 101, receiving indications related to the power plant management system 121 and / or the power generation system 101, and / or otherwise controlling the operation of the power plant management system 121 and / or the power generation system 101.

[0091] Although shown as two separate devices 124 and 122, the functions of the computing device 124 and the server 122 described herein can be integrated into a single computing device or can be divided among more than two devices. Additionally or alternatively, although shown as part of the power plant management system 121, the functions of one or both of the computing device 124 and the server 122 can be performed in whole or in part by a remote computing device such as a cloud-based computing system. Additionally or alternatively, although shown as communicating with a single power generation system 101 entity, the power plant management system 121 can communicate with multiple power generation system 101 entities.

[0092] Although Figure 1 the power generation source 102, the LODES system 104, and the SDES system 160 are shown as being located together, in various embodiments, they can be physically separated from each other. For example, the LODES system 104 can be located downstream of a transmission constraint, such as downstream of a part of the power grid 115, downstream of the power generation source 102 and the SDES system 160, etc. In this way, by placing the LODES system 104 downstream of the transmission constraint, charging the LODES system 104 when capacity is abundant, and discharging the LODES system 104 when transmission is insufficient, overbuilding of underutilized transmission facilities can be reduced or even avoided. Additionally or alternatively, the LODES system 104 can arbitrate electricity based on prevailing market prices to reduce the final electricity cost for customers.

[0093] Figure 2 is a system block diagram of power generation system 201, wherein, according to multiple embodiments, multiple components of power generation system 201 may be physically separated from each other. For clear and concise description, unless otherwise specified or clearly stated in the context, Figure 2 components having the same last two digits in Figure 1 should be understood to be similar or interchangeable with each other, so the same features will not be described again, and only the differences and specific features will be emphasized. For example, unless the context states or clearly indicates the opposite purpose, power generation system 101 ( Figure 1 ) should be understood to be similar to and / or interchangeable with power generation system 201.

[0094] As an example, power generation system 201 may include a power source 202 and one or more large-capacity energy storage systems, such as LODES system 204 and / or SDES system 260. Power source 202, LODES system 204 and / or SDES system 160 may be separated in power plants 231A, 231B, 231C. Although power plants 231A, 231B, 231C may be separated from each other, power generation system 201 and power plant management system 121 may operate with reference to the operation of power generation system 101 and power plant management system 121 ( Figure 1 ) as described above. Power plants 231A, 231B and 231C may be in the same location or geographically separated from each other. Power plants 231A, 231B and 231C may be connected to power grid 215 at different locations. For example, power plant 231A may be connected to power grid 215 upstream of the connection of power plant 231B.

[0095] In some embodiments, power plant 231A associated with power source 202 may include dedicated equipment for controlling power plant 231A and / or for transmitting power to / from power plant 231A. For example, power plant 231A may include power plant controller 212A and power controller 110A and / or transmission facility 230A. Power controller 210A and / or transmission facility 230 may be electrically communicatively connected to power plant controller 112A. For example, power plant controller 212A may monitor and control the operation of power controller 210A and / or transmission facility 230A, such as through multiple control signals. As an example, power plant controller 212A may control power controller 210A and / or transmission facility 230A to supply power from power source 202 to power grid 215, etc.

[0096] Additionally or alternatively, the power plant 231B associated with the LODES system 204 may include dedicated equipment for controlling the power plant 231B and / or for transmitting power to / from the power plant 231B. For example, the power plant 231B associated with the LODES system 204 may include a power plant controller 112B, a power controller 210B, and / or a transmission facility 230B. The power controller 210B and / or the transmission facility 230B may be connected to the power plant controller 212B. The power plant controller 212B may monitor and control the operation of the power controller 210B and / or the transmission facility 230B, for example, through a plurality of control signals. As an example, the power plant controller 212B may control the power controller 210B and / or the transmission facility 230B to supply power from the LODES system 204 to the power grid 215 and / or to supply power from the power grid 215 to the LODES system 204, etc.

[0097] Additionally or alternatively, the power plant 231C associated with the SDES system 260 may include dedicated equipment for controlling the power plant 231C and / or for transmitting power to / from the power plant 231C. For example, the power plant 231C associated with the SDES system 260 may include a power plant controller 212C, a power controller 210C, and / or a transmission facility 230C. The power controller 210C and / or the transmission facility 230C may be connected to the power plant controller 212C. The power plant controller 212C may monitor and control the operation of the power controller 210C and / or the transmission facility 230C, for example, through a plurality of control signals. As an example, the power plant controller 212C may monitor and control the operation of the power controller 210C and / or the transmission facility 230C, for example, through a plurality of control signals. As an example, the power plant controller 212 may control the power controller 210C and / or the transmission facility 230C to supply power from the SDES system 260 to the power grid 215 and / or to supply power from the power grid 215 to the SDES system 260, etc.

[0098] In multiple embodiments, power plant controllers 212A, 212B, 212C can each communicate with one another and / or with network 220. Using the connection to network 220, power plant controllers 212A, 212B, 212C can exchange data with network 220 and one or more devices connected to network 220 (such as power plant management system 221), exchange data with one another, or connect to any other device connected to network 220 to exchange data. In multiple embodiments, the operation of power plant controllers 212A, 212B, 212C can be monitored by power plant management system 221, and the operation of power plant controllers 212A, 212B, 212C can be controlled by power plant management system 221. Thus, the operation of power generation system 201 can be controlled by power plant management system 221.

[0099] Figure 3 can be used for one or more of the LODES systems described herein (e.g., Figure 1 the LODES system 204 in Figure 2 and / or the LODES system 204 in

[0100] In multiple embodiments, the anode 373 can be solid and the electrolyte can be excluded from the anode. In multiple embodiments, the anode 373 can be porous and the electrolyte 374 can geometrically interpenetrate the anode 373, creating a larger interfacial surface area for the reaction. Additionally or alternatively, the air electrode 203 can be porous and the electrolyte 374 can geometrically interpenetrate the anode 373, creating a larger interfacial surface area for the reaction. Additionally or alternatively, the GDE 372 can be located at the interface of the electrolyte 374 and the gas headspace ( Figure 3 not shown in the figure). For example, the gas headspace can be sealed in a shell. Additionally or alternatively, the shell can be unsealed and the gas headspace can be an open system that can freely exchange substances with the environment.

[0101] The anode 373 can be formed of a metal or metal alloy, such as lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), silicon (Si), aluminum (Al), zinc (Zn), or iron (Fe), or an alloy substantially composed of one or more of the foregoing metal elements, such as an aluminum alloy or iron alloy (e.g., FeAl, FeZn, FeMg, etc.) that can undergo an oxidation reaction for discharging. Thus, the anode 373 can be referred to herein as a metal electrode.

[0102] In certain embodiments, the battery pack 370 can be rechargeable, and when the battery pack 370 is charged, the anode 373 can undergo a reduction reaction. The anode 373 can be solid (including dense solid or porous solid), or a mesh or foam, or a collection of particles or granules, or can be a slurry, ink, suspension, or paste deposited within a shell. In multiple embodiments, the components of the anode 373 can be selected such that the anode 373 and the electrolyte 374 do not mix to any substantial extent, allowing only a small amount of solubility that does not affect the performance of the battery pack 370. For example, the anode 373 can be a metal electrode that can be a bulk solid. Additionally or alternatively, the anode 373 can include a collection of particles in a suspension, such as small particles or large volume particles, and the buoyancy of the collection of particles may not be sufficient to escape from the suspension into the electrolyte. Additionally or alternatively, the anode 373 can include particles that do not float in the electrolyte 374.

[0103] GDE 372 can support a reaction with oxygen. As an example, GDE 372 can be solid and can be located at the interface between the gas headspace and the electrolyte 374. During discharge, GDE 372 can support the reduction of oxygen from the gas headspace, namely the so-called oxygen reduction reaction (ORR). In certain embodiments, the battery pack 370 can be rechargeable, and a reverse reaction can occur, that is, GDE supports the reaction of oxygen evolution from the battery pack, namely the so-called oxygen evolution reaction (OER). The OER and ORR reactions are well known to those skilled in the art.

[0104] In various embodiments, the electrolyte 374 can be a liquid electrolyte. For example, the electrolyte 374 can be an aqueous solution, a non-aqueous solution, or a combination thereof. In various embodiments, the electrolyte 374 can be an aqueous solution, which can be acidic (low pH), neutral (intermediate pH), or basic (high pH; also referred to as alkaline or caustic). In certain embodiments, the electrolyte 374 can contain electropositive elements such as Li, K, Na, or a combination thereof. In some embodiments, the liquid electrolyte can be basic, that is, the pH is greater than 7. In some embodiments, the pH of the electrolyte can be greater than 10 (for example, greater than 12). For example, the electrolyte 374 can contain potassium hydroxide (KOH) at a concentration of 6 M (mol / liter). In certain embodiments, the electrolyte 374 can contain a combination of components such as 5.5 M potassium hydroxide (KOH) and 0.5 M lithium hydroxide (LiOH). In certain embodiments, the electrolyte 374 can contain sodium hydroxide (NaOH) at a concentration of 6 M (mol / liter). In certain embodiments, the electrolyte 374 can contain sodium hydroxide (NaOH) at a concentration of 5 M (mol / liter) and 1 M potassium hydroxide (KOH).

[0105] In certain embodiments, the battery pack 370 (e.g., a metal-air battery pack) can be discharged by reducing oxygen (O 2 ) that is typically from air. This may require a three-phase contact between gaseous oxygen, an electrochemically active conductor that provides electrons for the reduction reaction, and the electrolyte 374 that contains the product of the reduction step to be achieved. For example, in certain embodiments involving an aqueous alkaline electrolyte, oxygen from air can be reduced through the half-reaction O 2 +2H 2 O + 4e - →4OH -Hydroxide ions are formed upon reduction. Thus, delivering oxygen to a metal-air battery can include gas handling and maintaining a triple point. In certain embodiments, the GDE 372 can be positioned at the gas-liquid interface to facilitate and maintain a triple-phase boundary, sometimes referred to as a "normal air-breathing" configuration. The GDE 372 can be placed vertically, horizontally, or at any intermediate angle with respect to gravity and maintain the "normal air-breathing" configuration. In these "normal air-breathing" configurations, the gas phase is at atmospheric pressure (i.e., the gas phase is unpressurized except for the effects of gravity).

[0106] Figure 3 The battery pack 370 in is merely an example of one electrochemical cell according to multiple embodiments and is not intended to be limiting. Other configurations such as electrochemical cells with different types of containers and / or without a container 371, electrochemical cells with different types of air electrodes and / or without a GDE 372, electrochemical cells with different types of current collectors and / or without a current collector 375, electrochemical cells with different types of anodes and / or without an anode 373, and / or electrochemical cells with different types of electrolytes and / or without an electrolyte 374 can replace the exemplary configuration of the battery pack 370, and other arrangements are consistent with multiple embodiments.

[0107] In multiple embodiments, the container 371 can be made of a polymer such as polyethylene, acrylonitrile butadiene styrene (ABS), high-density polyethylene (HDPE), ultra-high molecular weight polyethylene (UHMW), polypropylene, and / or other polymers. In certain embodiments, the container 371 and / or the shell for the battery pack 370 can be made of a metal such as nickel, steel, anodized aluminum, nickel-plated steel, nickel-plated aluminum, or other metals.

[0108] In multiple embodiments, a battery pack (e.g., battery pack 370) can include three electrodes - an anode (e.g., anode 373) and a dual cathode (e.g., the GDE 372 includes two parts, such as a first cathode and a second cathode). The electrodes can have a limited service life and can be mechanically replaced. For example, the anode can be replaced seasonally. The first cathode of the dual cathode can be divided into two parts, with a first part having a hydrophilic surface and a second part having a hydrophobic surface. For example, the hydrophobic surface can have polytetrafluoroethylene (PTFE) (e.g., ) hydrophobic surface.

[0109] For example, the second part with a hydrophobic surface may include a microporous layer of high surface area carbon and polytetrafluoroethylene (PTFE), while the first part with a hydrophilic surface may include carbon fibers partially coated with PTFE. As another example, the second part may include a microporous layer of PTFE and carbon black, and the first part may include about 33 wt% of PTFE. As a further example, the second part may include a microporous layer of 23 wt% of PTFE and 77 wt% of carbon black, and the first part may include a low-loading microporous layer. The anode may be an iron (Fe) electrode or an iron alloy (Fe alloy) electrode (e.g., FeAl, FeZn, FeMg, etc.). The second cathode of the dual cathode may have a hydrophilic surface. The second cathode of the dual cathode may include a metal substrate coated with nickel (Ni), such as carbon (C), titanium (Ti), steel, etc. An electrolyte (e.g., electrolyte 140) may be placed between the three electrodes. The electrolyte may penetrate into one or more of the three electrodes.

[0110] The battery pack system may include a plurality of cells in series and / or parallel in a shared electrolyte bath and contained in a housing.

[0111] Now referring Figures 1 to 4C , Figure 4A , according to various embodiments, the electrochemical cell 400 may include at least one battery pack, such as at least one battery pack 200 entity. In some embodiments, the electrochemical cell 400 may include a container 401 (e.g., such as container 371), in which an air electrode (e.g., cathode) such as GDE 372, a negative electrode (e.g., anode) such as anode 373, and an electrolyte such as electrolyte 374 are placed. The electrolyte such as electrolyte 374 may rise to a given liquid level within the container 401, and a headspace may be formed between the top of the container 401 and the electrolyte liquid level in the electrochemical cell 400. The container 401 may have a height (e.g., z dimension), a width (e.g., y dimension), and a depth (e.g., x dimension). In an exemplary configuration, the height may be greater than the width and the depth, and the width may be greater than the depth, such that the container 401 is generally a rectangular parallelepiped. The container 401 may include one or more different connections, such as electrical connections, electrolyte connections, gas connections (e.g., air connections), ventilation holes, etc. Through the connections, two or more electrochemical cells (e.g., two or more electrochemical cell 400 entities) may be connected together, such as in series and / or parallel, to form a module.

[0112] In a module formed by multiple electrochemical cell 400 entities, each electrochemical cell 400 entity can be a self - contained unit that supports its respective air electrode (e.g., GDE 372), anode electrode (e.g., anode 373), and electrolyte (e.g., electrolyte 374). The module structure can support the container 401 of the electrochemical cells 400 placed within a given module.

[0113] The container 401 can house one or more anode assembly 402a, 402b entities (e.g., one or more anode 373 entities), one or more cathode entities (e.g., air electrode 203), and an electrolyte (e.g., electrolyte 374) inside it. As an example, each cathode assembly entity can include its respective oxygen evolution electrode (OEE) 403a, 403b entities and gas diffusion electrode (GDE) 404 entities. A battery pack including at least one OEE 403 entity and at least one GDE 404 entity can be referred to as a multi - cathode battery pack cell.

[0114] The first OEE 403a can be placed inside the container 401, between the first anode assembly 402a and the GDE 404. On the opposite side of the GDE 404, the second OEE 403b and the second anode assembly 402b can be configured mirror - symmetrically with respect to the GDE 404. That is, inside the container 401, the GDE 404 can be placed between the following symmetric arrangements: 1) the first anode assembly 402a and the first OEE 403a; and 2) the second anode assembly 402b and the second OEE 403b. As a specific example, the GDE 404 can be placed centrally within the volume defined by the container 401 such that the length and width of the GDE 404 are placed at least partially along a central plane that defines the length and width of the volume defined by the container 401 and intersects the mid - point of the depth dimension of the volume defined by the container 401. Air can enter the volume of the container 401 and enter the GDE 404 between the first OEE 403a and the second OEE 403b (e.g., enter the central portion of the GDE 404). The electrochemical cell 400 can include a first spacer element 451 between the first anode assembly 402a and the first OEE 403a and between the second anode assembly 402b and the second OEE 403b. Additionally or alternatively, the electrochemical cell 400 can include a second spacer element 452 between the first OEE 403a and the GDE 404 and between the second OEE 403b and the GDE 404. However, such an internal arrangement of the electrochemical cell 400 is only an exemplary configuration inside the container 401 and is not intended to be restrictive.

[0115] In some embodiments, the electrochemical cell 400 may include an electronics structure 450, which may include a printed circuit board assembly (PCBA), a circuit housing, etc., which may be used to support a plurality of electronic devices (e.g., controllers, sensors, switches, wiring buses, etc.) that may control and / or manage one or more operations of the electrochemical cell 400. The electrochemical cell 400 may additionally or alternatively include a lid 455 and an electrode support 454 on opposite sides along the length dimension of the container 401. A strap 453 may secure the lid 455 and the electrode support 454 to the container 401. In some configurations, the electronics structure 450 may be supported on the lid 455.

[0116] Generally, the first OEE 403a, the first anode assembly 402a, the GDE 404, the second OEE 403b, and the second anode assembly 402b may each be placed in the electrolyte 497 within the volume of the container 401 of the electrochemical cell 400. As discussed herein, the GDE 404 may include a two-part electrode having three edge-sealed faces to form a double-sided bag-like configuration defining a central air channel between the two faces. Compared to other configurations, by fabricating a 2-sided GDE (air in the middle, active faces on both sides), the amount of non-active material used in the GDE 404 configuration (e.g., flow field, epoxy “grooves” or frames) can be reduced. To facilitate the construction of the GDE 404, the first anode assembly 402a and the first OEE 403a may form a mirror image with the second anode assembly 402b and the second OEE 403b around the GDE 404. Along the depth dimension of the container 401, in Figure 4C the direction from right to left in, the electrode configuration within the container 401 of the electrochemical cell 400 may be: first anode assembly 402a | first OEE 403a | first part 404a of GDE404 | second part 404b of GDE 404 | second OEE 403b | second anode assembly 402b. For ease of manufacturing and assembly, each electrode may also be divided into two mechanically independent electrodes along the width dimension of the container 401, such that the dimensions result in the electrochemical cell having 4 anodes (e.g., two first anode assembly 402a entities and two second assembly 402b entities), 4 OEEs (e.g., two first OEE 403a entities and two second OEE 403b entities), and two GDE 404 entities. Electrically and electrochemically, all electrodes may operate as a parallel circuit (e.g., having a common potential between all anodes).

[0117] Referring to Figures 1 to 4C and Figure 5A, Module 501 is presented in a top-down view along the height (e.g., z-dimension) of a plurality of electrochemical cell 400 entities. Module 501 may generally have a square configuration, with the lengths of the front, back, and sides of Module 501 being approximately the same. In Module 501, a plurality of electrochemical cell 400 entities may be arranged in two rows such that the respective width dimensions of the plurality of electrochemical cell entities are parallel to the sides of Module 501, and the respective depths of the containers 401 are parallel to the front and back of Module 501. In the configuration of Module 501, the combined width of the two rows of a plurality of electrochemical cell 400 entities, as well as any spacing between the two rows and between the front and back of the module, may generally determine the length of each side of Module 501. The number of entities of the electrochemical cells 400 in each row, the depth dimension of each container 401 entity, the spacing between the container 401 entities in each row, and the spacing between each row and the sides of Module 501 may generally determine the length of Module 501 from the front to the back. As described in more detail below, other arrangements of the plurality of electrochemical cell 400 entities may additionally or alternatively form modules with other footprints.

[0118] Although multiple aspects of the electrochemical cells and modules of such electrochemical cells have been described, it should be understood that other embodiments are additionally or alternatively possible.

[0119] For example, although the electrochemical cell 400 has been described as including a class of anode assemblies and a mirror arrangement of the OEE relative to the GDE 404, it should be understood that another class of mirror arrangements is additionally or alternatively possible. For example, now referring to Figure 4D , along the depth dimension of the container 401’, in the Figure 4D from left to right direction, the electrode configuration within the container 401’ of the electrochemical cell 400’ may be: first OEE 403a’ | first anode assembly 402a’ | first part 404a’ of the GDE 404’ | second part 404b of the GDE 404’ | second anode assembly 402b | and second OEE 403b’. In this context, except to the extent necessary to accommodate different positions of the electrodes relative to the Figure 4D in the Figure 4B and Figure 4C shown positions, the element numbers marked with superscript symbols (’) should be understood to be the same as the corresponding element numbers without superscript symbols. Additionally or alternatively, the electrochemical cell 400’ should be understood to be interchangeable with the electrochemical cell 400 in the following specification. However, for clarity and effective description, the description and references in the following specification only refer to the electrochemical cell 400.

[0120] As another example, although Module 501 has been described as having a specific arrangement of electrochemical cells to form a specific footprint, it should be understood that other arrangements of electrochemical cells may additionally or alternatively form modules. As an example, referring toFigure 5B , the module 502 configuration may include a plurality of electrochemical cell 400 entities according to multiple embodiments. The module 502 configuration may generally be in a rectangular configuration, with the sides of the module 502 being longer than the back and front of the module 502. In the module 502, two rows of electrochemical cell 400 entities may be arranged such that the width of the plurality of electrochemical cell 400 entities is parallel to the front and back of the module 502, and the depth of the plurality of electrochemical cell 400 entities is parallel to the sides of the module 502. In the configuration of the module 502, the width of two electrochemical cell 400 entities (as well as any spacing between the rows of electrochemical cell 400 entities and the spacing between each row and the sides of the module 502) may generally determine the length of the front and back of the module 502. The number of entities in each row of electrochemical cells 400 and the depth of the plurality of electrochemical cell 400 entities (as well as the spacing between each row of the plurality of electrochemical cell 400 entities and the spacing between each row and the front and back of the module 502) may generally determine the length of the sides of the module 502.

[0121] As another example, now refer to Figure 5C , the module 503 configuration may include a plurality of electrochemical cell 400 entities according to multiple embodiments. The module 503 may generally be in a rectangular configuration, with the sides of the module 503 being longer than the back and front of the module 503. In the module 503, a single row of electrochemical cell 400 entities may be arranged such that the width of the plurality of electrochemical cell 400 entities is parallel to the front and back of the module 503, and the depth of the electrochemical cell 400 entities is parallel to the sides of the module 502. In the module 503, the width of the single row of electrochemical cell 400 entities (as well as any spacing between the sides of the module 503) may generally determine the length of the front and back of the module 503. The number of entities in the row of electrochemical cells 400 and the depth of the electrochemical cell 400 entities (as well as the spacing between the entities in the row of electrochemical cells 400 and the spacing between the front and back of the module 503) may generally determine the length of the sides of the module 503.

[0122] As yet another example, now refer to Figure 5D, the module 504 can generally be square, and the lengths of the front, back, and sides of the module 504 are substantially the same. In the module 504, two rows of electrochemical cell 400 entities can be arranged such that the width of the electrochemical cell 400 entities is parallel to the front and back of the module 504, and the depth of the electrochemical cell 400 entities is parallel to the sides of the module 504. In the module 504, the width of two electrochemical cell 400 entities (as well as any spacing between the rows of electrochemical cell 400 entities and the spacing between each row and the sides of the module 504) can generally determine the length of the front and back of the module 504. The number of entities in each row of the electrochemical cells 400 and the depth of the electrochemical cell 400 entities (as well as the spacing between each row of electrochemical cell 400 entities and the spacing between each row and the front and back of the module 504) can generally determine the length of the sides of the module 504.

[0123] Additionally or alternatively, other configurations of multiple electrochemical cell entities can be employed, such as modules with more or fewer rows, modules with non-linearly arranged electrochemical cells, modules with more or fewer electrochemical cells, etc., which can replace the exemplary configuration of the above-mentioned module, and the other configurations are consistent with multiple embodiments.

[0124] In multiple embodiments, a battery pack module having an electrochemical cell string can be encapsulated in a housing. The housing can accommodate one or more module entities, where each module entity has an electrochemical cell string therein. In the following description, the housing is described in terms of multiple module 501 ( Figure 5A ) entities. However, it should be understood that this is for clarity and effective illustration. That is, unless the context otherwise indicates or expressly states, any reference to the module 501 ( Figure 5A ) in the housing should be understood to equally apply to any other arrangement of electrochemical cells in the module, and thus should be understood to equally apply to the module 502 ( Figure 5B ), the module 503 ( Figure 5C ), and the module 504 ( Figure 5D ).

[0125] Field-deployed module 501 instances may need to be protected from the following elements: such as wind, dust, snow, rain, seismic activity, etc. Additionally or alternatively, instances of the module 501 may need to be fixed to the ground to reduce the possibility of movement during high winds and / or seismic activity. Personnel also need protection from high voltages, corrosive fluids, and any other hazardous situations associated with the operation of the battery pack system. Several auxiliary systems may also be required to support the operation of the battery energy storage system, including secondary protection, thermal management, hydrogen management, gas diffusion electrode (GDE) support, air supply, electrolyte / water management, etc.

[0126] Now refer to Figures 1 to 5A and Figures 6A to 6C, one or more module 501 entities may be located within an enclosure 605. As an example, the enclosure 605 may include a lower structure 602, walls 603, 604, 606, 607, a top 611, and doors 612, 614.

[0127] In some embodiments, the lower structure 602 may support the entire weight of multiple module 501 entities for transportation and installation. If secondary protection is included in the design, the secondary protection may be fabricated into the lower structure 602, for example, for handling possible spills and fire suppression water. Lifting points may be provided in the lower structure 602 such that the lower structure 602 may be lifted by the corners or include additional lifting points along its length. The bottom of the lower structure 602 may include attachment points to facilitate securing one or more module 501 entities to the enclosure 605, for example, to support transportation, seismic damping, etc. To facilitate protecting one or more module 501 entities during installation and / or transportation, the enclosure 605 may include doors 612 and 614. Additionally, other doors and / or hatches may be installed along other walls and / or the top of the enclosure 605. Figures 6A to 6C The illustrated configuration of the enclosure 605 shows a configuration of at least seven modules, but it should be understood that more or fewer modules may be present in the enclosure 605 depending on the enclosure size and / or configuration. Additionally or alternatively, the enclosure 605 may include attachment points for attachment to a variety of on-site installation structures during on-site deployment, such as foundation beams, piles, helical piles, foundations, etc.

[0128] In some embodiments, the enclosure 605 may include an auxiliary area 608. As an example, the auxiliary area 608 may be at one end of the enclosure 605. Additionally or alternatively, auxiliary equipment may be installed in the auxiliary area to support the operation of one or more module 501 entities. The auxiliary equipment may include pumps, blowers, controllers, switches, connectors, pipes, conduits, heaters, coolers, filters, reservoirs, storage tanks, electronics, or any other type of equipment that may support the operation of one or more module 501 entities within the enclosure 605. Support subsystems may be housed in the auxiliary area 608 and connected to one or more module 501 entities. The support subsystems may include a GDE air system, a thermal management system, a heating system, a hydrogen management system, a water and / or electrolyte management system, a power electronics system, a control electronics system, a communication system, telemetry sensors and equipment, and / or a disconnection from plant-level services, and any other type of subsystem. Additionally or alternatively, the bottom of the enclosure 605 may define perforations to allow for stubbing of electrical, water, or any other required connections during on-site installation. The perforations may maintain the secondary protection requirements of the lower structure 602.

[0129] The walls 603, 604, 606, and 607 can be connected to the lower structure 602 and, in some cases, can support the snow load borne by the top 611 and / or can handle the wind load on the housing 605. Additionally or alternatively, the structural shell formed by the walls 603, 604, 506, and 607 connected to the lower structure 602 can provide a base for auxiliary subsystems that need to operate throughout the housing 605 to support the operation of one or more module 501 entities. Although in some cases the walls 603, 604, 606, and 607 and the top 611 can each be metallic, it should be understood that all or part of the walls 603, 604, 606, and 607 and / or the top 611 can be formed of other materials such as fabric, cloth, etc.

[0130] In multiple embodiments, the housing 605 can form different regions, such as the auxiliary region 608 and the module bay 616. In multiple embodiments, the auxiliary region 608 can be covered by a door 612 on one or both long sides of the housing 605, and the module bay 616 can be covered by a door 614 on one or both long sides of the housing 605. The door 612 and / or the door 614 can facilitate access to auxiliary equipment and / or one or more module 501 entities for maintenance, repair, and / or replacement. In some embodiments, the perforations 610 can be defined by the wall 606 and / or by the top 611 to facilitate air exchange from the environment to the housing 605 and vice versa. The perforations 610 can include, for example, filter grilles. Additionally or alternatively, the housing 605 can maintain low dust ingress and / or prevent heavy rain.

[0131] Now referring to Figure 7A , the auxiliary region 608 can be within the housing 605 and co-located with one or more module 501 entities within the module bay 616. Although the housing 605 is shown as including seven module 501 entities, it should be understood that more or fewer module 501 entities can be placed in the housing 605, which can be used to accommodate different end-use cases.

[0132] Now referring to Figure 7B , the system 702 can include multiple housing 710 entities that support multiple module 501 entities. The shared auxiliary region 703 can support multiple housing 710 entities. The shared auxiliary region 703 can be connected to each of the multiple module 501 entities via one or more connectors 715, and the shared auxiliary region 703 can provide subsystem services to the multiple housing 710 entities and the multiple module 501 entities therein, such as services for the GDE air system, thermal management system, hydrogen management system, water and / or electrolyte management system, power electronics system, control electronics system, telemetry sensors and equipment, and / or services disconnected from the power plant level, as well as any other type of subsystem. AlthoughFigure 7B Four enclosure 710 entities are shown, but more or fewer enclosure 710 entities can be connected to the shared auxiliary area 703, and the size of the shared auxiliary area 703 can be varied according to the number of enclosures to be supported and the number of modules within the enclosures.

[0133] Now referring to Figure 7C , system 750 can include a shared auxiliary area 703 whose enclosures are connected to a plurality of enclosure 605 entities, each having an auxiliary area 608 within. In this way, some auxiliary system functions can be offloaded in whole or in part to the shared auxiliary area 705, and some auxiliary system functions can be located in whole or in part at the level of the enclosures 605.

[0134] Figures 8A to 8E is a schematic diagram of an exemplary layout of a plurality of module 501 entities within an enclosure 605. In each layout shown in Figures 8A to 8E , two module 501 entities are arranged from front to back within a given bay of the enclosure 605. In these layouts, electrical runs can be provided, and all wiring can be on the short ends of the enclosure 605. Additionally, space can be provided within the enclosure 605 to facilitate removal of the module 501 entities. Additionally or alternatively, the width of the electrodes of the electrochemical cells of the module 501 can be related to the minimum dimension of the enclosure 605. Additionally or alternatively, the thermal spacing of the electrochemical cells of the module 501 and / or the plurality of module 501 entities relative to each other can be related to the minimum dimension of the enclosure 605. Certain layouts can include connecting and / or not connecting the back portions of one or more module entities in each bay of the enclosure 605. Additionally or alternatively, the layout can facilitate some activities of personnel within the enclosure 605.

[0135] Now referring to Figure 8B , a thermal management conduit / piping system 803 can be within the enclosure 605 to facilitate installation and / or removal of one or more module 501 entities. Now referring to Figure 8C , an electrical system connection configuration 804 and electrical connectors 805 can be within the enclosure 605 to facilitate installation and / or removal of one or more module 501 entities. Now referring to Figure 8D , a GDE air system 806 and air connectors 807 can be within the enclosure 605 to facilitate installation and / or removal of one or more module 501 entities. Now referring to Figure 8E , a water and / or electrolyte system 808 and fluid connectors 809 can be within the enclosure 605 to facilitate installation and / or removal of one or more module 501 entities.

[0136] Figures 9A to 9Fis a schematic diagram of an exemplary layout of multiple module 502 entities within the housing 605. In each layout, module connectors can be on the doors of the modules 502. Now refer to Figure 9B , a thermal management conduit / plumbing system configuration 902 can be within the housing 605. Now refer to Figure 9C , electrical system connectors 904 can be within the housing 605. Now refer to Figure 9D , GDE air system connectors 906 can be within the housing 605. Now refer to Figure 9E , water and / or electrolyte system connectors 908 can be within the housing 605. Now refer to Figure 9F , a second electrical system connector 910 can be within the housing 605. The second electrical system connector 910 can include blind mating on the back and front side connectors of each module 502 entity.

[0137] Figures 10A to 10E is a schematic diagram of an exemplary layout of multiple module 504 entities within the housing 605. In each layout, two module 504 entities can be arranged in the compartment of the housing 605 from front to back. In these layouts, space can be provided within the housing 605 to facilitate the removal of one module 504 entity. Additionally or alternatively, in these layouts, the electrode width of the electrochemical cells in each module 504 entity can be independent of the width of the housing 605. These layouts can include connecting and / or not connecting the back of one of the two module 504 entities in each compartment. Additionally or alternatively, these layouts can facilitate certain activities by personnel within the housing 605.

[0138] Now refer to Figure 10B , a thermal management conduit / plumbing system 1003 can be within the housing 605. Now refer to Figure 10C , an electrical system 1004 and electrical connectors 1005 can be within the housing 605 to facilitate the installation and / or removal of one or more module 504 entities. Now refer to Figure 10D , a GDE air system 1006 and air connectors 1007 can be within the housing 605 to facilitate the installation and / or removal of one or more module 504 entities. Now refer to Figure 10E , a water and / or electrolyte system 1008 and fluid connectors 1009 can be within the housing 605 to facilitate the installation and / or removal of one or more module 504 entities.

[0139] Although Figures 8A to 10E shows various configurations of the housings and the modules within these housings, the layouts shown in Figures 8A to 10E should be understood as examples according to multiple embodiments and are not intended to be restrictive. Additionally or alternatively, other layouts of the housings and the modules within these housings are possible.

[0140] Sealing of the electrode to the lid (e.g., Figure 4B the seal between GDE404 and lid 455 in can pose challenges. For example, alkaline electrolytes have a tendency to creep along the negatively polarized electrode. As another example, reactions within the electrochemical cell can cause electrolyte mist to occupy the headspace of the cell. Such electrochemically driven creep and / or electrolyte mist can cause the electrolyte to leak out of the container of the electrochemical cell (e.g., leak out of Figure 4A and Figure 4B the container 401 in ) and contaminate the surrounding area. To reduce the likelihood of such accidental electrolyte leakage from the electrochemical cell, which can be critical to the performance of the electrochemical cell, an airtight seal can be formed between the lid and one or more sub-components of the electrochemical cell, including the electrode busbar and / or tubing attachments.

[0141] Now referring to Figures 1 to 11B , in multiple embodiments, the channel portion of the lid 455 can be formed of different plastics. One method of sealing the channel can include nesting plastic cups within the respective plastic parts, with an epoxy resin 1102 therebetween, to create a sealed channel through the lid 455 of the container 401. Figure 11A The method shown in can be a nested groove design that provides a potting reservoir between the lid 455 and the cathode air tube 1103, with little or no need for a secondary dam to reduce the likelihood of leakage during the potting process. This feature also facilitates sealing while only contacting the top surface of the lid, which provides flexibility in the operating sequence for assembling the electrochemical cell 400. The holes in the groove of the lid 455 can provide access points for potting the epoxy resin 1102 into the lower groove. The epoxy resin 1102 can seal the lid 455 and the cathode air tube 1103 together with little or no risk of seeping into the underlying cell area.

[0142] Figure 11C is a schematic view of an embodiment including a corrugated pipe fitting that seals the lid 455. In some cases, a low hardness thermoplastic elastomer (TPE) can be overmolded onto the hard plastic of the lid 455 to provide positioning flexibility between the sub-components of the electrochemical cell and the lid 455. The bellows 1105 in the TPE can facilitate free movement of the busbar of the electrochemical cell relative to the lid 455, with little or no transfer of mechanical load through the bellows 1105. Additionally or alternatively, the TPE can act as a gasket material to facilitate a mechanical seal between the TPE and the busbar having a radial hose clamp seal 1104 and / or a flange seal 1106 (including a nut 1107, a washer 1108, and a shouldered threaded stud 1110).

[0143] Now referring to Figure 12A and Figure 12B, in some cases, the GDE 404 can be sealed. For example, the GDE 404 can include a plastic protective member 1202. The GDE 404 can be an electrode pocket, and there is an open cavity region inside the GDE 404 where air can enter. During the construction of the GDE 404, the GDE 404 can be inverted relative to its operating direction, and the upper edge of the GDE 404 can be sealed with inverted epoxy resin to facilitate air passing through the active region of the GDE 404 after the GDE 404 is constructed. The upper edge and the final edge of the GDE 404 pocket can be sealed through an epoxy resin potting process opposite to the operating mode of the GDE 404. The liquid level can drop to a height sufficient to wet and seal the electrode region, and the plastic protective member 1202 can define a channel 1203 to guide air in and out of the GDE 404, otherwise the GDE 404 is sealed.

[0144] Figure 13A is for pressing the flow field 1311 in place during the sealing lamination process of an electrode (e.g., Figure 4B the GDE 404). The schematic diagram of an exemplary process. For example, when the electrodes are sealed together, the flow field can be installed in a double-sided electrode assembly (e.g., Figure 4B the GDE 404). The flow field 1311 is arranged between two independent electrode sheets 1310, and heat and / or pressure are applied to seal the three side edges around the flow field 1311. The back layer of the electrode can self-seal. For example, in the first step 1301, two independent electrode sheets 1310 and the flow field 1311 can be provided, and the flow field 1311 can be arranged between the two independent electrode sheets 1310. In the next step 1302, a heated tool 1312 can be pressed onto the two aligned independent electrode sheets 1310, so that the two independent electrode sheets 1310 melt together at the three sides to form a sealed edge and are used for the double-sided electrode assembly 1320 (e.g., GDE 404) in step 1303.

[0145] Figure 13B is for pressing the air flow field in place during the sealing lamination process of an electrode (e.g., Figure 4B the GDE 404). Another schematic diagram of an exemplary process. Figure 13B The exemplary process of Figure 13A is similar to the exemplary process shown in Figure 13B but the exemplary process shown in

[0146] Figure 14 is a schematic diagram of an exemplary method 1400 for inserting a flow field 1405 into a pre-sealed electrode assembly 1406 to form an electrode (e.g., Figure 4B GDE 404). For example, a pre-sealed electrode assembly 1406 with three seam seals to form a pocket can have the flow field 1405 installed according to the exemplary method 1400 by placing sliding sheets 1403 of low surface energy plastic on both sides of the flow field 1405. Compressed air from an air duct 1402 can be blown into the pre-sealed electrode assembly 1406 such that the pocket formed by the pre-sealed electrode assembly 1406 expands, and the sliding sheets 1403 and the flow field 1405 can be inserted into the pocket of the pre-sealed electrode assembly 1406. The sliding sheets 1403 can be removed after installation such that only the flow field 1405 remains in a proper position within the pocket defined by the pre-sealed electrode assembly 1406.

[0147] Now referring to Figure 15A , the flow field 1500 can include a porous medium such that an electrode (e.g., Figure 4B GDE 404) can form a low-pressure, highly uniform flow between two electrode plates (e.g., between a first portion 404a of the Figure 4C GDE 404 and a second portion 404b of the GDE 404 and / or between a first portion 404a’ of the Figure 4D GDE 404’ and a second portion 404b’ of the GDE 404’). In the flow field 1500, a symmetric stack of open-cell foams 1503, 1504, 1505 with different porosities is used to facilitate control of the pressure drop across the surface, and air can be distributed substantially uniformly over the long and narrow active area of the electrode. For example, the density of the open-cell foam 1503 can be lower than that of the open-cell foam 1504, and the density of the open-cell foam 1505 can be higher than that of the open-cell foam 1503 and the open-cell foam 1504. Air can enter the flow field 1500 through an inlet hole 1501 and leave the flow field 1500 through an outlet hole 1502 after passing through the open-cell foam 1503, the open-cell foam 1504, and / or the open-cell foam 1505. Additionally or alternatively, the flow field 1500 can mechanically and / or electrically separate the two faces of the electrode from each other, providing a mechanical cavity for air to contact the electrode. In the case where the flow field 1500 is formed of foam, the flow field 1500 can include pins therein to keep the two faces of the electrode from contacting each other.

[0148] Figure 15B shows computational fluid dynamics / finite element analysis simulation results of a flow field 1510, where two symmetrically opposed filter felts with a tapered geometry are used to balance the pressure drop from the electrode inlet to the outlet, and air is uniformly distributed over the electrode (e.g., Figure 4C GDE 404 and / orFigure 4D on the long and narrow active area of the GDE 404’).

[0149] Figure 15C is a schematic diagram of the flow field 1515. Generally, except that the flow field 1515 uses a vertically-fed and laterally-positioned porous medium strip to control and distribute the air flow, the flow field 1515 is similar to the flow field 1510( Figure 15B ).

[0150] Figure 15D shows the computational fluid dynamics / finite element analysis simulation results of the low-pressure, high-uniformity flow field 1520 formed by horizontal meandering channels 1521, 1522, 1523 with different heights. The flow field 1520 can distribute air substantially uniformly over the long and narrow active area of the electrode (e.g., between the first part 404a of the GDE 404 and the second part 404b of the GDE 404 in Figure 4C and / or between the first part 404a’ of the GDE 404’ and the second part 404b’ of the GDE 404’ in Figure 4D ), and the horizontal meandering channels can be symmetrically stacked and the height decreases from top to bottom to achieve a uniform path length from the inlet to the outlet over the entire surface. Additionally or alternatively, the flow field 1520 can resist flooding because the electrolyte at the bottom of the flow field 1520 may not block the flow to the entire electrode.

[0151] Figure 15E shows the computational fluid dynamics / finite element analysis simulation results of the flow field 1525 including vertical meandering channels fed from the top to the bottom of the flow field 1525 by a vertical inlet. Air can be sent downward to the bottom of the flow field 1525 and dispersed through the vertical meandering channels across the main part of the active area until the outlet.

[0152] Figure 15F is a schematic diagram of the long and narrow active area of the electrode, which includes an accordion fold with an increasing height from top to bottom to form the flow field 1530. The bend at the top of the active area creates smaller and narrower channels, while more open flow occurs at the bottom of the flow field 1530.

[0153] Figure 15G is a schematic diagram of the long and narrow active area of the electrode, which includes a stepped structure with an increasing spacing from the top to the bottom of the electrode to form the flow field 1540.

[0154] Using less inactive material in each electrochemical cell helps reduce system costs without sacrificing any performance. The container of an electrochemical cell serves a dual purpose of separating the electrochemical cell entities from each other and providing a structure that maintains the cell shape of each electrochemical cell entity. The amount of material required to achieve this function can result in high costs associated with the inactive material. By moving the structural function from the individual electrochemical cell entity level to the module level, the sole purpose of the container may become to provide electrical insulation. For example, this can be achieved by using thin plastic bags to house each electrochemical cell and sandwiching the bags between structural end walls. This reduces the amount of material required and thus lowers the overall cost.

[0155] Figure 16 is a perspective view of module 1600, which includes a plurality of electrochemical cell 1602 entities separated by bags 1605, where structural support is provided at the module 1600 level. Structural end walls 1603 can support a plurality of electrochemical cell 1602 entities therebetween. Each electrochemical cell 1602 entity can include a lid 1604 that can support one or more bags 1605. The lids 1604 of each electrochemical cell 1062 entity can be connected together with other lid 1604 entities and / or structural end walls 1603 to form module 1600 in which the plurality of electrochemical cell 1602 entities are connected to each other.

[0156] In multiple embodiments, the electrodes in the container (e.g., Figure 4B the first anode assembly 402a, the second anode assembly 402b, the first OEE 403a, the second OEE 403b, and the GDE 404) can be tightly encapsulated. The cathode (e.g., Figure 4B the first OEE 403a, the second OEE 403b, and the GDE 404) can be switched to cycle with the anode (e.g., the first anode assembly 402a and the second anode assembly 402b) based on the charge or discharge cycle of the electrochemical cell, but not simultaneously. To prevent accidental short circuits, electrical isolation of the cathode and anode is required. Additives to an electrochemical cell can improve the performance of one electrode but may be harmful to the other electrode. Methods of containing the additive in a local area around the electrode or reducing the likelihood or even preventing the additive from penetrating into other areas of the electrochemical cell may be beneficial to the performance of the electrochemical cell.

[0157] Figure 17 is a view that includes a separator 1701 and a cathode sub - assembly 1702 (e.g., Figure 4BSchematic diagram of the cathode 1700 of the first OEE 403a and / or the second OEE 403b). As an example, the separator 1701 may include separator material in the form of sheets and / or bags. As a specific example, the separator 1701 can be formed by folding a large sheet of separator material and sealing the edges or taking two separate pieces of separator material and sealing them along three edges. Thus, the separator 1701 can be open at the top. The cathode subassembly 1702 can be inserted into the separator 1701. The separator 1701 can be ion-conductive, allowing ions to pass freely through, but electrically insulating to prevent electrical short circuits between the electrodes. Additionally or alternatively, the material of the separator 1701 can allow ions to pass through while not allowing electrolyte additive substances to pass through. Additionally or alternatively, the separator 1701 can be impermeable to the bubbles generated by the cathode subassembly 1702 such that the bubbles do not reach the anode (e.g., Figure 4B the first anode assembly 402a and / or the second anode assembly 402b). Similarly, the material of the separator 1701 can be impermeable to the bubbles from the anode such that these bubbles do not reach the cathode subassembly 1702. The sealed bottom of the separator 1701 can also reduce the likelihood of electrical short circuits due to possible particle accumulation at the bottom of the electrochemical cell between the electrodes or even prevent electrical short circuits due to possible particle accumulation at the bottom of the electrochemical cell between the electrodes. In another embodiment, the bottom of the separator 1701 can be open instead of sealed, forming a sleeve-like design.

[0158] The electrodes in the electrochemical cell container may need to be electrically isolated from each other. Each electrode operates at a different electric potential. Some electrodes cannot operate at the same electric potential as other electrodes in the system. If the electric potentials of electrode A and electrode B are incompatible, a short circuit between the two electrodes may cause degradation of either electrode. During cycling, some electrodes generate bubbles, and these bubbles can coalesce and cause blockage between the electrodes. Blockage between the electrodes can increase the ohmic resistance, cause mass transport problems, dry out the electrodes resulting in performance loss, locally deteriorate the electrode surface, and / or have other negative effects on the battery. Additionally or alternatively, the operating electric potential of certain electrodes may cause degradation of the plastic used as the separator material and may cause a short circuit.

[0159] Multiple embodiments may include spacers and separators to reduce the likelihood of short circuits between the charging electrodes (e.g., any of the first anode assembly 402a and the second anode assembly 402b and the first OEE 403a and the second OEE 403b).

[0160] Now refer to Figure 18A and Figure 18B, the electrochemical cell 400 may include a separator 1801, a first spacer 1802, and a second spacer 1803. The first spacer 1802 may be placed between the OEE and the anode, and the second spacer 1804 may be placed between the GDE 404 and the first OEE 403a. The separator 1801 and the second spacer 1803 may be placed between the first OEE 403a and the first anode assembly 402a. The separator 1801 reduces the likelihood of a short circuit between the first anode assembly 402a and the first OEE 403a. The second spacer 1803 may provide space for oxygen bubbles generated during charging to vertically discharge from the active surface. The material of the second spacer 1803 may be compatible with the voltage of the first OEE 403a. The second spacer 1803 between the separator 1801 and the first OEE 403a may eliminate or at least reduce the material compatibility issue between the separator 1801 and the first OEE 403a. The first anode assembly 402a and the first OEE 403a are shown, but it should be understood that similar spacers and separators may be placed between the GDE 404 and the second OEE 403b and between the second OEE 403b and the second anode assembly 402b additionally or alternatively. For the sake of clear illustration and effective description, they will not be described separately.

[0161] In certain embodiments, the separator 1801 may be a sheet of separator material. For example, the material of the separator 1801 may be ion-conductive, allowing ions to freely pass through, but electrically insulating to prevent electrical short circuits between the electrodes. Additionally or alternatively, the material of the separator 1801 may allow ions to pass through while not allowing electrolyte additive substances to pass through. Additionally or alternatively, the separator 1801 may be impermeable to bubbles generated by the first OEE 403a and / or the GDE 404 such that the bubbles do not reach the first anode assembly 402a. Similarly, the material of the separator 1801 may be impermeable to bubbles from the first anode assembly 402a such that these bubbles do not reach the first OEE 403a and / or the GDE 404. Additionally or alternatively, although the separator 1801 is shown as placed on the first anode assembly 402a, it should be understood that the separator 1801 may be supported on the first OEE 403a and / or one or more structural components of the electrochemical cell 400. Additionally or alternatively, the separator 1801 may be placed between the GDE 404 and the first OEE 403a. Additionally or alternatively, it should be understood that more than one separator 1801 entity may be placed within the electrochemical cell 400, which may be used to restrict the movement of bubbles and / or electrolyte additive substances within the electrochemical cell 400 while allowing ions to move within the electrochemical cell 400.

[0162] Now referring to Figure 19 , the electrodes may be placed within the container of the electrochemical cell in a manner that supports battery performance. For example, the electrode support 19 may support one or more electrodes (e.g.,Figure 4B Portions of the GDE 404, first anode assembly 402a, first OEE 403a, second anode assembly 402b, and second OEE 403b) in the container 401. For example, the electrode support 19 can be extruded. Additionally or alternatively, the electrode support 1902 can be based on the positions of the first anode assembly 402a and the second anode assembly 402b at the bottom of the electrochemical cell. The wall at the bottom of the electrode support 1902 can limit the distance that the first anode assembly 402a and the second anode assembly 402b can move toward the cathode stack to set the electrode spacing and reduce the likelihood of crushing the cathode (GDE 404, first OEE 403a, and second OEE 403b).

[0163] In some embodiments, a metal-air battery pack can be constructed without using a separator, such as an iron-air battery pack, and the electrodes in the metal-air battery pack can be separated to prevent short circuits. In some embodiments, the physical design of the electrochemical cell can provide the required electrode gap without using a specific separator material. Particularly in an iron-air battery pack where the required electrode gap can be on the order of millimeters, a separatorless configuration may be advantageous.

[0164] Now referring to Figure 20A , a mesh spacer 2002 can be placed between two electrodes (shown as electrode A and electrode B and should be understood to include any two electrodes described herein). The gap between the electrodes serves to prevent electrical short circuits. The gap also defines the minimum length that must be closed to cause a short circuit. The mesh spacer 2002 between electrode A and electrode B is used to define the gap between the active surfaces. The vertical members of the mesh spacer 2002 can be greater than the horizontal members of the mesh spacer 2002. This allows the gap between electrode A and electrode B to be greater than the perceived gap that an object would need to span to short-circuit the electrodes.

[0165] Now referring to Figure 20B , a corrugated spacer 2003 can be used to separate two electrodes (e.g., any two electrodes described herein). The holes and spacing of the corrugations of the corrugated spacer 2003 can make the path of a shorting body tortuous while having a large open area in a plan view to reduce the likelihood of blockage between the electrodes.

[0166] Now referring to Figure 20A and Figure 20B, the spacer can contribute to foam management. During operation, bubbles are generated within the electrochemical cell. These bubbles are a product of circulation but can have a negative impact on the performance of the electrochemical cell. For example, the bubbles can coalesce in the cell and cause blockages, dry out the electrodes leading to degradation, and may cause surface damage to a particular anode. The spacer for electrical isolation can facilitate the management of bubbles. For example, the corrugated spacer 2003 can provide a vertical channel for the bubbles to escape from the electrochemical cell. As another example, the horizontal members of the mesh spacer 2002 can be slightly embedded in the vertical members to define a channel for the bubbles to exit the electrochemical cell.

[0167] The current generated from the electrodes must be output from the electrochemical cell while limiting ohmic losses, minimizing the non-uniformity of current distribution, and optimizing cost. Multiple embodiments can include electrode current collection.

[0168] Now referring to Figure 21 , several methods can be used to reduce the ohmic drop along the electrode height and improve the current uniformity in the electrode plane. These methods can include: interrupting the expansion process of the solid conductive part in the active field of the electrode; interrupting the expansion process to produce solid parts, forming solid parts (such as hemming) to generate 3D busbars in the mesh; adding busbars after expansion in the active field of the electrode; joining the coated wire after expanding the mesh; and different combinations of the above. In addition, it has been determined that methods to reduce the ohmic drop along the electrode height and improve the current uniformity in the electrode plane can include changing the direction and size of the expanded mesh to minimize the ohmic drop.

[0169] When current accumulates along the electrode length, concentration gradients can form. These concentration gradients have a negative impact on the efficiency of the electrochemical cell.

[0170] Now referring to Figure 22 , multiple embodiments can include anode current collection methods. To counteract the concentration gradients generated due to current collection at the top of the electrode, collecting current at the bottom of one electrode and the top of the opposite electrode can reverse the concentration gradients of adjacent electrodes relative to each other. This can better utilize each electrode and reduce the inefficiency due to concentration gradient matching.

[0171] Multiple embodiments can include a distributed electrode switching architecture. A large battery pack format with a single switch to operate the battery pack may have to have busbar current over long distances. This can result in high losses, reduced efficiency, and increased heat generation in the system.

[0172] Now referring to Figures 23A to 23D , aspects of the electrode switch control device can support distributed electrode switching. Different from a single centralized switch on a small printed circuit board (PCB) as shown in Figure 23A shown, such asFigures 23B to 23D As shown, multiple parallel switches can be distributed across the width of the electrochemical cells on a relatively large PCB. In this example, the GDE and OEE have four separate switch "islands" and the anode has two "islands". The parallel connection can be made through the PCB (e.g., Figure 4B the electronic structure 450 in). This can significantly reduce the losses due to bus bar current. In one configuration, groups of switch elements can be mounted onto a single large PCB. Alternatively, several smaller, separate PCBs can be connected to each other. The switching can be done with solid state switch elements (MOSFETs), and in addition or alternatively, the switching can be done with mechanical or electromechanical relays. In a variation using relays, all of the relays can be connected through a single mechanical linkage system. This can reduce or completely eliminate the need for a cell-level PCB.

[0173] Figures 24A to 25H is a schematic illustration of aspects of battery defogging, fire blocking, and hydrogen management according to multiple embodiments.

[0174] Figure 24A and Figure 24B shows a schematic illustration of the top portion of the container of an electrochemical cell (e.g., Figure 4A the electrochemical cell 400 in) and the filter attachment for the vent hole. Figure 24C is a schematic illustration of a method for recombining hydrogen and oxygen into water in the headspace 2405 of the container of an electrochemical cell (e.g., Figure 4A the electrochemical cell 400 in).

[0175] Now referring to Figures 24A to 24C , the vent hole on the side of the container 401 can include a flame arrester 2402, which can be used for any one or more of several functions, including quenching any burning flames to reduce the likelihood of a continuous explosion, removing electrolyte mist to keep the electrolyte within the volume of the container 401, and filtering any salts or debris that may form in the electrochemical cell during operation. The location of the flame arrester 2402 on the side of the container 401 can make it more difficult for the mist to escape from the cell, such that the effectiveness of the defogger is less critical. That is, additionally or alternatively, the flame arrester 2402 can serve a defogging function. Figure 24AThe velocity "u" shown is from gas generation in the electrochemical cell. When charging generates gas, the bubbles on the electrolyte surface burst, generating a mist carrying the electrolyte liquid. To reduce the electrolyte level loss associated with such a mist, a filter 2404 can be supported on the flame arrester 2402 to facilitate the separation of the liquid from the gas to retain the electrolyte within the electrochemical cell. In this configuration, the velocity "u" should be understood as related to attracting the gas through the headspace 2405 to carry out the gas generated in the electrolyte volume out of the electrochemical cell by forced convection. To remove the explosive gas generated in the electrochemical cell, a catalyst can be provided to the headspace 2405 to combine the explosive H 2 / O 2 mixture into water. This can facilitate the use of only ventilation holes on the electrochemical cell instead of a piping solution for driving the explosive gas out of the container 401 by forced convection.

[0176] Now referring to Figure 25A , during the charging of the battery, hydrogen gas may be generated and fill the headspace 2405 below the lid 455. This gas mixture may explode when the hydrogen level is high enough. For safety and reliability, the electrochemical cell can reduce the likelihood that a potential hydrogen fire in the headspace 2405 may spread to adjacent electrochemical cells or otherwise damage adjacent electrochemical cells.

[0177] A method of reducing the likelihood of hydrogen fire spreading to adjacent electrochemical cells can be to reduce the size of the headspace 2405', such that only a small amount of hydrogen gas can be present in the headspace 2405 at any given time. The hydrogen gas can be vented out of the small-volume headspace 2405' through a vent 2506 on one side of the electrochemical cell. Since the pressure in the headspace 2405' will be equal to the ambient pressure of the manifold fluidly connected to the vent 2506, the hydrogen % in each headspace region remains constant. Thus, by reducing the headspace region, the amount of hydrogen gas available for a combustion event is reduced.

[0178] Now referring to Figure 25C , in some embodiments, the lid 455 can act as a pressure relief disk. A method of minimizing the maximum pressure experienced by the electrochemical cell 400 can be to incorporate one or more pressure relief elements that open at a predetermined pressure. This can reduce the likelihood that the electrochemical cell may exceed this predetermined pressure value. The lid 455 can have a large surface with a small bond line to the container 401. The bond line can fail at the predetermined pressure, which can be used to control the failure mode during a hydrogen event. Since the lid 455 is above the electrolyte level and perpendicular to all adjacent electrochemical cells, the failure of this bond line between the lid 455 and the container 401 will not likely result in electrolyte loss or damage to adjacent electrochemical cells.

[0179] Now referring toFigure 25D In multiple embodiments, the TPE seal of the lid 455 can function as a knockout vent. One technique for sealing the busbar to the lid 455 involves using a flexible thermoplastic elastomer (TPE) piece, such as the bellows 1105. The stress at which these flexible pieces fail can be much lower than the failure stress associated with the rigid thermoplastic plastics that can make up the rest of the electrochemical cell container. By designing these TPE pieces to fail at a certain headspace pressure, the failure mode and maximum pressure during a hydrogen ignition event can be controlled. Since these TPE pieces are above the electrolyte level and perpendicular to all adjacent electrochemical cells, failure at these points will not likely result in any electrolyte loss or damage to adjacent electrochemical cells.

[0180] Now referring to Figure 25E In multiple embodiments, multiple headspaces can be provided to facilitate the management of hydrogen events. By restricting the amount of hydrogen present at the ignition point, the maximum pressure during an ignition event can be minimized or at least controlled. Using the lid 455 to define separate cavities 2503 within the container 401, the amount of hydrogen available for ignition can be restricted to a single, smaller headspace portion. These separate cavities 2503 can fully control pressure events. Alternatively, these separate cavities 2503 can allow propagation between the separate cavities 2503, which will result in multiple ignition events but reduce the maximum pressure (compared to a single ignition event in the nominal headspace volume) and spread it over a longer period of time.

[0181] Now referring to Figure 25F and Figure 25G Gas can be delivered to a specific space to manage hydrogen events. For example, by delivering the generated hydrogen to an area that does not contain a busbar or other ignition source, the likelihood of a hydrogen-related pressure event can be significantly reduced with the amount of hydrogen available for combustion in the headspace. By utilizing a floating surface 2508 that is impermeable to hydrogen, the electrolyte level can change during the charge / discharge cycle of the electrochemical cell without changing the headspace volume available for hydrogen.

[0182] Now referring to Figure 25H To manage hydrogen events, the container 401 can be strengthened to withstand the maximum pressure associated with a hydrogen ignition event. Strengthening the container 401 to withstand the maximum pressure generated during a hydrogen ignition event can reduce the likelihood that a hydrogen ignition can affect the surrounding electrochemical cells.

[0183] Figures 26A to 26C is a schematic diagram of aspects of an anode assembly (e.g., Figure 4B the first anode assembly 402a and / or the second anode assembly 402b in

[0184] Now referring toFigure 26A The anode assembly can be a hot - pressed anode (HCA) structure. The structure and current collector of the HCA structure can be made of a metal sheet stamped into a "sheet - pan" shape, with the solid back facing away from the cathode in the electrochemical cell. The busbar can be welded to the top - most edge of the sheet pan. Advantages of such a "sheet - pan" design can include: the pan can be pre - filled with anode materials (e.g., iron powder, DRI, additives) before pressing and sintering, without secondary forming; the back of the pan can be non - porous, which can be beneficial for conductivity (compared to perforated or expanded); the hard steel - sheet back and sides can protect the anode assembly from handling - related damage; and / or the solid top can provide a surface for welding the busbar.

[0185] Now referring to Figure 26B The busbar can be connected to the top of the pan to conduct current from the electrode through the lid. A round low - carbon steel busbar can be used because it: is easy to weld to the pan (like metal); is a relatively low - cost conductor (comparable to a Cu conductor); is electrochemically compatible at the anode potential, so encapsulation is not required; is structurally strong and suitable for lifting and moving the anode and the electrochemical cell; and is easy to seal onto the lid with mechanical seals (e.g., gaskets and hose clamps). Methods of busbar attachment can include: resistance plug welding, threaded rod + nut in the sheet pan, and / or spot - welding tabs on the sheet pan.

[0186] Now referring to Figure 26C The mesh / guard attachment for the anode can include a porous steel sheet (usually perforated or expanded) to accommodate any particles > 1 mm in size that may shift in the anode. These particles can cause the watering system to short - circuit or become blocked.

[0187] Chemical reactions within the alkaline electrochemical cell can cause electrolyte mist to fill the headspace of the cell. This mist can cause the conductive electrolyte to leak out of the cell and contaminate the surrounding area. To reduce the likelihood of this spread, establishing an airtight seal between the lid and the container may be crucial for the function of the electrochemical cell. However, due to the length of the seam, it may be difficult to form such a seal.

[0188] Figures 27A to 27D is a schematic diagram of aspects of the seal between the lid and the container (e.g., Figure 4B sealing the lid 455 to the container 401 in

[0189] Now referring to Figure 27A, the seal between the lid 455 and the container 401 may need to be able to account for large dimensional tolerances between the lid and the container, due to the size of the two parts and / or the use of a lower tolerance manufacturing method (blow molding) to cost-effectively manufacture the container. The clamping force required between the lid 455 and the container 401 during the sealing process may need to be separated from the wall of the container 401 (e.g., in the case where the wall of the container 401 is too fragile) and / or from other components of the electrochemical cell subassembly. Additionally or alternatively, the seal between the lid 455 and the container 401 may need to fit within the existing X, Y, and Z boundaries of the container 401.

[0190] Now referring Figure 27B , welding (e.g., hot gas welding or laser welding) can be used to seal the lid 455 to the container 401. Notable features of such embodiments can include: the weld compensating for any tolerances between the two parts; the flange in the container 401 providing a clamping surface to reduce the likelihood of any clamping being transmitted to the container 401 during the welding process; the internal support wall on the lid 455 reducing the likelihood of the container 401 slipping during the welding process; and increasing the thickness of the container 401 at the flange points. Minimizing the thickness of the container 401 may be crucial for reducing the cost of non-active materials in the battery. Thus, the nominal wall thickness of the container 401 can be thinner than the optimal wall thickness for welding. By utilizing preform profiling during the blow molding process, the container thickness can be increased within a specific height window of the container 401. Using the top flange of the container 401 rather than the bottom of the container 401 as a reference can eliminate or at least reduce the need for strict tolerances on the height of the container 401, which can be approximately 1 m in some cases.

[0191] Now referring Figure 27C , a hot gas welding joint geometry can be used to seal the lid 455 to the container 401. Notable features of such a hot gas welding joint geometry can include: an angular opening that allows for large displacements of the top edge of the container 401 to compensate for any lack of tolerance on that surface; the flange in the container 401 providing a clamping surface to reduce the likelihood of the clamping force being accidentally transmitted downward to the container 401; the internal support wall on the lid 455 can reduce the likelihood of the container 401 slipping during the welding process; and using the top flange of the container 401 rather than the bottom of the container 401 as a reference can eliminate or at least reduce the need for strict tolerances on the height of the container 401 (e.g., approximately 1 m).

[0192] Now referring Figure 27D , the container 401 can include a flexible wall to facilitate a large available overlap between the lid 455 and the container 401. Utilizing the flexible wall of the container 401 to achieve a large available overlap between the lid 455 and the container 401 can be applicable to all the welding geometries described herein, e.g., Figure 27B andFigure 27C For those. To facilitate optimizing the footprint of an electrochemical cell, the frame size of the electrochemical cell can be determined by the size of the sub-stack (anode + cathode) of the electrochemical cell, while the additional area is only allocated to the container wall thickness and the cooling channels. The overlapping surface between the flange of the container 401 and the lid 455 may be too small to enable reliable plastic welding. By taking advantage of the flexibility of the container 401, there can be a nominal interference between the sub-stack and the top portion of the container 401, since the container 401 can deform during the insertion process to allow the sub-stack to slide in.

[0193] Now referring to Figure 28 , the anode (e.g., Figure 4B the second entity of the first anode assembly 402a and / or the second anode assembly 402b in

[0194] can operate as the main structural component of the electrochemical cell. That is, due to the mass and rigidity relative to other cell components, the anode of the electrochemical cell can serve as the structural backbone of the electrochemical cell. Reducing material costs means reducing materials, and not all components and seals can withstand the forces exerted during lifting or operation. In the case of lifting, the electrochemical cell can be lifted by the anode, and the anode can support the weight of the cathode through parts on the cathode plastic portion. The lid can be supported by the cathode plastic, and only the container-to-lid seam has to bear the weight of the container. During operation, the weight of the anode can offset the buoyancy force in the GDE through the frictional force between the anode and the cathode plastic. Straps can bind the anode to the plastic. The resulting frictional force of the GDE plastic can offset the buoyancy force.

[0195] Now referring to Figure 29 , a schematic diagram showing aspects of the anode serving as the battery container is presented. The anode can include a metal such as iron encapsulated in a steel disc. Utilizing the structure of the anode to achieve the structural function of the electrochemical cell container, rather than relying on a separate container to house all components, can remove a large amount of non-active material from the electrochemical cell. A dielectric coating can be applied to the steel anode housing to provide electrical insulation. Cooling channels can be integrated into the stamped container to meet the thermal system air flow requirements. This can be beneficial for reducing the costs associated with non-active cell materials and part manufacturing.

[0196] Multiple embodiments may include a blow molded design for module cooling and structure. In multiple embodiments, the container of the electrochemical cell may have a geometry that facilitates achieving the desired cell cooling. Additionally or alternatively, the container may electrically insulate the electrochemical cell. The container may be compatible with an alkaline electrolyte. The container may define a hermetically sealed cavity. The container may withstand forces acting on the container, such as a safety factor of 1.5. The container may limit the hydrostatic pressure from the liquid electrolyte. The container may accommodate an air flow for cooling.

[0197] In multiple embodiments, the container of the electrochemical cell may include a cooling channel geometry that changes with the height of the cell to facilitate directing more cooling to the top of the electrochemical cell, where the electrolyte tends to be hotter due to natural convection. Additionally or alternatively, changing the cooling channel geometry may maximize the strength of the container wall at the bottom of the electrochemical cell where the hydrostatic load is higher. In such embodiments, the container may be a multi-functional component that provides mechanical structure, thermal cooling channels, and / or electrolyte protection.

[0198] Figure 30 is a schematic diagram of the thermal management of a module using forced air cooling between electrochemical cells. In some embodiments, forced air cooling between the electrochemical cell containers may be achieved by moving air along the faces of the containers toward the center of the electrochemical cell module.

[0199] Figure 31 is a schematic diagram of aspects of an electrochemical cell container. The container of the electrochemical cell may be blow molded high density polyethylene (HDPE), which provides electrolyte protection and defines air cooling channels between adjacent container entities when multiple container entities are arranged width face to width face (i.e., y dimension to y dimension) in a module (e.g., as shown in module 502( Figure 5B ). As shown in the exploded y-axis view portion of Figure 31 , ribbed structures on the containers may define air cooling channels between them through physical interaction.

[0200] Figure 32 is a perspective view of a blow molded container of an electrochemical cell, Figure 33 showing the air flow in Figure 32Computational fluid dynamics / finite element analysis simulation results of a blow-molded battery container. The material of the container 401 can be any suitable material, such as HDPE, acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyethylene terephthalate (PET), etc. The container 401 can be manufactured by blow molding. As an example, the nominal wall thickness of the container 401 can be 1.5 mm. Additionally or alternatively, the size and other forming methods of the container enable it to have a lifespan of at least 20 years when filled with caustic electrolyte. The container 401 can withstand a hydrostatic load of 15 kPa at the bottom of the container. The container 401 can be configured to withstand environmental temperatures from -30 °C to 40 °C. In multiple embodiments, the container 401 can have a series of ribbed structures 3203, separated by channels with different channel heights (e.g., CH1, CH2, CH3, CH4, CH5, etc.) between consecutive ribbed structure entities. The geometry of the container 401 can vary with the height of the container 401 to meet airflow requirements and space limitations, while considering the increasing hydrostatic load with the depth of the electrolyte within the container 401. For example, the channel heights CH1 to CH5 can range from 8 mm at the bottom of the container 401 to 35 mm at the top of the container 401 to provide wall strength at the bottom and a cooling area at the top. The container 401 can include a recess 3202 towards the top of the container 401 to provide space for a watering system. The full fillet 3204 at the bottom of the container 401 can reduce wall stress. The ribbed structures 3203 of the container 401 can define multiple channels that are parallel to each other and can surround the container 401. The pressure drop of the container in a parallel flow configuration can be less than or equal to 150 Pa, and computational fluid dynamics / finite element analysis indicates that the pressure drop can be 58 Pa. The maximum temperature requirement of the container can be less than or equal to 45 °C, and computational fluid dynamics / finite element analysis indicates that the maximum temperature of the container can be 39 °C. The maximum wall stress requirement can be less than or equal to 1.2 MPa, and the finite element analysis results indicate that the maximum wall stress can be 1.1 MPa.

[0201] Figure 34 is a perspective view of the container 3400 that defines a curved channel. Except that the container 3400 can define a curved channel, the container 3400 can be similar to the container 401 ( Figure 4A ). When arranging electrochemical cells in a module, the reverse curve direction of the channels on each side of the container 3400 can reduce the likelihood of interference with the channels of adjacent electrochemical cells.

[0202] Figure 35 is a schematic diagram of continuous airflow through an electrochemical cell module. In such embodiments, air can be drawn through two rows of electrochemical cells of the module instead of being drawn to the center of the module. This can save space and reduce (e.g., halve) the number of air collection chambers required for each skid of the module.

[0203] Figure 36 is a schematic diagram of a parallel flow configuration of stacked container 401 entities n1 to n4 in rows within a module (such as the module 502 in Figure 5B ). The wide faces - those extending along the y dimension - can be arranged facing each other. Multiple container 401 entities can be mechanically stacked in rows within the external support structure of the module. When multiple container 401 entities are arranged adjacent to each other, the containers 401 can withstand the liquid pressure load on the side walls of the containers 401. Multiple container 401 entities can be stacked in rows of any length, providing flexibility in the string length of the electrochemical cells of the module. Individually, an electrochemical cell may not be able to stand on its own and / or may experience side wall deflection when filled with electrolyte. However, in the module assembly, each container 401 entity can be stabilized by adjacent container 401 entities and / or by the mechanical structure at the module level. The ribbed structure 3203 of the container 401 can support the mechanical load or pressure exerted by adjacent container 401 entities. This mechanical structure can facilitate meeting the mechanical design requirements with a small amount of non-active material and at low cost.

[0204] The material of the container 401 can be any suitable material, such as HDPE, ABS, polypropylene, PET, etc. HDPE can be low-cost and compatible with the electrolyte. ABS can be easily bonded, weldable, and compatible with the electrolyte. Polypropylene can be low-cost and compatible with the electrolyte. PET can have a high strength-to-cost ratio.

[0205] The foregoing method descriptions and process flow diagrams are provided only as illustrative examples and are not intended to require or imply that the steps of the various embodiments should be performed in the order presented. As will be understood by those skilled in the art, the steps in the foregoing embodiments can be performed in any order. Words such as "thereafter," "then," "next," etc. are not intended to limit the order of the steps; these words are only used to guide the reader through the method description. Additionally, any reference to a claim element in the singular (e.g., using an article (indefinite article ("a," "an") or definite article ("the"))) should not be construed as limiting the element to the singular form. In this document, "about" can refer to a range of + / - 5%.

[0206] Furthermore, any step of any of the embodiments described herein can be used in any other embodiment. The description of the foregoing disclosed embodiments is provided to enable those skilled in the art to make or use the claims. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be applied to other embodiments without departing from the scope of the claims. Therefore, the present disclosure is not intended to be limited by the embodiments shown herein, but should be accorded the widest scope consistent with the following claims and the principles and novel features disclosed herein.

Claims

1. An electrochemical cell, include: container; at least two anode assembly entities; At least two oxygen evolution electrodes (OEE) entities; and A gas diffusion electrode (GDE), wherein, in said container, said GDE is placed between mirror-image arrangements of said at least two OEE entities and said at least two anode assembly entities.

2. The electrochemical cell according to claim 1, in, From one side of the container to the other side of the container, the mirror image arrangement includes a first anode assembly entity, a first OEE entity, the GDE, a second OEE entity, and a second anode assembly entity.

3. The electrochemical cell according to claim 1, in, From one side of the container to the other side of the container, the mirror image arrangement includes a first OEE entity, a first anode assembly entity, the GDE, a second anode assembly entity, and a second OEE entity.

4. The electrochemical cell of claim 1, further comprising an electrolyte disposed in the container, wherein the at least two anode assembly entities, the at least two OEE entities, and the gas diffusion electrode are each at least partially immersed in the electrolyte in the container.

5. The electrochemical cell of claim 1, wherein the container comprises a cover comprising a nesting groove, a bellows, a flange seal, a heat welded joint, and / or a laser welded joint.

6. The electrochemical cell of claim 1, wherein the GDE defines an air channel between two faces of the GDE.

7. The electrochemical cell of claim 1, wherein the GDE is a three-edge sealed double-sided electrode comprising two electrode sheets and a flow field between the two electrode sheets.

8. The electrochemical cell of claim 7, wherein the flow field comprises a stack of foams of varying porosity, filter felt strips, serpentine channels, folded channels, or a combination thereof.

9. The electrochemical cell of claim 7, wherein the flow field mechanically and electrically separates the two sides of the double-sided electrode.

10. The electrochemical cell of claim 7, further comprising a bag of separator material, one or more spacers, and / or an electrode support that supports the at least two anode assembly entities, the GDE, and the at least two OEE entities in the container.

11. The electrochemical cell of claim 1, wherein the container includes electronic structures that provide distributed electrode switching.

12. The electrochemical cell of claim 1, wherein the container comprises a cell demisting structure and / or a flame arrester structure associated with a headspace of the container.

13. The electrochemical cell of claim 1, wherein the at least two anode assembly entities comprise metal stampings.

14. The electrochemical cell of claim 1, wherein the at least two anode assembly entities, the at least two OEE entities, and the GDE are each restrained to prevent movement relative to each other within the container.

15. The electrochemical cell of claim 1, wherein an outer wall of the container is physically formed by the at least two anode assemblies.

16. The electrochemical cell of claim 1, wherein the container comprises a plurality of rib-like structures on an outer wall of the container, the plurality of rib-like structures being spaced apart from one another to define a plurality of channels between consecutive rib-like structures.

17. The electrochemical cell of claim 16, wherein the plurality of channels have different heights ranging from a smaller height at the bottom of the container to a larger height at the top of the container.

18. The electrochemical cell of claim 16, wherein the container is formed of blow molded high density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), polypropylene (PP), or polyethylene terephthalate (PET).

19. The electrochemical cell of claim 1, wherein the container is a pouch physically supported by a module into which the electrochemical cell is insertable.

20. The electrochemical cell of claim 1, further comprising a separator, wherein the separator is a sheet disposed between one of the OEE entities and the GDE, and / or a sheet disposed between one of the OEE entities and one of the anode assembly entities.

21. The electrochemical cell of claim 20, wherein said sheet is supported on one of said OEE entities.

22. The electrochemical cell of claim 1, wherein the electrochemical cell is an iron-air type battery cell, a zinc-air type battery cell, and / or a lithium-air battery cell.

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