Open cell battery module with permeable electrode

Abstract

A battery module (400) of a static open cell single cell battery whose electrode elements (442, 443) of the same polarity can be electrically connected spaced apart from each other but in parallel and immersed in a common electrolyte cell (405) suspended from a common bus bar, and a battery cartridge (400) is additionally provided for receiving a plurality of electrode elements into the common electrolyte cell of the open cell battery. The electrode elements (442, 443) are alternating cathode elements (442) and anode elements (443). Methods of making the battery module are also described herein.

Description

[0001] Related applications This application claims priority and benefit to U.S. Provisional Application 63 / 526,821, filed July 14, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The battery module described herein is a static open cell battery that may have electrodes spaced apart from but electrically connected in parallel with other electrodes of the same polarity, and these electrodes are suspended from a common bus and immersed in a common electrolyte cell, and also has a battery box that receives multiple electrode elements into the common electrolyte cell of the open cell battery. Background Technology

[0003] Batteries containing liquid electrolytes present inherent challenges in sealing the electrolyte, which must be sealed both to the battery itself and to the individual cells within it. Specifically, this sealed battery design struggles to achieve low cost and high production volumes. In an early design, bipolar battery electrodes were assembled by linking individual modular subassemblies of cells or frames together in a manner repeated on the required number of cells in series in a bipolar electrode stack. Isolation between adjacent cells and between cells and the external environment was achieved through various linking methods, including compression sealing, infrared welding, laser welding, vibration welding, or adhesive sealing. This assembly paradigm limited manufacturing and automation options, as the externally facing seals resulted in low overall yields, and multiple sequential subprocesses could be involved in assembling a single stack. The number of modular parts assembled together necessitates a high level of process control and tolerances across multiple assembly steps, and the large number of complex modular parts that must be molded or otherwise manufactured increases the cost of the battery. Furthermore, all of the aforementioned linking methods typically employ rigid metal electrodes within the frame, which may provide chemical, thermal, and mechanical resistance to the assembly process.

[0004] In one aspect of early designs, the bipolar electrode was formed from a conductive plastic electrode. Other proposed battery designs for conductive plastic electrodes required the frame or battery casing to be co-injected with the conductive plastic electrode. However, the challenge with this technology is that it severely limits the materials that can be used for the conductive plastic electrode, as only a small fraction of the material can be injection molded.

[0005] Historically, the biggest challenge in implementing bipolar batteries has been sealing individual cells, including sealing them from the external environment and internally sealing them between adjacent cells. Designs that weld individual cells together require robust welding over a large surface area to seal the battery from the external environment, and gaskets or seals to internally seal them with adjacent cells. These sealing solutions can result in high variability, long assembly cycles, and large assembly equipment requirements. The construction of batteries with multiple cells may also require the use of separators, which increases battery size, cost, and design complexity.

[0006] Furthermore, in battery constructions with conductive plastic electrodes, the conductive plastic electrode material with optimal performance must also have a high proportion of conductive diluent relative to the amount of plastic. This conductive diluent typically contains carbon, graphite, metals, or other conductive materials. When the volume fraction of this diluent is high relative to the low-melting-point polymer, it is difficult to weld them together or injection mold them. Therefore, there is a search for simpler and cheaper construction and methods for batteries using liquid electrolytes, which are also more suitable for materials and methods used to construct such batteries at a lower cost. Summary of the Invention

[0007] This paper describes a static open-cell battery module in which conductive electrodes of the same polarity are electrically connected to each other via a common busbar. These electrodes are suspended from the busbar and immersed in a common electrolyte pool. A battery box is also included to receive the suspended electrodes into the common electrolyte pool. There is no separation or partitioning of the electrolyte between the common electrodes. The electrolyte in this open-cell battery can be zinc bromide, but other electrolytes can also be considered. Because all electrodes are suspended in a common electrolyte pool and are not sealed to each other, a single high-capacity cell is formed. This structure simplifies battery design and manufacturing, as each module requires only one cell. The module can be a single cell or multiple modules within a Battery Energy Storage System (BESS).

[0008] While flow batteries typically share a common electrolyte pumped through multiple cells, static batteries have historically been designed to physically / mechanically isolate the electrolyte of each individual cell from that of adjacent cells in the module.

[0009] Unlike bipolar batteries, the open-cell battery construction described in this paper does not have seals within the cell (the battery casing is described as an electrolyte tank) to define separate battery cells. This alternative construction provides the same energy density for the same amount of active material as a bipolar design (where one side of the bipolar electrode is the cathode and the other the anode), but eliminates the need for sealed electrodes to form a single battery cell. This design removes a key cost driver, a critical point of failure, and the entire subassembly from existing battery designs with multiple cells. Therefore, this design allows for simpler, more robust, and more cost-effective batteries without sacrificing performance. Furthermore, in this design, each porous electrode element has electrode elements of opposite polarity on both sides, rather than on only one side as in traditional bipolar designs. This design thus makes better use of the entire porous electrode element, which could otherwise be heavily biased towards the side closest to the opposite polarity electrode. This effect, coupled with the fact that the size and spacing of the electrode elements can be easily adjusted to achieve the desired performance in such designs, makes the battery performance reliable without the need for a separator between the anode and cathode elements (traditionally a porous membrane between the anode and cathode that allows certain ions to permeate but not others and / or molecules). This simplifies the battery construction and reduces manufacturing costs without compromising battery performance. This simplification stems from the fact that multiple different anode electrode elements and multiple different cathode electrode elements share a common electrolyte within the static battery cell. By designing the electrodes to be porous and eliminating separators, which are a major part of the static battery construction with multiple anode / cathode pairs, a shared electrolyte channel is achieved between all electrodes. The advantage of this construction over existing designs is that it allows a single cell to contain a large amount of electrode material and achieve extremely high capacity, while minimizing manufacturing complexity and eliminating the need for mechanical seals between cells.

[0010] Various aspects of this disclosure provide a sealed battery housing (i.e., a "battery case" herein) and a method of assembling it, the battery housing housing electrode elements within a common electrolyte pool. The battery case can be formed from a non-conductive elastomer or resin. Non-conductive battery cases can be formed using conventional techniques such as injection molding, extrusion, blow molding, rotational molding, etc. The interior of the bipolar battery case is configured to house the electrode elements in such a way that a continuous electrolyte pool is formed over the entire battery case. In one aspect, the battery case includes a plurality of separators extending laterally across the width of the battery case. The separators (and the electrode elements received therein) are housed within the battery case, which has a plurality of longitudinal plates, a plurality of transverse plates, a bottom plate, and a top. The separators are not seals. The separators ensure that the electrodes do not come into contact with each other, as such contact could cause a short circuit in the battery. The electrode elements can be cathodes or anodes. In one aspect, the battery has a plurality of cathode elements converging on a common cathode bus and a plurality of anode elements converging on a common anode bus. This forms a single cathode and a single anode that are electrically continuous but physically separated into multiple elements. This effectively connects the individual components in parallel rather than in series, forming a high-current battery instead of a high-voltage battery. Therefore, the battery will have a voltage at a single electrode, but it can maintain a current equal to the sum of the currents at each electrode.

[0011] In some aspects, the battery box is a single-piece (i.e., molded) box made of a non-conductive composite resin with an open interior for receiving electrode elements and other battery components. The non-conductive resin is a blend of one or more non-conductive polymers, which may include polypropylene, high-density polyethylene, polystyrene, polyphenylene oxide, polyvinyl chloride, or polyphenylene ether, or any other suitable thermoplastic material chemically compatible with the electrolyte used in the battery device. The material may be further blended with structural fillers (including glass fibers, glass beads, or silica powder), coloring materials (including carbon black or titanium dioxide), or flame retardants. In some aspects, the battery box may be injection molded or machined. In some aspects, the non-conductive composite resin may be a multi-layer coated article. In these aspects, the battery box substrate or base does not need to be thermoplastic.

[0012] The battery case houses multiple electrode elements, namely at least one anode element and at least one cathode element. To achieve the advantages of this design, a construction with multiple cathode elements and multiple anode elements is considered. In one aspect, at least some electrode elements have components made of sheets of non-conductive plastic containing pores to allow ion transport, wherein electrode materials are attached to both sides by methods such as hot pressing. In another aspect, the material used for the cathode is graphite felt or a graphite-like material with a high surface area. In another aspect, the material used for the anode or cathode element is carbon cloth or carbon foam. In addition to having a high surface area, the electrode materials are also porous to ensure that the material is sufficiently wetted by the electrolyte. Therefore, due to the porosity of the electrode elements, the electrolyte contained within the open-cell battery comes into contact with each electrode element. Thus, the battery case has at least two adjacent "cells" (i.e., anode and cathode elements separated by electrolyte), which are physically separate but placed in a common electrolyte pool (i.e., the electrolyte is not physically separated between the cells).

[0013] In another aspect, at least one or more electrode elements are constructed using a monolithic porous carbon or graphite material not fixed to a perforated plastic substrate. In this aspect, the amount of material used will be minimal, but the electrode elements are sufficiently secured to prevent excessive movement of any soft electrodes (such as felt), which would pose a risk of short circuit if the cathode comes into contact with the anode, and vice versa. In this aspect, the side separators within the housing-defined cylinder described herein can be used to maintain electrode separation. Furthermore, an electrical connection is required between the electrode elements and a busbar at the top of the battery compartment. Examples of busbars include wires or rods.

[0014] In cases where a separator is present inside the battery casing, each electrode element is received in a slot defined by the separator. The separator does not isolate the electrolyte in any way, as the electrodes are all suspended from the bus and immersed in the common electrolyte. The separator is provided solely to ensure that adjacent electrodes do not come into physical contact, which could cause a short circuit in the battery.

[0015] The conductive material used in the electrode elements can serve as both the electrode surface and the current collector, which transmits current to the top of the cell (i.e., the common bus). The current collector can have various configurations. Regardless of the configuration chosen, the current collector will be located at the top of the battery compartment.

[0016] This document describes a method for assembling a battery with a casing made of non-conductive plastic. Therefore, the casing can be molded or formed using other techniques such as 3D printing and welding. In one aspect, the battery casing defines a cylinder in which an electrolyte is contained. The cylinder may have non-conductive separators extending from its internal sides. Gap between the separators receives either an anode element or a cathode element. In one aspect, the electrode assembly is pre-formed by attaching electrode elements to a common busbar structure. The common busbar structure has a cathode busbar and an anode busbar. The cathode element is electrically connected to and structurally fixed to the cathode busbar, but insulated from and structurally attached to the anode busbar. The anode element is electrically connected to and structurally fixed to the anode busbar, but insulated from and structurally fixed to the cathode busbar. Conductive and non-conductive adhesives used to attach the electrode elements to the cathode and anode busbars are well known to those skilled in the art and will not be described in detail here. The electrode elements can also be attached to the busbar elements by sintering or welding.

[0017] Electrolyte can be added to the open-cell battery box before or after the electrode assembly is assembled to the battery box housing. In one approach, after the cylinder receives the electrolyte, a cover is placed on the battery box, and then the electrode assembly is assembled to the battery box. In another approach, the electrode assembly can be assembled to the battery box, and then the electrolyte is added. In yet another approach, the electrode assembly can be pre-formed with the battery cover and placed on the battery box before or after the electrolyte is added to the cylinder. The cover can be secured to the battery box by any conventional method, such as welding, thermoforming, adhesives, etc. Attached Figure Description

[0018] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0019] Figure 1 This is a perspective view of a molded battery box with electrode separators, based on one aspect of the open-cell battery assembly described herein.

[0020] Figure 2 This is a perspective view of a molded battery box without dividers.

[0021] Figures 3A to 3D This is a perspective view of the cover assembly, in which the cover assembly is filled with electrode elements.

[0022] Figure 4 The completed cap / electrode assembly is shown being inserted. Figure 2 In the battery compartment.

[0023] Figure 5 This is a perspective view of the electrode assembly, in which the molded battery box is shown in dashed lines.

[0024] Figure 6 A graph showing the voltage (top) and current (bottom) of the test cycle of the open-cell battery described herein is presented. Detailed Implementation

[0025] Embodiments of this disclosure are described in detail with reference to the accompanying drawings, wherein similar reference numerals identify similar or identical elements. It should be understood that the disclosed embodiments are merely examples of this disclosure and can be embodied in various forms. To avoid obscuring this disclosure with unnecessary detail, well-known functions or structures have not been described in detail. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as the basis for the claims and as a representative foundation for teaching those skilled in the art to use this disclosure in various ways within virtually any reasonably detailed structure.

[0026] I. Definition The terminology used herein is for describing specific exemplary configurations only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular terms “a,” “an,” and “the,” as used herein, may be intended to include the plural forms. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as having to be performed in the specific order discussed or shown, unless specifically specified as such. Additional or optional steps may be employed.

[0027] When an element or layer is described as “on another element or layer,” “attached to another element or layer,” “connected to another element or layer,” “linked to another element or layer,” or “coupled to another element or layer,” it may be directly on, attached to, connected to, linked to, or coupled to another element or layer, or there may be intermediate elements or layers present. In contrast, when an element is described as “directly on another element or layer,” “directly attached to another element or layer,” “directly connected to another element or layer,” “directly linked to another element or layer,” or “directly coupled to another element or layer,” there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “next to,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the related listed items.

[0028] The terms first, second, third, etc., may be used to describe various elements, components, regions, layers, and / or parts. These elements, components, regions, layers, and / or parts should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or part from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms do not imply sequence or order. Therefore, without departing from the teachings of the example configuration, the first element, component, region, layer, or part discussed below may be referred to as the second element, component, region, layer, or part.

[0029] The terms up, down, above, below, right, left, etc., are used herein to describe the position of various elements relative to other elements. These terms indicate the position of elements in an example configuration. However, those skilled in the art will understand that the frame assembly can be rotated in space without departing from this disclosure, and therefore these terms should not be used to limit the scope of this disclosure.

[0030] As used herein, the term "battery" includes an energy storage device that includes at least one electrochemical cell.

[0031] As used herein, the terms “electrochemical cell” or “cell” are used interchangeably to refer to a device capable of generating electrical energy through a chemical reaction or promoting a chemical reaction by introducing electrical energy.

[0032] As used herein, “electrolyte” refers to a substance that acts as an ionicly conductive medium. For example, an electrolyte facilitates the movement of electrons and cations within a battery cell. Electrolytes include mixtures of materials, such as aqueous solutions of metal halide salts (e.g., ZnBr2, ZnCl2, etc.).

[0033] As used herein, the term "electrode element" refers to a single conductive component of an electrode assembly. An electrode element can also refer to an anode element or a cathode element.

[0034] As used herein, the term "anode element" refers to the negative electrode element from which electrons flow during the battery discharge phase. The anode element is also the electrode element that undergoes chemical oxidation during the discharge phase. However, in rechargeable cells, the anode element is the electrode element that undergoes chemical reduction during the cell charging phase. Anode elements are formed from conductive or semiconductor materials, such as conductive plastics or composites, metals (e.g., titanium or aluminum), metal oxides, metal alloys, metal composites, semiconductors (e.g., TiC, SiC), and so on. Anode elements can be porous to allow electrolyte to flow through them, thoroughly wetting their surface area.

[0035] As used herein, the term "cathode element" refers to the positive electrode through which electrons flow during the battery discharge phase. The cathode element is also the electrode that undergoes chemical reduction during the discharge phase. However, in secondary or rechargeable cells, the cathode is the electrode that undergoes chemical oxidation during the cell charging phase. Cathodes are formed from conductive or semiconductor materials, such as conductive plastics or composites, metals (e.g., titanium or aluminum), metal oxides, metal alloys, metal composites, semiconductors (e.g., TiC, SiC), and so on. In one aspect, the cathode element has a component made of a sheet of non-conductive plastic, which is at least partially perforated to allow electrolyte flow, thereby increasing the surface area of ​​the cathode element wetted by the electrolyte.

[0036] The term "electrode assembly" refers to an assembly having multiple electrode elements, wherein a first portion of the electrode elements is electrically connected to a common anode bus and is at the same potential, and a second portion of the electrode elements is electrically connected to a common cathode bus and is at a common potential.

[0037] In a further aspect, the cathode element may at least comprise a substrate made of a sheet of non-conductive plastic containing pores that allow ion transport, with porous electrode material attached to both sides. The anode element may be formed of an electrode material similar to that of the cathode element, but the electrode material used for the anode element is optionally porous. The assembly secures the porous electrodes to the busbar. The electrodes may be welded or sintered. Any securing method is considered applicable. The electrode elements provide electrochemically active surfaces.

[0038] If the conductive material of the anode element / anode element is porous, then the porosity depends largely on the design choice. Those skilled in the art will understand that if the electrolyte will flow freely through and wet the conductive material, the conductive material needs to have a large open volume to support this goal. There will be a trade-off between open volume and performance (in terms of the degree of charge exchange between the electrode material and the electrolyte). In this regard, electrode materials with an open volume of at least about 50% can be considered. In some aspects, the open volume of the conductive material is about 80% (80) to about 99% (99). In other aspects, the open volume of the electrode material can be about 90% (90) to about 95% (95). In one aspect, the open volume of the cathode conductive material is about 90% (90) to about 95% (95).

[0039] II. Exemplary Structure This paper describes a battery with an electrode assembly having electrode elements made of a sheet of non-conductive plastic, on which a high surface area material, such as graphite felt, carbon cloth, carbon foam, etc., is placed. The electrode elements are suspended from a common bus structure in a non-conductive battery case that houses a common electrolyte pool in which the electrode elements are at least partially immersed. The battery described herein employs a design that alleviates the challenge of requiring seals and spacers between cells in multi-cell battery constructions. A single-cell construction requires only one common electrolyte pool in which all electrode elements are suspended from a common bus. In one aspect, the individual electrode elements are received in side slots defined by non-conductive separators. The separators do not isolate the electrolyte, nor do they create individual battery cells. The separators merely prevent contact between adjacent anode / cathode elements. In another aspect, the electrode assembly, consisting of electrodes, a cathode bus, anode bus, and a cover, is pre-formed and fixed as a single assembly to the non-conductive battery case housing. The cover is sealed to the housing, but the cathode and anode busbars extend out of the housing to allow the battery to be electrically connected to other devices or systems.

[0040] This design reduces costs and simplifies battery manufacturing by decreasing the total number of components to be manufactured in the battery casing or relaxing requirements on component material properties. Because it allows for assembly without sealing individual electrode elements, it also offers greater flexibility compared to using rigid metal electrodes, softer conductive plastic electrodes, or other bipolar electrode materials in the battery assembly. Overall, these advantages improve manufacturing yield, simplify manufacturing, and reduce the overall cost of the battery compared to other designs.

[0041] In one aspect, this paper describes the design of a static open-cell battery with an electrochemical cell within a molded cartridge and a method for assembling such a battery. In one aspect, the electrolyte is zinc bromide, but other electrolytes (e.g., zinc halides, etc.) are also considered. Combinations of zinc chloride, zinc iodide, or different halides are possible. This design can also be used with other aqueous electrolytes having sufficiently high conductivity. Aqueous electrolytes with sufficient conductivity are well known to those skilled in the art and will not be described in detail herein. Examples include electrolytes that release ions such as Na, Zn, K, Mg, Ca, and Al. See Zhang, H. et al., “Challenges and Strategies for High-Energy Aqueous Electrolyte Rechargeable Batteries”. Angew. Chem. Int. Volume 60, pp. 598-616 (2021), the contents of which are incorporated herein by reference.

[0042] After the battery case is filled with electrolyte, a cover with the electrode assembly can be welded (or otherwise attached) to the top of the molded case containing the electrodes. This design creates an open-cell battery that prevents electrolyte leakage from the bottom or sides because all electrodes are enclosed within the molded case, with only the top sealed (i.e., there are no potential leakage paths from the bottom or sides of the molded, one-piece, and monolithic battery case). Furthermore, this design allows for more efficient manufacturing compared to the assembly process of multi-cell batteries.

[0043] While this article describes zinc-bromine batteries, this description is illustrative and not limiting. The battery design and fabrication methods described herein can be used in any salt-based, static (i.e., non-flowing) zinc halide electrolyte battery chemistry system.

[0044] Furthermore, although this article describes the battery case as being made by molding or injection molding, the battery case can also be manufactured by machining or any other suitable conventional techniques for manufacturing plastic articles. Molding is a low-cost method with higher production volumes.

[0045] The battery case and separators come in various sizes and shapes, with separators separating electrodes without separating the electrolyte. The number and orientation of separators that may be included in the battery case depend largely on the design choices and the number of electrodes that need to be separated. Different methods for making external electrical contact with the anode and cathode buses are considered. Various methods for attaching / sealing the cover to the battery case after the electrodes are inserted and the electrolyte is filled are also considered. Various methods for creating vent valves or pressure relief valves on the case cover can be considered. Various methods for assembling a perforated, non-conductive plastic electrode substrate onto a high surface area graphite felt / carbon cloth / carbon foam are considered. As previously mentioned, the conductive electrode material can be porous to allow the electrolyte to flow freely and wet the high surface area conductive material assembled onto the perforated, non-conductive plastic electrode substrate. Various methods for attaching carbon material to the non-conductive plastic electrodes before inserting the electrodes into the case are considered. However, the battery case is now described in an illustrative manner.

[0046] As shown below, the two sides of the battery box are as follows: Figure 1 and Figure 2 As shown. Figures 3A-3D It is pending. Figure 2 The bottom view of the electrode assembly received by the battery box during assembly. Figure 4 yes Figures 3A-3D A perspective view of the electrode assembly when inserted into the molded battery box. Figure 5 It is an assembled open-cell battery.

[0047] After assembly, the cover is sealed onto the battery box, and the electrode assembly is suspended on the part of the cover facing the inside of the battery box. Figure 4The battery case cover is also shown, with the anode bus and cathode bus extending from the cover for external electrical connections.

[0048] Reference Figure 1 A molded battery case 100 is shown comprising multiple separators 106 enclosed within multiple longitudinal walls 102. As used herein, length is the direction through which individual cells pass, while width is the direction of the cell stack. The molded battery case also has multiple transverse walls (e.g., side walls) 103, a bottom wall 104, and a top 105. Each separator 106 provides a small local partition that prevents physical contact between the anode and cathode, thereby preventing short circuits. The separators form side openings 107 that do not separate the electrolyte contained in a common reservoir, with all electrodes at least partially immersed in the electrolyte. The bottom of the molded battery case may also have a separator 108.

[0049] Figure 2 An alternative embodiment of the molded battery case 101 is shown. This molded battery case also has longitudinal sidewalls 102, transverse walls 103, side walls 104, a bottom wall 104, and a top, but lacks... Figure 1 The separator shown.

[0050] refer to Figures 3A-3D It is an open-cell battery molding box ( Figure 5 The image shows a bottom view of an electrode assembly 200, which, when assembled, has multiple cathode elements 242 and anode elements 243. The battery case receiving the electrode assembly is a non-conductive box-shaped structure composed of a non-conductive composite resin. For example, the non-conductive resin can be a blend of one or more non-conductive polymers, including polypropylene, high-density polyethylene, polystyrene, polyphenylene oxide, or polyphenylene ether. This material can be further mixed with structural fillers (including glass fibers, glass beads, or silica powder), coloring materials (including carbon black or titanium dioxide), or flame retardants. In some embodiments, the battery case can be formed by injection molding, or it can be formed by machining, 3D printing, or other conventional methods used to form such a structure.

[0051] exist Figures 3A-3DIn the electrode assembly shown, cathode element 242 is electrically connected to and physically fixed to cathode bus 222, and physically fixed to but electrically isolated from anode bus 223. Anode element 243 is electrically connected to and physically fixed to anode bus 223, and physically fixed to but electrically isolated from cathode bus 222. The cathode element is provided with a contact piece 2421 that contacts cathode bus 222. The remainder of cathode element 242 is placed on spacer 225, which electrically isolates the cathode element from anode bus 223. Similarly, anode element 243 is provided with a contact piece 2431 that contacts anode bus 223. The remainder of anode element 243 is placed on spacer 225, which electrically isolates the anode element 243 from cathode bus 222. Cathode element 242 and anode element 243 are received in electrode socket 226 defined by a shallow separator formed in electrode assembly 200. The electrode assembly 200 also has a notch 227 in which the cathode busbar 222 and the anode busbar 223 are received. For example... Figure 3B As shown, the electrode assembly 200 exposes only the cathode bus 222 and anode bus 223 to the locations where they contact the corresponding terminals 2421 and 2431 of the cathode element 242 and anode element 243.

[0052] Reference Figure 4 The image shows a perspective view of the electrode assembly 300 about to be assembled into the battery box 400. Figures 3A-3D A molded battery case with an electrode assembly is shown, wherein cathode elements 342 and anode elements 343 are separated by shallow separators 301 formed in the electrode assembly 200. As described above, each cathode element 342 is connected together using a cathode bus 322, and each anode element 343 is connected together using an anode bus 323. As described above, the cathode elements 342 and anode elements 343 are permeable, and preferably highly permeable. As described herein, permeable electrode materials are described as having open volume or porosity. In one aspect, the cathode and anode have a non-conductive perforated substrate, typically plastic. As described above, the cathode element is formed by depositing a high surface area graphite felt on a perforated plastic substrate. The anode element is formed by depositing carbon cloth or carbon foam on a non-conductive perforated plastic substrate.

[0053] Reference Figure 5 In some aspects, Figures 3A-3DThe electrode assembly shown is inverted, and a top cover 451 suspending the cathode element 442 and anode element 443 is placed on the battery case housing 404 to form a battery. Inside the housing 404 is a pool 405 containing a common electrolyte into which the cathode element 442 and anode element 443 are immersed. As described above, the battery case interior may have side partitions to ensure that adjacent electrode elements do not contact each other. The battery case pool 405 receives the electrolyte, and the cathode element 442 and anode element 443 are received into the common electrolyte pool. The cover may be a suitably sized solid non-conductive resin sheet to seal the battery case. After assembly, the cover can be sealed to the battery case and external terminals using a sealing material (e.g., compression seal, elastomer, adhesive, etc.) or infrared, vibration, laser, or other known plastic welding methods. Sealing materials for battery cases are well known and will not be described in detail here. Suitable sealing materials provide a liquid / gas-tight seal, preventing electrolyte and headspace gas from escaping from the sealed battery case. The battery cover may include other features to facilitate the filling of the common electrolyte pool with electrolyte.

[0054] Figure 6 Two graphs are shown, illustrating the functional relationship between voltage (top) and current (bottom) and test time. Figure 6 The effectiveness of a battery design with a single common electrolyte cell as described in this paper is demonstrated.

[0055] Based on the foregoing and with reference to the various accompanying drawings, those skilled in the art will understand that certain modifications may be made to this disclosure without departing from its scope. While several embodiments of this disclosure are shown in the accompanying drawings, it is not intended to limit the disclosure thereto, as the intention is to define the scope of the disclosure as permissible in the art, and the specification shall be interpreted in the same manner. Therefore, the foregoing description should not be construed as limiting, but merely as examples of particular embodiments. Those skilled in the art will contemplate other modifications within the scope and spirit of the appended claims.

[0056] Although specific advantages have been listed above, various implementations may include some, none, or all of the listed advantages.

[0057] Other technical advantages will be readily apparent to those skilled in the art upon reading the following figures and description.

[0058] First, it should be understood that although exemplary embodiments are shown and described in the accompanying drawings, the principles of this disclosure can be implemented using any number of techniques, whether or not such techniques are currently known. This disclosure should in no way be limited to the exemplary embodiments and techniques shown and described in the following drawings.

[0059] Unless otherwise specified, the items depicted in the accompanying drawings are not necessarily drawn to scale.

[0060] Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of this disclosure. For example, components of the systems and apparatuses may be integrated or separated. Furthermore, the operation of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components, and the described methods may include more, fewer, or other steps. Moreover, the steps may be performed in any suitable order. As used herein, "each" means each member of a set or each member of a subset of a set.

Claims

1. A single-cell battery, comprising: A non-conductive housing defining the battery cell, the non-conductive housing being configured to receive a cover thereon; An electrode assembly comprising a plurality of cathode elements and a plurality of anode elements, wherein the cathode elements optionally comprise a perforated non-conductive substrate on which a high surface area conductive material is fixed, and the anode elements optionally comprise a perforated non-conductive substrate on which a high surface area conductive material is fixed, wherein the anode elements and cathode elements are supported by and extend therefrom a common cathode bus and a common anode bus, wherein the cathode elements are electrically connected and physically connected to the cathode bus and electrically insulated from the anode bus, and wherein the anode elements are electrically connected and physically connected to the anode bus and electrically insulated from the cathode bus; A storage tank containing a common electrolyte, wherein all said cathode and anode elements are at least partially immersed in the common electrolyte; and A cover, the electrode assembly extending from the cover into the cell defined by the housing, wherein the cover is secured to the housing to allow external electrical connection with the cathode bus and the anode bus, and wherein the cover is secured to the housing to form a liquid-tight seal.

2. The single-cell battery according to claim 1, wherein the high surface area conductive material is porous.

3. The single-cell battery according to claim 2, wherein the high surface area conductive cathode material is porous.

4. The single-cell battery according to any one of claims 1 to 3, wherein the anode comprises a conductive material or a semiconductor material.

5. The single-cell battery according to claim 4, wherein the conductive anode material is selected from the group consisting of conductive plastics, conductive composite materials, metals, metal oxides, metal alloys, and metal composite materials.

6. The single-cell battery according to claim 4, wherein the anode semiconductor material is selected from TiC or SiC.

7. The single-cell battery according to claim 5, wherein the metal is one of titanium or aluminum.

8. The single-cell battery according to claim 5, wherein the conductive composite material is selected from the group consisting of carbon felt, porous carbon, carbon cloth, carbon foam, and graphitized form of the conductive composite material.

9. The single-cell battery according to any one of claims 4 to 8, wherein the conductive anode material is porous.

10. The single-cell battery according to claim 9, wherein the porous conductive material has at least about 50% of the open volume.

11. The single-cell battery of claim 10, wherein the porous conductive material has an open volume of at least about 80% to about 99%.

12. The single-cell battery according to claim 3, wherein the porous cathode material is supported on a perforated non-conductive substrate.

13. The single-cell battery according to claim 12, wherein the porous cathode material is selected from the group consisting of carbon felt, porous carbon, carbon cloth, carbon foam, and the graphitized form of the conductive composite material.

14. The single-cell battery of claim 13, wherein the porous cathode material has an opening volume of at least about 50%.

15. The single-cell battery of claim 14, wherein the porous cathode material has an opening volume of at least about 80% to about 99%.

16. The single-cell battery of claim 15, wherein the porous conductive material has an open volume of at least about 90% to about 95%.

17. The single-cell battery according to claim 12, wherein the non-conductive substrate is selected from the group consisting of polypropylene, high-density polyethylene, polystyrene, polyphenylene oxide, and polyphenylene ether.

18. The single-cell battery according to any one of the preceding claims, wherein the casing and the cover are formed of non-conductive plastic.

19. The single-cell battery according to any one of the preceding claims, wherein the cell in the housing has a bottom surface and sidewalls, wherein a plurality of separators extend from at least one of the bottom surface or sidewalls, wherein the separators define slots that prevent contact between the cathode and adjacent anodes but do not prevent electrolyte contact with all electrode elements and cathode elements.

20. The single-cell battery according to any one of the preceding claims, wherein the electrolyte is present in an electrolyte reservoir.

21. The single-cell battery according to claim 20, wherein the electrolyte is a zinc halide solution.

22. The single-cell battery according to claim 20, wherein the electrolyte release is selected from sodium (Na) + ), Zinc (Zn) + ), potassium (K) + ), magnesium (Mg) + ), calcium (Ca + ) and aluminum (Al) + The group of metal ions.

23. The single-cell battery according to any one of the preceding claims, wherein there is no physical barrier in the electrolyte reservoir that electrically isolates a portion of the common electrolyte from another portion of the common electrolyte.

24. A method for assembling a single-cell battery, comprising: A non-conductive housing is provided for defining the battery cell, the non-conductive housing being configured to receive a cover thereon; An electrode assembly is provided comprising a plurality of cathode elements and a plurality of anode elements, wherein the cathode elements optionally comprise a perforated non-conductive substrate on which a high surface area conductive material is fixed, and the anode elements optionally comprise a perforated non-conductive substrate on which a high surface area conductive material is fixed, wherein the anode elements and cathode elements are supported by and extend therefrom a common cathode bus and a common anode bus, wherein the cathode elements are electrically connected and physically connected to the cathode bus and electrically insulated but physically connected to the anode bus, and wherein the anode elements are electrically connected and physically connected to the anode bus and electrically insulated and physically connected to the cathode bus; Electrolyte is added to a single electrolyte reservoir, in which all the cathode and anode elements are at least partially immersed; and A cover is provided, the electrode assembly extending from the cover into the cell defined by the housing, wherein the cover is secured to the housing to allow external electrical connection with the cathode bus and the anode bus, and wherein the cover is secured to the housing to form a liquid-tight seal.

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