Large aspect ratio electrochemical cell module and method for producing same

Abstract

Embodiments described herein relate to electrochemical cell assemblies having structural members for applying compressive forces. In some aspects, an electrochemical cell assembly may include: a plurality of electrochemical cells arranged in a stack; a first planar sheet in contact with a first side of the stack; a second planar sheet in contact with a second side of the stack; a first structural member in compressive contact with the first planar sheet; and a second structural member in compressive contact with the second planar sheet, wherein the compressive contact between the first structural member and the first planar sheet and the compressive contact between the second structural member and the second planar sheet collectively provide structural stiffness to the electrochemical cell assembly.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 428,210, filed on November 28, 2022, entitled "Large Aspect Ratio Electrochemical Cell Modules, and Methods of Producing the Same", the content of which is incorporated herein by reference in its entirety. Technical Field

[0003] The embodiments described herein relate to the design of large - sized, high - density modules and packs for electrochemical cell systems. Background Art

[0004] Existing cell technologies have several limitations in terms of the size of the cells. These limitations are related to the uniform application of pressure across the dimensions of low aspect ratio cells. Performance issues arise from the non - uniform application of pressure in such cells. Mitigating this pressure distribution can address these problems. Summary of the Invention

[0005] The embodiments described herein relate to an electrochemical cell assembly having structural members for applying a compressive force. In some aspects, the electrochemical cell assembly can include: a plurality of electrochemical cells arranged in a stack; a first planar sheet in contact with a first side of the stack; a second planar sheet in contact with a second side of the stack; a first structural member in compressive contact with the first planar sheet; and a second structural member in compressive contact with the second planar sheet, wherein the compressive contact between the first structural member and the first planar sheet and the compressive contact between the second structural member and the second planar sheet together provide structural stiffness to the electrochemical cell assembly. In some embodiments, the first structural member and the second structural member can include pressure plates having small blocks that apply a compressive force to the first planar sheet and the second planar sheet. In some embodiments, the small blocks have a first length at a position near the horizontal center of the electrochemical cell stack and a second length at a position near the horizontal edge of the electrochemical cell stack, and the first length is greater than the second length. Brief Description of the Drawings

[0006] Figure 1 is a block diagram of an electrochemical cell assembly according to an embodiment.

[0007] Figure 2 is an illustration of an electrochemical cell stack according to an embodiment.

[0008] Figure 3 It is a diagram of an electrochemical cell unit assembly according to an embodiment.

[0009] Figures 4A to 4B It is a diagram of an electrochemical cell unit assembly according to an embodiment and its formation.

[0010] Figures 5A to 5D It is a diagram of an electrochemical cell unit assembly according to an embodiment and its formation.

[0011] Figures 6A to 6B It is a diagram of an electrochemical cell unit assembly according to an embodiment.

[0012] Figures 7A to 7C It is a diagram of an electrochemical cell unit assembly according to an embodiment.

[0013] Figure 8 It is a diagram of an electrochemical cell unit assembly according to an embodiment.

[0014] Figures 9A to 9D It is a diagram of an electrochemical cell unit assembly according to an embodiment. Detailed Description

[0015] The embodiments described herein relate to the manufacture of large-sized electrochemical cells having a low length-to-width aspect ratio. Such electrochemical cells can be used to construct large, high-energy density electrochemical cell modules. Large-sized low-aspect ratio modules can have a relatively high energy density and dissipate heat effectively. The electrochemical cell modules described herein include structural members for allowing compression of the cells. The structural members contact the planar sheet to distribute the force uniformly along the length and width of the electrochemical cell stack. Even force distribution along the length and width of the electrochemical cell stack can ensure that the cells function as expected and improve heat dissipation via enhanced thermal contact.

[0016] In some embodiments, the electrochemical cell unit assemblies described herein can be arranged in close contact with a heat exchange device. In some embodiments, the heat exchange device can include a plate and a pathway for the movement of a heat exchange fluid (e.g., air, liquid). In some embodiments, the heat exchange device can include recesses for turbulence of the heat exchange fluid. In some embodiments, the recesses can be the same as or substantially similar to the recesses described in U.S. Provisional Patent Application No. 63 / 416,774, titled "Heat Transfer Plates in Electrochemical Cell Systems, and Methods of Producing the Same", filed on October 17, 2022, the disclosure of which is hereby incorporated by reference in its entirety.

[0017] In some embodiments, the electrochemical cell unit assemblies described herein may be included in a vehicle. In some embodiments, the electrochemical cell unit assemblies may be integrated into the structure of a vehicle. In some embodiments, the electrochemical cell unit assemblies described herein may be self - supporting, with few or additional other support structures. In some embodiments, the electrochemical cell units described herein may include spacers for integrated cooling. In some embodiments, the electrochemical cell units described herein may include hermetically sealed electrochemical cell units that allow for the use of a non - sealed enclosure for the electrochemical cell unit stack. In some embodiments, the air handling in the cooling system need not be of IP67 water - proof level. In some embodiments, cooling features may be included in the electrochemical cell unit assembly structure.

[0018] In some embodiments, the electrochemical cell unit assembly may include a module for providing cell compression. In some embodiments, the electrochemical cell unit assembly may include stiffening ribs, pre - loaded compression bars, progressive clamping and small - piece features and / or pressure bladders. The design of the electrochemical cell unit assembly enables efficient air cooling, reducing the sealing overhead in the case of a small volume - to - seal area. In some embodiments, ambient air cooling may be used. In some embodiments, the compression means included in the electrochemical cell unit assembly may include compression means nested into opposing void regions. The compression means may provide channels for the cooling medium. In some embodiments, the module connections may support multiple modular connections. In some embodiments, the vehicle structure may provide at least a portion of the compression force applied to the electrochemical cell unit assembly, thereby limiting the module cost.

[0019] In some embodiments, the electrochemical cell units described herein may include an anode and a cathode with a separator therebetween. In some embodiments, the electrochemical cell units described herein may include a pouch, as described in U.S. Patent No. 10,181,587, titled “Single Pouch Battery Cells and Methods of Manufacture,” filed on June 17, 2016 (“the ‘587 patent”), the disclosure of which is hereby incorporated by reference in its entirety. In some embodiments, the electrodes described herein may include conventional solid electrodes. In some embodiments, the solid electrodes may include a binder. In some embodiments, the electrodes described herein may include semi-solid electrodes. The semi-solid electrodes described herein may be made to be: (i) thicker (e.g., greater than 100 μm to up to 2,000 μm or even greater) due to the reduced tortuosity and higher conductivity of the semi-solid electrodes, (ii) have a higher active material loading, and (iii) have a simplified manufacturing process that utilizes less equipment. These relatively thick semi-solid electrodes reduce the volume, mass, and cost contribution of the inactive components relative to the active components, thereby enhancing the commercial attractiveness of the batteries made from the semi-solid electrodes. In some embodiments, the semi-solid electrodes described herein are binder-free and / or do not use the binders used in conventional battery manufacturing. Instead, the volume in a conventional electrode that is typically occupied by the binder is now occupied by: 1) an electrolyte, which serves to reduce tortuosity and increase the total salt available for ion diffusion, thereby offsetting the typical salt depletion effect of thick conventional electrodes when used at high rates, 2) an active material, which serves to increase the charge capacity of the battery, or 3) a conductive additive, which serves to increase the electronic conductivity of the electrode, thereby offsetting the high internal impedance of thick conventional electrodes. The reduced tortuosity and higher electronic conductivity of the semi-solid electrodes described herein result in excellent rate performance and charge capacity of the electrochemical cell units formed from the semi-solid electrodes. Since the semi-solid electrodes described herein can be made much thicker than conventional electrodes, the ratio of the active material (i.e., the semi-solid cathode and / or anode) to the inactive material (i.e., the current collector and the separator) may be much higher in the batteries formed by stacking electrochemical cell units including semi-solid electrodes than in similar batteries formed by stacking electrochemical cell units including conventional electrodes. This significantly increases the overall charge capacity and energy density of the batteries including the semi-solid electrodes described herein.

[0020] In some embodiments, the electrode materials described herein can be flowable semi-solid or gelled liquid compositions. In some embodiments, the electrode materials described herein can be binder-free or substantially binder-free. A flowable semi-solid electrode can include a suspension of electrochemically active materials (anode or cathode particles or microparticles) and optionally an electronically conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. In other words, the active electrode particles and the conductive particles are co-suspended in the electrolyte to produce a semi-solid electrode. Examples of battery architectures utilizing semi-solid suspensions are described in International Patent Publication No. WO 2012 / 024499, entitled "Stationary, Fluid Redox Electrode", and International Patent Publication No. WO 2012 / 088442, entitled "Semi-Solid Filled Battery and Method of Manufacture", the entire disclosures of which are hereby incorporated by reference.

[0021] As used in this specification, unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" include plural referents. Thus, for example, the term "member" is intended to mean a single member or a combination of members, and the term "material" is intended to mean one or more materials or combinations thereof.

[0022] When used in connection with "cylindrical", "linear", and / or other geometric relationships, the term "substantially" is intended to convey that the structure so qualified is nominally cylindrical, linear, etc. As an example, a portion of a support member described as "substantially linear" is intended to convey that while linearity of the portion is desired, some non-linearity may be present in the "substantially linear" portion. Such non-linearity can be produced by manufacturing tolerances or other practical considerations such as, for example, pressure or force applied to the support member. Thus, a geometric construct modified by the term "substantially" includes such geometric properties within a tolerance of plus or minus 5% of the stated geometric construct. For example, a "substantially linear" portion is one in which the linearity error defining the axis or centerline is within plus or minus 5%.

[0023] As used herein, the terms "group" and "plurality" can refer to multiple features or a single feature having multiple parts. For example, when referring to a group of electrodes, the group of electrodes can be considered as one electrode having multiple parts, or the group of electrodes can be considered as multiple different electrodes. Additionally, for example, when referring to a plurality of electrochemical cell units, the plurality of electrochemical cell units can be considered as multiple different electrochemical cell units or as one electrochemical cell unit having multiple parts. Thus, a group of parts or a plurality of parts can include multiple parts that are continuous or discontinuous with each other. A plurality of particles or a plurality of materials can also be made from multiple articles that are produced separately and then joined together (e.g., via mixing, an adhesive, or any suitable method).

[0024] As used herein, the term "semi-solid" refers to a material that is a mixture of a liquid phase and a solid phase, e.g., a particle suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle.

[0025] Figure 1 is a block diagram of an electrochemical cell unit system 100 according to an embodiment. As shown, the electrochemical cell unit system 100 includes an electrochemical cell unit stack 110, a first planar sheet 120a and a second planar sheet 120b (collectively referred to as planar sheets 120) disposed on either side of the electrochemical cell unit stack 110, and a first structural member 130a and a second structural member 130b (collectively referred to as structural members 130) disposed on either side of the planar sheets 120. The electrochemical cell assembly 100 further includes a containment structure 140 that houses the electrochemical cell unit stack 110, the planar sheets 120, and the structural members 130.

[0026] In some embodiments, the electrochemical cell units in the electrochemical cell unit stack 110 can be the same as or substantially similar to the electrochemical cell units described in the '587 patent. Each electrochemical cell unit in the electrochemical cell units can include an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, and a separator disposed between the anode material and the cathode material. In some embodiments, the separator can be large enough such that a portion of the separator extends beyond the outer edges of the anode material and the cathode material. The electrochemical cell unit can further include a pouch material that at least partially encapsulates the anode material, the anode current collector, the cathode material, the cathode current collector, and the separator. In some embodiments, the pouch material can contact the anode current collector, the cathode current collector, and / or the separator. The pouch material can be large enough such that a portion of the pouch material extends beyond the outer boundary of the separator.

[0027] The electrochemical cell unit stack 110 includes a plurality of electrochemical cell units arranged in a stack. In some embodiments, the electrochemical cell unit stack 110 may include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, or at least about 450 electrochemical cell units. In some embodiments, the electrochemical cell unit stack 110 may include no more than about 500, no more than about 450, no more than about 400, no more than about 350, no more than about 300, no more than about 250, no more than about 200, no more than about 150, no more than about 100, no more than about 90, no more than about 80, no more than about 70, no more than about 60, no more than about 50, no more than about 40, no more than about 30, no more than about 20, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, no more than about 4, no more than about 3, or no more than about 2 electrochemical cell units. Combinations of the above-mentioned quantities of electrochemical cell units are also possible (e.g., at least about 1 electrochemical cell unit and no more than about 500 electrochemical cell units or at least about 5 electrochemical cell units and no more than about 50 electrochemical cell units), including all values and ranges therebetween. In some embodiments, the electrochemical cell unit stack 110 may include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 100, about 150, about 200, about 250, about 300, about 350, about 400, about 450, or about 500 electrochemical cell units. In some embodiments, the electrochemical cell unit stack 110 may be divided into subgroups of electrochemical cell units having thermal spacers between each subgroup. In some embodiments, each subgroup shares the same set of restraint hardware.

[0028] The planar sheet 120 helps to evenly distribute forces on the outer surface of the electrochemical cell stack 110. In some embodiments, the planar sheet 120 may have the same or substantially similar length and width dimensions as the electrochemical cell stack 110. In some embodiments, the planar sheet 120 may have a slightly larger length and a slightly larger width compared to the electrochemical cells in the electrochemical cell stack 110 such that the planar sheet 120 may wrap around the electrochemical cell stack 110. In some embodiments, the planar sheet 120 may be composed of metal (e.g., aluminum, stainless steel, high strength low alloy steel). In some embodiments, the planar sheet 120 may be composed of a polymer (e.g., polyethylene, polypropylene). In some embodiments, the planar sheet 120 may be composed of ceramic, alumina, carbide, composite material, glass filled plastic, carbon fiber, or any combination thereof. In some embodiments, the electrochemical cell assembly 100 may include a compliant material (not shown) on the surface of the electrochemical cell stack 110 as a means of evenly distributing pressure. In some embodiments, the compliant material may include foam, rubber, or any combination thereof.

[0029] The structural member 130 presses down against the planar sheet 120. In some embodiments, the structural member 130 may include a leaf spring. In some embodiments, the structural member 130 may include an inflatable bladder. In some embodiments, the structural member 130 may include a stiffening rib. In some embodiments, the structural member 130 may include a preloaded compression rod. In some embodiments, the structural member 130 may include a progressive clamp. In some embodiments, the structural member 130 may include a small block for applying a force to the planar sheet 120.

[0030] The containment structure 140 may hold the electrochemical cell stack 110, the planar sheet 120, and the structural member 130. In some embodiments, the containment structure 140 may contact the structural member 130. In some embodiments, the structural member 130 may be received within the containment structure 140 such that internal loads are generated through the interaction between the structural member 130 and the containment structure 140. In some embodiments, the containment structure 140 may include a cell housing that is the same or substantially similar to the housing described in the '587 patent.

[0031] Figure 2 is an illustration of an electrochemical cell stack 210 according to an embodiment. In some embodiments, the electrochemical cell stack 210 may be the same or substantially similar to the electrochemical cell stack 110 described above with reference to Figure 1 Accordingly, certain aspects of the electrochemical cell stack 210 are not described in more detail herein.

[0032] As shown, the electrochemical cell unit stack 210 has a length L, a width W, and a thickness T. As shown, the thickness T of the electrochemical cell unit stack 210 is the vertical dimension along which the electrochemical cells are stacked. As shown, the length L is the longer of the two dimensions that describe the extent of the electrochemical cells in the electrochemical cell unit stack 210, and the width W is the shorter of the two dimensions that describe the extent of the electrochemical cells in the electrochemical cell unit stack 210.

[0033] In some embodiments, the length L of the electrochemical cell unit stack 210 can be at least about 5 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm, at least about 9 cm, at least about 10 cm, at least about 20 cm, at least about 30 cm, at least about 40 cm, at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, at least about 90 cm, at least about 1 m, at least about 1.5 m, at least about 2 m, at least about 2.5 m, at least about 3 m, at least about 3.5 m, at least about 4 m, or at least about 4.5 m. In some embodiments, the length L of the electrochemical cell unit stack 210 can be no more than about 5 m, no more than about 4.5 m, no more than about 4 m, no more than about 3.5 m, no more than about 3 m, no more than about 2.5 m, no more than about 2 m, no more than about 1.5 m, no more than about 1 m, no more than about 90 cm, no more than about 80 cm, no more than about 70 cm, no more than about 60 cm, no more than about 50 cm, no more than about 40 cm, no more than about 30 cm, no more than about 20 cm, no more than about 10 cm, no more than about 9 cm, no more than about 8 cm, no more than about 7 cm, no more than about 6 cm, no more than about 5 cm, no more than about 4 cm, no more than about 3 cm, no more than about 2 cm, or no more than about 1 cm. Combinations of the lengths mentioned above are also possible (e.g., at least about 5 mm and no more than about 5 m or at least about 5 cm and no more than 40 cm), including all values and ranges therebetween. In some embodiments, the length L of the electrochemical cell unit stack 210 can be about 5 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, about 10 cm, about 20 cm, about 30 cm, about 40 cm, about 50 cm, about 60 cm, about 70 cm, about 80 cm, about 90 cm, about 1 m, about 1.5 m, about 2 m, about 2.5 m, about 3 m, about 3.5 m, about 4 m, about 4.5 m, or about 5 m.

[0034] In some embodiments, the width W can be at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm, at least about 9 cm, at least about 10 cm, at least about 20 cm, at least about 30 cm, at least about 40 cm, at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, at least about 90 cm, at least about 1 m, or at least about 1.5 m. In some embodiments, the width W can be no more than about 2 m, no more than about 1.5 m, no more than about 1 m, no more than about 90 cm, no more than about 80 cm, no more than about 70 cm, no more than about 60 cm, no more than about 50 cm, no more than about 40 cm, no more than about 30 cm, no more than about 20 cm, no more than about 10 cm, no more than about 9 cm, no more than about 8 cm, no more than about 7 cm, no more than about 6 cm, no more than about 5 cm, no more than about 4 cm, no more than about 3 cm, no more than about 2 cm, no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, or no more than about 2 mm. Combinations of the widths mentioned above are also possible (e.g., at least about 1 mm and no more than 2 m or at least about 5 cm and no more than about 30 cm), including all values and ranges therebetween. In some embodiments, the width W can be about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, about 10 cm, about 20 cm, about 30 cm, about 40 cm, about 50 cm, about 60 cm, about 70 cm, about 80 cm, about 90 cm, about 1 m, about 1.5 m, or about 2 m.

[0035] In some embodiments, the thickness T can be at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm, at least about 9 cm, at least about 10 cm, at least about 11 cm, at least about 12 cm, at least about 13 cm, at least about 14 cm, at least about 15 cm, at least about 16 cm, at least about 17 cm, at least about 18 cm or at least about 19 cm. In some embodiments, the thickness T can be no more than about 20 cm, no more than about 19 cm, no more than about 18 cm, no more than about 17 cm, no more than about 16 cm, no more than about 15 cm, no more than about 14 cm, no more than about 13 cm, no more than about 12 cm, no more than about 11 cm, no more than about 10 cm, no more than about 9 cm, no more than about 8 cm, no more than about 7 cm, no more than about 6 cm, no more than about 5 cm, no more than about 4 cm, no more than about 3 cm, no more than about 2 cm, no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, no more than about 2 mm, no more than about 1 mm, no more than about 900 μm, no more than about 800 μm, no more than about 700 μm, no more than about 600 μm, no more than about 500 μm, no more than about 400 μm or no more than about 300 μm. Combinations of the above-mentioned thicknesses are also possible (e.g., at least about 200 μm and no more than about 20 cm or at least about 1 mm and no more than about 2 cm), including all values and ranges therebetween. In some embodiments, the thickness T can be about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, about 10 cm, about 11 cm, about 12 cm, about 13 cm, about 14 cm, about 15 cm, about 16 cm, about 17 cm, about 18 cm, about 19 cm or about 20 cm.

[0036] Large-sized battery cells having a large aspect ratio (i.e., the ratio of length L to thickness T or width W to thickness T) can contribute to heat dissipation from the electrochemical cell stack 210. In some embodiments, the ratio of the length L to the thickness T of the electrochemical cell stack 210 can be at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, at least about 800, at least about 900, or at least about 1,000. In some embodiments, the ratio of the width W to the thickness T of the electrochemical cell stack 210 can be at least about 1.5, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, or at least about 800.

[0037] Figure 3 An electrochemical cell assembly 300 according to an embodiment is shown. The electrochemical cell assembly 300 includes an electrochemical cell stack (not shown) having a planar sheet (not shown) disposed inside a containment structure 340, the containment structure having structural members 330 integrated into the containment structure 340. As shown, the electrochemical cell assembly 300 includes a common anode tab 311 in electrical contact with a plurality of anode tabs (not shown) and a common cathode tab 312 in electrical contact with a plurality of cathode tabs (not shown).

[0038] As shown, structural member 330 includes stiffeners integrated into receiving structure 340. In some embodiments, structural member 330 may be curved in its natural relaxed state and may be flattened when integrated into receiving structure 340. The curvature of structural member 330 may create internal loads such that structural member 330 applies pressure to the planar sheet and the electrochemical cell unit stack. As shown, electrochemical cell unit assembly 300 includes five stiffeners on a first side of electrochemical cell unit assembly 300 and four stiffeners on a second side of electrochemical cell unit assembly 300 opposite the first side. As shown, the stiffeners on the first side are offset from the stiffeners on the second side. This arrangement may allow multiple electrochemical cell unit assemblies to be stacked and nested against each other. In some embodiments, the stiffeners may be arranged parallel to each other. In some embodiments, electrochemical cell unit assembly 300 may include from about two, about three, about four, about five, about six, about seven, about eight, about nine, about ten, about twenty, about thirty, about forty, about fifty, about sixty, about seventy, about eighty, about ninety, or about one hundred stiffeners on either side of electrochemical cell unit assembly 300, including all values and ranges therebetween.

[0039] Figures 4A to 4B The formation of electrochemical cell unit assembly 400 is shown. As shown, electrochemical cell unit assembly 400 includes electrochemical cell units 410a, 410b (collectively electrochemical cell unit stack 410), planar sheets 420a, 420b (collectively planar sheets 420), structural members 430a, 430b (collectively structural member 430) having small pieces 432, and receiving structure 440. In some embodiments, electrochemical cell unit stack 410, planar sheets 420, structural member 430, and receiving structure 440 may be the same as or substantially similar to electrochemical cell unit stack 110, planar sheets 120, structural member 430, and receiving structure 140 as described above with reference to Figure 1 Therefore, certain aspects of electrochemical cell unit stack 410, planar sheets 420, structural member 430, and receiving structure 440 are not described in more detail herein. Figure 4A The separate components of electrochemical cell unit assembly 400 are shown, while Figure 4B the fully formed electrochemical cell unit assembly 400 is shown.

[0040] In some embodiments, the planar sheets 420 may each have a thickness that is the same as or substantially similar to the thickness of the electrochemical cell unit stack 410. In some embodiments, the planar sheets 420 may each have a thickness that is less than the thickness of the electrochemical cell unit stack 410. In some embodiments, the planar sheets 420 may each have a thickness that is greater than the thickness of the electrochemical cell unit stack 410. In some embodiments, the planar sheet 420a and the planar sheet 420b may each have the same or substantially similar thickness. In some embodiments, the planar sheet 420a may have a thickness different from that of the planar sheet 420b.

[0041] In some embodiments, the planar sheet 420a and / or the planar sheet 420b may have a thickness of at least about 100 μm, at least about 200 μm, at least about 400 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, or at least about 4 cm. In some embodiments, the planar sheet 420a and / or the planar sheet 420b may have a thickness of no more than about 5 cm, no more than about 4 cm, no more than about 3 cm, no more than about 2 cm, no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, no more than about 2 mm, no more than about 1 mm, no more than about 900 μm, no more than about 800 μm, no more than about 700 μm, no more than about 600 μm, no more than about 500 μm, no more than about 400 μm, no more than about 400 μm, or no more than about 200 μm. Combinations of the above-mentioned thicknesses are also possible (e.g., at least about 100 μm and no more than about 5 cm or at least about 1 mm and no more than about 8 mm), including all values and ranges therebetween. In some embodiments, the planar sheet 420a and / or the planar sheet 420b may have a thickness of about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, or about 5 cm.

[0042] As shown, structural member 430 includes a pressure plate having tabs 432 that are longer near the horizontal center of the electrochemical cell unit stack 410 than near the edges of the electrochemical cell unit stack 410. The profile of the tabs 432 can be selected to counteract displacement of the planar portion of the structural member 430 under load. When a force is applied (i.e., via the receiving structure 440), the tabs 432 contact the planar sheet 420. The planar sheet 420 distributes the force applied by the tabs 432. As shown, the tabs 432 have rounded distal ends. In some embodiments, the tabs 432 can be part of the same material block as the structural member 430. In some embodiments, the tabs 432 can be incorporated into the structural member 430 (e.g., via an adhesive). In some embodiments, the tabs 432 can be composed of a polymer, vulcanized rubber, aluminum, steel, ceramic, composite material, or any combination thereof.

[0043] As shown, each of the structural members 430 includes seven tabs 432. In some embodiments, each of the structural members 430 can include at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, at least about 45, at least about 50, at least about 55, at least about 60, at least about 65, at least about 70, at least about 75, at least about 80, at least about 85, at least about 90, or at least about 95 tabs 432. In some embodiments, each of the structural members 430 can include no more than about 100, no more than about 95, no more than about 90, no more than about 85, no more than about 80, no more than about 75, no more than about 70, no more than about 65, no more than about 60, no more than about 55, no more than about 50, no more than about 45, no more than about 40, no more than about 35, no more than about 30, no more than about 25, no more than about 20, no more than about 15, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, or no more than about 4 tabs 432. Combinations of the above-mentioned numbers of tabs 432 are also possible (e.g., at least about 3 tabs 432 and no more than about 100 tabs 432 or at least about 5 tabs 432 and no more than about 15 tabs 432). In some embodiments, each of the structural members 430 can include about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, about 95, or about 100 tabs 432.

[0044] In some embodiments, the patches 432 may be arranged in an m x n pattern along the plane of the structural member 430. In some embodiments, m and / or n may be about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 11, about 12, about 13, about 14, about 15, about 16, about 17, about 18, about 19, about 20, about 21, about 22, about 23, about 24, or about 25. In some embodiments, the patches 432 may be wide such that they extend along the length or width of the structural member 430. In other words, the patches 432 may extend along the dimensions of the page going in and out Figure 4A and Figure 4B of the page. In some embodiments, the patches 432 may have a width of about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, or about 100% of the width of the structural member 430.

[0045] As shown, starting from the edge of the electrochemical cell unit stack 410, the small pieces 432 sequentially become longer until they reach their maximum length near the horizontal center of the electrochemical cell unit stack 410. In some embodiments, the small pieces 432 can have a length of at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm or at least about 9 cm. In some embodiments, the small pieces 432 can have a length not exceeding about 10 cm, not exceeding about 9 cm, not exceeding about 8 cm, not exceeding about 7 cm, not exceeding about 6 cm, not exceeding about 5 cm, not exceeding about 4 cm, not exceeding about 3 cm, not exceeding about 2 cm, not exceeding about 1 cm, not exceeding about 9 mm, not exceeding about 8 mm, not exceeding about 7 mm, not exceeding about 6 mm, not exceeding about 5 mm, not exceeding about 4 mm, not exceeding about 3 mm, not exceeding about 2 mm, not exceeding about 1 mm, not exceeding about 900 μm, not exceeding about 800 μm, not exceeding about 700 μm, not exceeding about 600 μm, not exceeding about 500 μm, not exceeding about 400 μm, not exceeding about 400 μm or not exceeding about 200 μm. Combinations of the above-mentioned lengths of the small pieces 432 are also possible (e.g., at least about 100 μm and not exceeding about 10 cm or at least about 5 mm and not exceeding about 2 cm), including all values and ranges therebetween. In some embodiments, the small pieces 432 can have a length of about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm or about 10 cm.

[0046] In some embodiments, the ratio of the length of the longest one in the small block 432 (i.e., near the horizontal center of the electrochemical cell unit stack 410) to the length of the shortest one in the small block 432 (i.e., near the outer edge of the electrochemical cell unit stack 410) can be at least about 1.5:1, at least about 1.6:1, at least about 1.7:1, at least about 1.8:1, at least about 1.9:1, at least about 2:1, at least about 2.5:1, at least about 3:1, at least about 3.5:1, at least about 4:1, at least about 4.5:1, at least about 5:1, at least about 6:1, at least about 7:1, at least about 8:1, at least about 9:1, at least about 10:1, at least about 20:1, at least about 30:1, or at least about 40:1. In some embodiments, the ratio of the length of the longest one in the small block 432 to the length of the shortest one in the small block 432 can be no more than about 50:1, no more than about 40:1, no more than about 30:1, no more than about 20:1, no more than about 10:1, no more than about 9:1, no more than about 8:1, no more than about 7:1, no more than about 6:1, no more than about 5:1, no more than about 4:1, no more than about 3:1, no more than about 2:1, no more than about 1.9:1, no more than about 1.8:1, no more than about 1.7:1, or no more than about 1.6:1. Combinations of the above-mentioned length ratios are also possible (e.g., at least about 1.5:1 and no more than about 50:1 or at least about 5:1 and no more than about 20:1), including all values and ranges therebetween. In some embodiments, the ratio of the length of the longest one in the small block 432 to the length of the shortest one in the small block 432 can be about 1.5:1, about 1.6:1, about 1.7:1, about 1.8:1, about 1.9:1, about 2:1, about 2.5:1, about 3:1, about 3.5:1, about 4:1, about 4.5:1, about 5:1, about 6:1, about 7:1, about 8:1, about 9:1, about 10:1, about 20:1, about 30:1, about 40:1, or about 50:1.

[0047] The receiving structure 440 holds the structural member 430 in place against the planar sheet 420. In some embodiments, the receiving structure 440 may include a single block of material surrounding the electrochemical cell unit stack 410. In some embodiments, the receiving structure 440 may include multiple blocks of material each clamped to a portion of the structural member 430. In some embodiments, the receiving structure 440 may be composed of a rigid material. In some embodiments, the receiving structure 440 may be composed of a flexible material. In some embodiments, the receiving structure 440 may be composed of a material having a modulus of elasticity greater than or equal to that of structural steel. In some embodiments, the receiving structure 440 may be composed of other high-strength materials, including metals or alloys. In some embodiments, the receiving structure 440 may be composed of the same material as the structural member 430. As shown, the structural member 430 is wedged under the ridge of the receiving structure 440 to be held in place. In some embodiments, the receiving structure 440 may be bonded to the structural member 430 (e.g., via an adhesive). In some embodiments, the receiving structure 440 may be fixed to the structural member 430 via a latch (not shown).

[0048] In some embodiments, the structural member 430 can press down on the planar sheet 420 with a force of at least about 1 N, at least about 2 N, at least about 3 N, at least about 4 N, at least about 5 N, at least about 6 N, at least about 7 N, at least about 8 N, at least about 9 N, at least about 10 N, at least about 20 N, at least about 30 N, at least about 40 N, at least about 50 N, at least about 60 N, at least about 70 N, at least about 80 N, at least about 90 N, at least about 100 N, at least about 200 N, at least about 300 N, at least about 400 N, at least about 500 N, at least about 600 N, at least about 700 N, at least about 800 N, at least about 900 N, at least about 1,000 N, at least about 2,000 N, at least about 3,000 N, at least about 4,000 N, at least about 5,000 N, at least about 6,000 N, at least about 7,000 N, at least about 8,000 N, at least about 9,000 N, at least about 10,000 N, at least about 20,000 N, at least about 30,000 N, at least about 40,000 N, at least about 50,000 N, at least about 60,000 N, at least about 70,000 N, at least about 80,000 N, at least about 90,000 N, at least about 100,000 N, at least about 200,000 N, at least about 300,000 N, at least about 400,000 N, at least about 500,000 N, at least about 600,000 N, at least about 700,000 N, at least about 800,000 N, or at least about 900,000 N.In some embodiments, the structural member 430 can be depressed against the planar sheet 420 with a force of no more than about 1,000,000 N, no more than about 900,000 N, no more than about 800,000 N, no more than about 700,000 N, no more than about 600,000 N, no more than about 500,000 N, no more than about 400,000 N, no more than about 300,000 N, no more than about 200,000 N, no more than about 100,000 N, no more than about 90,000 N, no more than about 80,000 N, no more than about 70,000 N, no more than about 60,000 N, no more than about 50,000 N, no more than about 40,000 N, no more than about 30,000 N, no more than about 20,000 N, no more than about 10,000 N, no more than about 9,000 N, no more than about 8,000 N, no more than about 7,000 N, no more than about 6,000 N, no more than about 5,000 N, no more than about 4,000 N, no more than about 3,000 N, no more than about 2,000 N, no more than about 1,000 N, no more than about 900 N, no more than about 800 N, no more than about 700 N, no more than about 600 N, no more than about 500 N, no more than about 400 N, no more than about 300 N, no more than about 200 N, no more than about 100 N, no more than about 90 N, no more than about 80 N, no more than about 70 N, no more than about 60 N, no more than about 50 N, no more than about 40 N, no more than about 30 N, no more than about 20 N, no more than about 10 N, no more than about 9 N, no more than about 8 N, no more than about 7 N, no more than about 6 N, no more than about 5 N, no more than about 4 N, no more than about 3 N, or no more than about 2 N. Combinations of the above-recited forces are also possible (e.g., at least about 1 N and no more than about 1,000,000 N or at least about 20 N and no more than about 200 N), including all values or ranges therebetween.In some embodiments, the structural member 430 can press down on the planar sheet 420 with a force of approximately 1 N, approximately 2 N, approximately 3 N, approximately 4 N, approximately 5 N, approximately 6 N, approximately 7 N, approximately 8 N, approximately 9 N, approximately 10 N, approximately 20 N, approximately 30 N, approximately 40 N, approximately 50 N, approximately 60 N, approximately 70 N, approximately 80 N, approximately 90 N, approximately 100 N, approximately 200 N, approximately 300 N, approximately 400 N, approximately 500 N, approximately 600 N, approximately 700 N, approximately 800 N, approximately 900 N, approximately 1,000 N, approximately 2,000 N, approximately 3,000 N, approximately 4,000 N, approximately 5,000 N, approximately 6,000 N, approximately 7,000 N, approximately 8,000 N, approximately 9,000 N, approximately 10,000 N, approximately 20,000 N, approximately 30,000 N, approximately 40,000 N, approximately 50,000 N, approximately 60,000 N, approximately 70,000 N, approximately 80,000 N, approximately 90,000 N, approximately 100,000 N, approximately 200,000 N, approximately 300,000 N, approximately 400,000 N, approximately 500,000 N, approximately 600,000 N, approximately 700,000 N, approximately 800,000 N, approximately 900,000 N, approximately 1,000,000 N.

[0049] In some embodiments, the structural member 430 can generate a pressure of about 10 kPa (gauge pressure), at least about 20 kPa, at least about 30 kPa, at least about 40 kPa, at least about 50 kPa, at least about 60 kPa, at least about 70 kPa, at least about 80 kPa, at least about 90 kPa, at least about 100 kPa, at least about 200 kPa, at least about 300 kPa, at least about 400 kPa, at least about 500 kPa, at least about 600 kPa, at least about 700 kPa, at least about 800 kPa, or at least about 900 kPa in the electrochemical cell unit stack 410. In some embodiments, the structural member 430 can generate a pressure not exceeding about 1,000 kPa, not exceeding about 900 kPa, not exceeding about 800 kPa, not exceeding about 700 kPa, not exceeding about 600 kPa, not exceeding about 500 kPa, not exceeding about 400 kPa, not exceeding about 300 kPa, not exceeding about 200 kPa, not exceeding about 100 kPa, not exceeding about 90 kPa, not exceeding about 80 kPa, not exceeding about 70 kPa, not exceeding about 60 kPa, not exceeding about 50 kPa, not exceeding about 40 kPa, not exceeding about 30 kPa, or not exceeding about 20 kPa in the electrochemical cell unit stack 410. Combinations of the above pressures are also possible (e.g., at least about 10 kPa and not exceeding about 1,000 kPa or at least about 50 kPa and not exceeding about 500 kPa), including all values and ranges therebetween. In some embodiments, the structural member 430 can generate a pressure of about 10 kPa, about 20 kPa, about 30 kPa, about 40 kPa, about 50 kPa, about 60 kPa, about 70 kPa, about 80 kPa, about 90 kPa, about 100 kPa, about 200 kPa, about 300 kPa, about 400 kPa, about 500 kPa, about 600 kPa, about 700 kPa, about 800 kPa, about 900 kPa, or about 1,000 kPa in the electrochemical cell unit stack 410.

[0050] Figures 5A to 5D The formation of an electrochemical cell unit assembly 500 according to an embodiment is shown. As shown, the electrochemical cell unit assembly 500 includes an electrochemical cell unit stack 510, planar sheets 520a, 520b (collectively referred to as planar sheets 520), a structural member 530, and a housing structure 540. In some embodiments, the electrochemical cell unit stack 510, the planar sheets 520, the structural member 530, and the housing structure 540 can be the same as or substantially similar to the electrochemical cell unit stack 110, the planar sheets 120, the structural member 130, and the housing structure 140 described above with reference to Figure 1 Thus, certain aspects of the electrochemical cell unit stack 510, the planar sheets 520, the structural member 530, and the housing structure 540 are not described in more detail herein.

[0051] As shown, structural member 530 is a pre-loaded strip, similar to a leaf spring. Structural member 530 is in a bent state when not loaded and can apply a load to flatten the structural member. Figure 5A Structural member 530 in a relaxed bent state is shown. Figure 5B Partially flattened structural member 530 is shown, and Figure 5C fully flattened structural member 530 is shown such that they apply a load to planar sheet 520a and electrochemical cell unit stack 510. Containment structure 540 is not shown in Figure 5C such that structural member 530 can be seen. Figure 5D Containment structure 540 in place is shown. Figures 5A to 5D Structural member 530 is shown only on the first side of electrochemical cell unit assembly 500. In some embodiments, structural member 530 can be placed on both sides of electrochemical cell unit assembly 500 (i.e., in contact with planar sheet 520a and planar sheet 520b).

[0052] In some embodiments, structural member 530 can be composed of a shape memory material (e.g., nitinol, shape memory polymer). In some embodiments, each of the structural members 530 can include a solid continuous length of material. As shown, 3 structural members 530 are in contact with planar sheet 520a. In some embodiments, about 1, about 2, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, about 95, about 100 or at least about 100 structural members 530 can be in contact with planar sheet 520a and / or planar sheet 520b, including all values and ranges therebetween.

[0053] In some embodiments, structural member 530 can be oriented along the width dimension of electrochemical cell unit stack 510. In some embodiments, structural member 530 can be oriented along the length dimension of electrochemical cell unit stack 510. In some embodiments, when flattened, structural member 530 can extend the full width or length of electrochemical cell unit stack 510. In some embodiments, when flattened, structural member 530 can extend about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 96%, about 97%, about 98% or about 99% of the length or width of electrochemical cell unit stack 510, including all values and ranges therebetween.

[0054] Figures 6A to 6B An electrochemical cell unit assembly 600 according to an embodiment is shown. As shown, the electrochemical cell unit assembly 600 includes electrochemical cell units 610a, 610b (collectively referred to as the electrochemical cell unit stack 610), planar sheets 620a, 620b (collectively referred to as the planar sheets 620), structural members 630a, 630b (collectively referred to as the structural members 630), and a containment structure 640. In some embodiments, the electrochemical cell unit stack 610, the planar sheets 620, the structural members 630, and the containment structure 640 may be the same as or substantially similar to the electrochemical cell unit stack 110, the planar sheets 120, the structural members 130, and the containment structure 140 described above with reference to Figure 1 Those described. Accordingly, certain aspects of the electrochemical cell unit stack 610, the planar sheets 620, the structural members 630, and the containment structure 640 are not described in more detail herein.

[0055] As shown, the structural member 630 is an inflatable bladder. Figure 6A The structural member 630 is shown in an uninflated state, while Figure 6B The structural member 630 is shown in an inflated state such that the structural member 630 exerts a force on the planar sheet 620. As shown, the structural member 630 deforms the containment structure 640. In some embodiments, the structural member 630 may be inflated by a factor of about 1.1, about 1.2, about 1.3, about 1.4, about 1.5, about 1.6, about 1.7, about 1.8, about 1.9, about 2, about 2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 5.5, about 6, about 6.5, about 7, about 7.5, about 8, about 8.5, about 9, about 9.5, or about 10, including all values and ranges therebetween. In some embodiments, the structural member 630 may be pneumatically inflated. In some embodiments, the structural member 630 may be hydraulically inflated. In some embodiments, the structural member 630 may be composed of a flexible material. In some embodiments, the structural member 630 may be composed of urethane, vinyl-coated fabric, rubber, polyurethane, nitrile, rubber, Kevlar, nylon, polyester, neoprene, or any combination thereof. In some embodiments, the structural member 630 may be composed of metal. In some embodiments, the structural member 630 may include a welded metal bellows.

[0056] In some embodiments, the structural member 630 can be pressurized to a pressure of at least about 10 kPa (gauge pressure), at least about 20 kPa, at least about 30 kPa, at least about 40 kPa, at least about 50 kPa, at least about 60 kPa, at least about 70 kPa, at least about 80 kPa, at least about 90 kPa, at least about 100 kPa, at least about 200 kPa, at least about 300 kPa, at least about 400 kPa, at least about 500 kPa, at least about 600 kPa, at least about 700 kPa, at least about 800 kPa, or at least about 900 kPa. In some embodiments, the structural member 630 can be pressurized to a pressure not exceeding about 1,000 kPa, not exceeding about 900 kPa, not exceeding about 800 kPa, not exceeding about 700 kPa, not exceeding about 600 kPa, not exceeding about 500 kPa, not exceeding about 400 kPa, not exceeding about 300 kPa, not exceeding about 200 kPa, not exceeding about 100 kPa, not exceeding about 90 kPa, not exceeding about 80 kPa, not exceeding about 70 kPa, not exceeding about 60 kPa, not exceeding about 50 kPa, not exceeding about 40 kPa, not exceeding about 30 kPa, or not exceeding about 20 kPa. Combinations of the above pressures are also possible (e.g., at least about 10 kPa and not exceeding about 1,000 kPa or at least about 50 kPa and not exceeding about 500 kPa), including all values and ranges therebetween. In some embodiments, the structural member 630 can be pressurized to a pressure of about 10 kPa, about 20 kPa, about 30 kPa, about 40 kPa, about 50 kPa, about 60 kPa, about 70 kPa, about 80 kPa, about 90 kPa, about 100 kPa, about 200 kPa, about 300 kPa, about 400 kPa, about 500 kPa, about 600 kPa, about 700 kPa, about 800 kPa, about 900 kPa, or about 1,000 kPa.

[0057] In some embodiments, the containment structure 640 can be flexible and can expand when the structural member 630 expands. In some embodiments, the containment structure 640 can have an elastic modulus greater than that of the structural member 630 such that the containment structure 640 expands but limits the expansion of the structural member 630. In some embodiments, the structural member 630 can be composed of a material different from that of the containment structure 640. In some embodiments, the containment structure 640 can have a wall thickness greater than that of the structural member 630. In some embodiments, the containment structure 640 can be composed of the same material as the structural member 630.

[0058] In some embodiments, the structural member 630 may have a modulus of elasticity of at least about 1 MPa, at least about 2 MPa, at least about 3 MPa, at least about 4 MPa, at least about 5 MPa, at least about 6 MPa, at least about 7 MPa, at least about 8 MPa, at least about 9 MPa, at least about 10 MPa, at least about 20 MPa, at least about 30 MPa, at least about 40 MPa, at least about 50 MPa, at least about 60 MPa, at least about 70 MPa, at least about 80 MPa, at least about 90 MPa, at least about 100 MPa, at least about 200 MPa, at least about 300 MPa, at least about 400 MPa, at least about 500 MPa, at least about 600 MPa, at least about 700 MPa, at least about 800 MPa, or at least about 900 MPa, at least about 1 GPa, at least about 5 GPa, at least about 10 GPa, at least about 50 GPa, at least about 100 GPa, at least about 200 GPa, at least about 300 GPa, or at least about 400 GPa. In some embodiments, the structural member 630 may have a modulus of elasticity not exceeding about 500 GPa, not exceeding about 400 GPa, not exceeding about 300 GPa, not exceeding about 200 GPa, not exceeding about 100 GPa, not exceeding about 50 GPa, not exceeding about 10 GPa, not exceeding about 5 GPa, not exceeding about 1 GPa, not exceeding about 900 MPa, not exceeding about 800 MPa, not exceeding about 700 MPa, not exceeding about 600 MPa, not exceeding about 500 MPa, not exceeding about 400 MPa, not exceeding about 300 MPa, not exceeding about 200 MPa, not exceeding about 100 MPa, not exceeding about 90 MPa, not exceeding about 80 MPa, not exceeding about 70 MPa, not exceeding about 60 MPa, not exceeding about 50 MPa, not exceeding about 40 MPa, not exceeding about 30 MPa, not exceeding about 20 MPa, not exceeding about 10 MPa, not exceeding about 9 MPa, not exceeding about 8 MPa, not exceeding about 7 MPa, not exceeding about 6 MPa, not exceeding about 5 MPa, not exceeding about 4 MPa, not exceeding about 3 MPa, or not exceeding about 2 MPa. Combinations of the above-mentioned moduli of elasticity are also possible (e.g., at least about 1 MPa and not exceeding about 1 GPa or at least about 50 MPa and not exceeding about 900 MPa), including all values and ranges therebetween.In some embodiments, the structural member 630 may have a modulus of elasticity of about 1 MPa, about 2 MPa, about 3 MPa, about 4 MPa, about 5 MPa, about 6 MPa, about 7 MPa, about 8 MPa, about 9 MPa, about 10 MPa, about 20 MPa, about 30 MPa, about 40 MPa, about 50 MPa, about 60 MPa, about 70 MPa, about 80 MPa, about 90 MPa, about 100 MPa, about 200 MPa, about 300 MPa, about 400 MPa, about 500 MPa, about 600 MPa, about 700 MPa, about 800 MPa, about 900 MPa, about 1 GPa, about 5 GPa, about 10 GPa, about 50 GPa, about 100 GPa, about 200 GPa, about 300 GPa, about 400 GPa, or about 500 GPa.

[0059] In some embodiments, the accommodating structure 640 may have a modulus of elasticity of at least about 10 MPa, at least about 20 MPa, at least about 30 MPa, at least about 40 MPa, at least about 50 MPa, at least about 60 MPa, at least about 70 MPa, at least about 80 MPa, at least about 90 MPa, at least about 100 MPa, at least about 200 MPa, at least about 300 MPa, at least about 400 MPa, at least about 500 MPa, at least about 600 MPa, at least about 700 MPa, at least about 800 MPa, at least about 900 MPa, at least about 1 GPa, at least about 2 GPa, at least about 3 GPa, at least about 4 GPa, at least about 5 GPa, at least about 6 GPa, at least about 7 GPa, at least about 8 GPa, at least about 9 GPa, at least about 10 GPa, at least about 50 GPa, at least about 100 GPa, at least about 200 GPa, at least about 300 GPa or at least about 400 GPa. In some embodiments, the structural member 630 may have a modulus of elasticity of not more than about 500 GPa, not more than about 400 GPa, not more than about 300 GPa, not more than about 200 GPa, not more than about 100 GPa, not more than about 50 GPa, not more than about 10 GPa, not more than about 9 GPa, not more than about 8 GPa, not more than about 7 GPa, not more than about 6 GPa, not more than about 5 GPa, not more than about 4 GPa, not more than about 3 GPa, not more than about 2 GPa, not more than about 1 GPa, not more than about 900 MPa, not more than about 800 MPa, not more than about 700 MPa, not more than about 600 MPa, not more than about 500 MPa, not more than about 400 MPa, not more than about 300 MPa, not more than about 200 MPa, not more than about 100 MPa, not more than about 90 MPa, not more than about 80 MPa, not more than about 70 MPa, not more than about 60 MPa, not more than about 50 MPa, not more than about 40 MPa, not more than about 30 MPa or not more than about 20 MPa. Combinations of the above-mentioned moduli of elasticity are also possible (e.g., at least about 10 MPa and not more than about 500 GPa or at least about 500 MPa and not more than about 1 GPa), including all values and ranges therebetween.In some embodiments, the structural member 630 may have a modulus of elasticity of about 10 MPa, about 20 MPa, about 30 MPa, about 40 MPa, about 50 MPa, about 60 MPa, about 70 MPa, about 80 MPa, about 90 MPa, about 100 MPa, about 200 MPa, about 300 MPa, about 400 MPa, about 500 MPa, about 600 MPa, about 700 MPa, about 800 MPa, about 900 MPa, about 1 GPa, about 2 GPa, about 3 GPa, about 4 GPa, about 5 GPa, about 6 GPa, about 7 GPa, about 8 GPa, about 9 GPa, about 10 GPa, about 50 GPa, about 100 GPa, about 200 GPa, about 300 GPa, about 400 GPa, or about 500 GPa.

[0060] In some embodiments, the pressure in the structural member 630 may be static. In some embodiments, the pressure in the structural member 630 may be actively regulated and dynamic (e.g., via a controller). In some embodiments, the structural member 630 may include valves for regulating the inflow and / or outflow of fluid. Higher pressure in the structural member 630 results in higher pressure and lower cell resistance in the electrochemical cell unit stack 610. Lower pressure in the structural member 630 results in lower pressure and higher cell resistance in the electrochemical cell unit stack 610. In some embodiments, the pressure in the structural member 630 may be adjusted during the life cycle of the electrochemical cell unit stack 610 based on the changes over time of the electrochemical cells 610a, 610b.

[0061] Figures 7A to 7C is a diagram of an electrochemical cell unit assembly 700 according to an embodiment. As shown, the electrochemical cell unit assembly 700 includes an electrochemical cell unit stack 710, planar sheets 720a, 720b (collectively referred to as planar sheets 720), structural members 730a, 730b, 730c, 730d, 730e, 730f (collectively referred to as structural members 730), and housing structures 740a, 740b (collectively referred to as housing structures 740). In some embodiments, the electrochemical cell unit stack 710, planar sheets 720, structural members 730, and housing structures 740 may be the same as or substantially similar to the electrochemical cell unit stack 110, planar sheets 120, structural members 130, and housing structures 140 described above with reference to Figure 1 Therefore, certain aspects of the electrochemical cell unit stack 710, planar sheets 720, structural members 730, and housing structures 740 are not described in more detail herein. Figure 7A A perspective view of the electrochemical cell unit assembly 700 is shown. Figure 7B A cross-sectional view of the electrochemical cell unit assembly 700 is shown and Figure 7CShows a close-up view of one side of the electrochemical cell unit assembly 700.

[0062] As shown, the structural member 730 is designed as a rib extending along the width of the receiving structure 740. The rib structure can control the deformation of the electrochemical cells in the electrochemical cell unit stack 710. As shown, the electrochemical cell unit system 700 includes 3 structural members 730 on either side. In some embodiments, the electrochemical cell unit system 700 may include from about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45 or about 50 structural members 730 on either side, including all values and ranges therebetween. In some embodiments, the structural members 730 may each be composed of the same material. In some embodiments, the structural members 730 may be composed of different materials. In some embodiments, the structural members 730 may be composed of a material lighter than the planar sheet 720 and / or the receiving structure 740 to reduce the weight of the electrochemical cell unit assembly 700. In some embodiments, the structural members 730 may be composed of fiberglass, polymers, carbon fiber, metals, aluminum, or any combination thereof. In some embodiments, the structural members 730 may be composed of a material having a modulus of elasticity greater than or equal to that of structural steel.

[0063] As shown, the edges of the structural member 730c (and the edges of other outer structural members 730) are recessed a distance d from the edges of the planar sheet 720a and the receiving structure 740a. In some embodiments, the distance d may be at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm or at least about 9 cm. In some embodiments, the distance d may be no more than about 10 cm, no more than about 9 cm, no more than about 8 cm, no more than about 7 cm, no more than about 6 cm, no more than about 5 cm, no more than about 4 cm, no more than about 3 cm, no more than about 2 cm, no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm or no more than about 2 mm.

[0064] In some embodiments, the structural members 730 may each have the same or substantially similar lengths. In some embodiments, the structural members 730 may have different lengths to evenly distribute pressure across the planar sheet 720. In some embodiments, the lengths of the structural members 730 may be optimized via finite element analysis (FEA) simulations. Forces along the planar sheet 720 may be maintained by compressing and welding the receiving structure 740 to the structural members 730 and / or by compressing and welding the structural members 730 to the planar sheet 720. In some embodiments, the structural members 730 may be concave such that pressure is evenly distributed across the planar sheet 720. More specifically, the receiving structure 740 may be bent toward the structural members 730 to apply sufficient and uniform pressure on and then from the planar sheet 720 to the electrochemical cell unit stack 710.

[0065] Figure 8 is an illustration of an electrochemical cell unit assembly 800 according to an embodiment. As shown, the electrochemical cell unit assembly 800 includes an electrochemical cell unit stack 810, planar sheets 820a, 820b (collectively referred to as planar sheets 820), and structural members 830a, 830b (collectively referred to as structural members 830) having small blocks 832. In some embodiments, the electrochemical cell unit stack 810, planar sheets 820, structural members 830, and blocks 832 may be the same as or substantially similar to the electrochemical cell unit stack 410, planar sheets 420, structural members 430, and small blocks 432 described above with reference to Figures 4A to 4B Thus, certain aspects of the electrochemical cell unit stack 810, planar sheets 820, structural members 830, and blocks 832 are not described in more detail herein.

[0066] As shown in the figure, the structural member 830 includes a steel small plate. In some embodiments, the structural member 830 may be composed of 1095 steel. The structural member 830 has a total thickness including the basic thickness of the steel plate and the thickness of the small plate. In some embodiments, the basic thickness of the structural member 830 may be at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, or at least about 9 mm. In some embodiments, the basic thickness of the structural member 830 may be no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, or no more than about 2 mm. Combinations of the above-mentioned thicknesses are also possible (e.g., at least about 1 mm and no more than about 1 cm or at least about 3 mm and no more than about 8 mm), including all values and ranges therebetween. In some embodiments, the basic thickness of the structural member 830 may be about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, or about 1 cm.

[0067] In some embodiments, the thickness of the small plate 832 may be at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, or at least about 9 mm. In some embodiments, the thickness of the small plate 832 may be no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, or no more than about 2 mm. Combinations of the above-mentioned thicknesses are also possible (e.g., at least about 1 mm and no more than about 1 cm or at least about 3 mm and no more than about 8 mm), including all values and ranges therebetween. In some embodiments, the thickness of the small plate 832 may be about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, or about 1 cm.

[0068] In some embodiments, the planar sheet 820 may have a thickness of at least about 500 μm, at least about 1 mm, at least about 1.5 mm, at least about 2 mm, at least about 2.5 mm, at least about 3 mm, at least about 3.5 mm, at least about 4 mm, or at least about 4.5 mm. In some embodiments, the planar sheet 820 may have a thickness of no more than about 5 mm, no more than about 4.5 mm, no more than about 4 mm, no more than about 3.5 mm, no more than about 3 mm, no more than about 2.5 mm, no more than about 2 mm, no more than about 1.5 mm, or no more than about 1 mm. Combinations of the above-mentioned thicknesses are also possible (e.g., at least about 500 μm and no more than about 5 mm or at least about 2 mm and no more than about 4 mm), including all values and ranges therebetween. In some embodiments, the planar sheet 820 may have a thickness of at least about 500 μm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, or about 5 mm.

[0069] In some embodiments, the electrochemical cell stack 810 may have a thickness of at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm, at least about 9 cm, at least about 10 cm, at least about 11 cm, at least about 12 cm, at least about 13 cm, at least about 14 cm, at least about 15 cm, at least about 16 cm, at least about 17 cm, at least about 18 cm, or at least about 19 cm. In some embodiments, the electrochemical cell stack 810 may have a thickness of no more than about 20 cm, no more than about 19 cm, no more than about 18 cm, no more than about 17 cm, no more than about 16 cm, no more than about 15 cm, no more than about 14 cm, no more than about 13 cm, no more than about 12 cm, no more than about 11 cm, no more than about 10 cm, no more than about 9 cm, no more than about 8 cm, no more than about 7 cm, no more than about 6 cm, no more than about 5 cm, no more than about 4 cm, no more than about 3 cm, or no more than about 2 cm. Combinations of the above-mentioned thicknesses are also possible (e.g., at least about 1 cm and no more than about 20 cm or at least about 5 cm and no more than about 15 cm), including all values and ranges therebetween. In some embodiments, the electrochemical cell stack 810 may have a thickness of about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, about 10 cm, about 11 cm, about 12 cm, about 13 cm, about 14 cm, about 15 cm, about 16 cm, about 17 cm, about 18 cm, about 19 cm, or about 20 cm.

[0070] Figures 9A to 9DFIG. is a diagram of an electrochemical cell unit assembly 900 according to an embodiment. As shown, the electrochemical cell unit assembly 900 includes an electrochemical cell unit stack 910, planar sheets 920a, 920b (collectively referred to as planar sheets 920), structural members 930a, 930b (collectively referred to as structural members 930), and receiving structures 940a, 940b (collectively referred to as receiving structures 940). As shown, the structural member 930 has a honeycomb structure including honeycomb cells 933. In some embodiments, the structural member 930 may adhere the skin to each side of the honeycomb structure. The combination of the skin and the structural member 930 may provide very high hardness. In some embodiments, the electrochemical cell unit stack 910, the planar sheets 920, the structural members 930, and the receiving structures 940 may be the same as or substantially similar to the electrochemical cell unit stack 110, the planar sheets 120, the structural members 130, and the receiving structures 140 as described above with reference to Figure 1 The electrochemical cell unit stack 110, the planar sheets 120, the structural members 130, and the receiving structures 140. Accordingly, certain aspects of the electrochemical cell unit stack 910, the planar sheets 920, the structural members 930, and the receiving structures 940 are not described in more detail herein. Figure 9A FIG. shows a perspective view of the electrochemical cell unit assembly 900. Figure 9B FIG. shows a cross-sectional view of a portion of the electrochemical cell unit assembly 900. Figure 9C FIG. shows the structural member 930a. Figure 9D FIG. shows a single honeycomb cell 933 from the structural member 930a.

[0071] In some embodiments, the structural member 930 may be adhered to the planar sheet 920. The honeycomb structure of the structural member 930 may contribute to the uniform distribution of force throughout the planar sheet 920. In some embodiments, the force on the planar sheet 920 may be maintained by compressing and / or welding the receiving structure 940 to the planar sheet 920. In some embodiments, the electrochemical cell unit stack 910, the structural member 930, and the receiving structure 940 may form a single assembly. For example, each component may be glued together to serve as a single structure. They are all glued together and work as one structure.

[0072] As shown in the figure, the structural member 930 has a thickness t. In some embodiments, the thickness t can be at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, at least about 11 mm, at least about 12 mm, at least about 13 mm, at least about 14 mm, at least about 15 mm, at least about 16 mm, at least about 17 mm, at least about 18 mm, or at least about 19 mm. In some embodiments, the thickness t can be no more than about 20 mm, no more than about 19 mm, no more than about 18 mm, no more than about 17 mm, no more than about 16 mm, no more than about 15 mm, no more than about 14 mm, no more than about 13 mm, no more than about 12 mm, no more than about 11 mm, no more than about 10 mm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, or no more than about 2 mm. Combinations of the thicknesses mentioned above are also possible (e.g., at least about 1 mm and no more than about 20 mm or at least about 5 mm and no more than about 15 mm), including all values and ranges therebetween. In some embodiments, the thickness t can be about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, about 15 mm, about 16 mm, about 17 mm, about 18 mm, about 19 mm, or about 20 mm.

[0073] As shown in the figure, the honeycomb battery cell has a wall thickness wt and a height h. In some embodiments, the wall thickness wt can be at least about 100 μm, at least about 150 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 1 mm, at least about 1.5 mm, at least about 2 mm, at least about 2.5 mm, at least about 3 mm, at least about 3.5 mm, at least about 4 mm, or at least about 4.5 mm. In some embodiments, the wall thickness wt can be no more than about 5 mm, no more than about 4.5 mm, no more than about 5 mm, no more than about 3.5 mm, no more than about 3 mm, no more than about 2.5 mm, no more than about 2 mm, no more than about 1.5 mm, no more than about 1 mm, no more than about 500 μm, no more than about 400 μm, no more than about 300 μm, no more than about 200 μm, or no more than about 150 μm. Combinations of the wall thicknesses mentioned above are also possible (e.g., at least about 500 μm and no more than about 5 mm or at least about 2 mm and no more than about 5 mm), including all values and ranges therebetween. In some embodiments, the wall thickness wt can be about 100 μm, 150 μm, 200 μm, 300 μm, 400 μm, 500 μm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, or about 5 mm.

[0074] In some embodiments, the height h can be at least about 5 mm, at least about 1 cm, at least about 1.5 cm, at least about 2 cm, at least about 2.5 cm, at least about 3 cm, at least about 3.5 cm, at least about 4 cm, or at least about 4.5 cm. In some embodiments, the height h can be no more than about 5 cm, no more than about 4.5 cm, no more than about 4 cm, no more than about 3.5 cm, no more than about 3 cm, no more than about 2.5 cm, no more than about 2 cm, no more than about 1.5 cm, or no more than about 1 cm. Combinations of the height h mentioned above are also possible (e.g., at least about 5 mm and no more than about 5 cm or at least about 2 cm and no more than about 4 cm), including all values and ranges therebetween. In some embodiments, the height h can be about 5 mm, about 1 cm, about 1.5 cm, about 2 cm, about 2.5 cm, about 3 cm, about 3.5 cm, about 4 cm, about 4.5 cm, or about 5 cm.

[0075] Various concepts can be implemented as one or more methods, with at least one example provided. The actions performed as part of a method can be ordered in any suitable way. Thus, embodiments can be constructed in which the actions are performed in an order different from the order illustrated, which can include performing some actions simultaneously, even if shown as sequential actions in the exemplary embodiments. In other words, it should be understood that such features are not necessarily limited to a particular execution order, but can be executed by any number of threads, processes, services, servers, etc. in a serial, asynchronous, concurrent, parallel, simultaneous, synchronous, etc. manner consistent with the present disclosure. Thus, some of these features may be mutually contradictory because they cannot exist in a single embodiment simultaneously. Similarly, some features apply to one aspect of the innovation and not to other aspects.

[0076] Furthermore, the present disclosure may include other innovations not currently described. The applicant reserves all rights to such innovations, including the right to embody such innovations, file additional applications, continuations, partial continuations, divisional applications, etc. Thus, it should be understood that the advantages, embodiments, examples, functions, features, logic, operations, organizations, structures, topologies, and / or other aspects of the present disclosure should not be considered as limitations to the present disclosure as defined by the embodiments or to the equivalents of the embodiments. Depending on the specific expectations and / or characteristics of individual and / or enterprise users, database configurations and / or relational models, data types, data transmission and / or network architectures, syntactic structures, etc., various embodiments of the technologies disclosed herein can be implemented in a manner that achieves a great deal of flexibility and customization as described herein.

[0077] All definitions as defined and used herein should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or the ordinary meaning of the defined terms.

[0078] As used herein, in a particular embodiment, the term "about" or "approximately" when preceding a numerical value indicates a range of plus or minus 10% of that value. Where a range of values is provided, it is understood that each intermediate value between the upper and lower limits of that range (to one-tenth of the unit of the lower limit, unless the context clearly dictates otherwise) as well as any other stated value or intermediate value within the stated range is encompassed within the present disclosure. The upper and lower limits of these smaller ranges can independently be included in a smaller range and are also encompassed within the present disclosure, subject to any specific exclusion limits stated within the stated range. Where the stated range includes one or both of the limits, ranges excluding any one or both of the included limits are also included within the present disclosure.

[0079] As used herein in the specification and in the examples, the phrase "and / or" shall be understood to mean "either or both" of the elements so combined, i.e., elements that are present jointly in some cases and separately in other cases. Multiple elements listed with "and / or" shall be construed in the same manner, i.e., "one or more" of the elements so combined. Except for the elements specifically identified by the "and / or" clause, other elements may optionally exist, whether related or unrelated to those specifically identified. Thus, as a non-limiting example, when used in conjunction with open-ended language such as "comprising", a reference to "A and / or B" may in one embodiment refer to only A (optionally including elements other than B); in another embodiment, to only B (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); and so forth.

[0080] As used herein in the specification and in the examples, "or" shall be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as inclusive, i.e., including at least one element of a plurality of elements or of a list of elements, but also including more than one element, as well as optional additional unlisted items. Only terms such as "only one of... " or "exactly one of... " or when used in the examples, "consisting of... " that explicitly state the contrary shall refer to including exactly one element of a plurality of elements or of a list of elements. In general, the term "or" as used herein shall be interpreted as indicating exclusive alternatives (i.e., "one or the other but not both") only when preceded by exclusive terms such as "any one of", "one of... ", "only one of... " or "exactly one of... ". When used in the examples, "consisting essentially of... " shall have the ordinary meaning as used in the field of patent law.

[0081] As used herein in the specification and in the examples, the phrase "at least one" with respect to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each element specifically listed within the list of elements, and not excluding any combinations of elements in the list of elements. This definition also allows elements other than those specifically identified within the list of elements referred to in the phrase "at least one" to optionally be present, whether related or unrelated to those specifically identified. Thus, by way of non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently "at least one of A and / or B") can in one embodiment mean at least one, optionally including more than one A, with no B present (and optionally including elements other than B); in another embodiment, it can mean at least one, optionally including more than one B, with no A present (and optionally including elements other than A); in yet another embodiment, it can mean at least one, optionally including more than one A and at least one, optionally including more than one B (and optionally including other elements); and so on.

[0082] In the examples and in the foregoing specification, all transitional phrases such as "comprising", "including", "carrying", "having", "containing", "involving", "holding", "consisting of", etc. should be understood to be open-ended, i.e., meaning including but not limited to. As set forth in Section 2111.03 of the United States Patent and Trademark Office's Manual of Patent Examining Procedure, only the transitional phrases "consisting of" and "consisting essentially of" should be closed or semi-closed transitional phrases, respectively.

[0083] Although specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those of ordinary skill in the art. Accordingly, the embodiments set forth herein are intended to be illustrative and not limiting. Various changes can be made without departing from the spirit and scope of the present disclosure. Where the above methods and steps indicate specific events occurring in a particular order, those of ordinary skill in the art benefiting from the present disclosure will recognize that the order of the specific steps can be modified, and such modifications are variations of the present invention. Additionally, where possible, some of the steps can be performed simultaneously in a parallel process, as well as sequentially as described above. Embodiments have been specifically shown and described, but it should be understood that various changes in form and detail can be made.

Claims

1. An electrochemical cell unit assembly, comprising: A plurality of electrochemical cell units arranged in a stack; A first planar sheet in contact with a first side of the stack; A second planar sheet in contact with a second side of the stack; A first structural member in compressive contact with the first planar sheet; And A second structural member in compressive contact with the second planar sheet, Wherein the compressive contact between the first structural member and the first planar sheet and the compressive contact between the second structural member and the second planar sheet together provide structural stiffness to the electrochemical cell unit assembly.

2. The electrochemical cell unit assembly according to claim 1, wherein the first structural member and the second structural member comprise pressure plates having small blocks configured to apply a compressive force to the first planar sheet and the second planar sheet.

3. The electrochemical cell unit assembly according to claim 2, wherein the small blocks have a first length at a position near the horizontal center of the electrochemical cell unit stack and a second length at a position near the horizontal edge of the electrochemical cell unit stack, and the first length is greater than the second length.

4. The electrochemical cell unit assembly according to claim 3, further comprising a clamp configured to apply a compressive force to the first structural member and the second structural member.

5. The electrochemical cell unit assembly according to claim 1, wherein the stack has a length-to-thickness aspect ratio of at least about 100.

6. The electrochemical cell unit assembly according to claim 1, wherein the first structural member and the second structural member each comprise a leaf spring configured to apply a compressive force to the first planar sheet and the second planar sheet.

7. The electrochemical cell unit assembly according to claim 1, further comprising a housing structure configured to house the structural members.

8. The electrochemical cell unit assembly according to claim 1, wherein the first structural member and the second structural member each comprise an inflatable bladder.

9. The electrochemical cell unit assembly according to claim 1, wherein the stack of electrochemical cell units has a length-to-thickness aspect ratio of at least about 20.

10. A method of forming an electrochemical cell unit assembly, the method comprising: Stacking a plurality of electrochemical cell units to form an electrochemical cell unit stack; Providing a first planar structure on a first side of the electrochemical cell unit stack; Providing a second planar structure on a second side of the electrochemical cell unit stack, the second side being opposite to the first side; Providing a first structural member on the first planar structure; And Providing a second structural member on the second planar structure to form the electrochemical cell unit assembly, Wherein the first structural member applies a force to the first planar structure and the second structural member applies a force to the second planar structure.

11. The method according to claim 10, further comprising: Arranging the plurality of electrochemical cell units, the first planar structure, the second planar structure, the first structural member, and the second structural member in a containment structure, wherein the containment structure applies a force to the first structural member and the second structural member such that the first structural member applies a force to the first planar structure and the second structural member applies a force to the second planar structure.

12. The method according to claim 10, wherein each of the first structural member and the second structural member comprises a plurality of small pieces, the plurality of small pieces having a first length near a horizontal center of the stack of the electrochemical cell units and a second length near a horizontal edge of the stack of the electrochemical cell units, the first length being greater than the second length.

13. The method according to claim 10, wherein each of the first structural member and the second structural member comprises a leaf spring.

14. The method according to claim 10, wherein each of the first structural member and the second structural member comprises an inflatable member.

15. The method according to claim 14, further comprising: Arranging the plurality of electrochemical cell units, the first planar structure, the second planar structure, the first structural member, and the second structural member in a containment structure; and Inflating the first structural member and the second structural member.

16. The method according to claim 10, wherein the stack of the electrochemical cell units has an aspect ratio of at least about 20:

1.

17. An electrochemical cell unit assembly, comprising: A plurality of electrochemical cell units arranged in a stack of electrochemical cell units; A planar structure disposed on the stack of the electrochemical cell units; and A structural member disposed on the planar structure, the structural member comprising at least one of a leaf spring, an inflatable member, a stiffening rib, a planar sheet including a plurality of small pieces, or a material sheet forming a honeycomb structure; wherein the structural member is configured to apply a compressive force to the planar structure.

18. The electrochemical cell unit assembly according to claim 17, wherein the stack of the electrochemical cell units has an aspect ratio of at least about 20:

1.

19. The electrochemical cell unit assembly according to claim 17, further comprising: A containment structure configured to contain and contact the structural member.

20. The electrochemical cell unit assembly according to claim 19, wherein the structural member comprises a planar sheet including a plurality of small pieces, and the containment structure comprises a clamp configured to clamp the planar sheet such that the small pieces of the planar sheet contact the planar structure.

21. The electrochemical cell unit assembly according to claim 20, wherein the plurality of small pieces have a first length near a horizontal center of the stack of electrochemical cell units and a second length near a horizontal edge of the stack of electrochemical cell units, and the first length is greater than the second length.

22. The electrochemical cell unit assembly according to claim 20, wherein the structural member includes a plurality of leaf springs, and the plurality of leaf springs are in a relaxed state when in a bent orientation and in a tension state when in a straight orientation.

23. The electrochemical cell unit assembly according to claim 17, wherein the structural member includes an inflatable member, and the electrochemical cell unit assembly further includes: a housing structure configured to house the stack of electrochemical cell units, the planar structure, and the structural member, and the housing structure has an elastic modulus higher than that of the structural member.

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