Nickel-hydrogen battery configuration for grid-scale energy storage

Abstract

A metal-hydrogen battery is proposed. The battery includes: a bridgeless CPV superstack having K cells, each cell comprising a first layer and a second layer, wherein the first layer comprises L / 2 intermediate anode-cathodes, and wherein the second layer comprises end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes; a pressure vessel encapsulating the bridgeless CPV superstack; and an electrolyte within the pressure vessel. The bridgeless CPV superstack comprises K cells, each cell comprising a first layer and a second layer, wherein the first layer comprises L / 2 intermediate anode-cathodes, and wherein the second layer comprises end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

Description

[0001] Related applications

[0002] This application claims priority to U.S. non-provisional application No. 18 / 987,378 entitled “Nickel-Hydrogen Battery Configurations for Grid-Scale Energy Storage”, filed December 19, 2024; U.S. provisional application No. 63 / 614,260 entitled “Nickel-Hydrogen Battery Configurations for Grid-Scale Energy Storage”, filed December 22, 2023; and U.S. provisional application No. 63 / 658,165 entitled “Nickel-Hydrogen Battery Configurations for Grid-Scale Energy Storage”, filed June 10, 2024, each of which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to metal-hydrogen batteries, and more specifically, to a common pressure vessel (CPV) configuration for metal-hydrogen batteries for grid-scale energy storage. Background Technology

[0004] To enable renewable energy sources such as wind and solar power to compete with traditional fossil fuels, large-scale energy storage systems are needed to mitigate their inherent intermittency. Cost and long lifespan are primary considerations for constructing large-scale energy storage. Currently, pumped hydro storage dominates the grid-scale energy storage market due to its inexpensive long-term (approximately 50 years) storage of large amounts of energy, but it is constrained by a lack of suitable sites and environmental footprint. Other technologies, such as compressed air and flywheel storage, also exhibit some different advantages, but their relatively lower efficiency and higher cost should be significantly improved for grid-scale energy storage. Rechargeable batteries offer a good opportunity for low-cost, high-capacity, and highly reliable systems for large-scale energy storage. Improving the reliability of rechargeable batteries and reducing their cost have become important issues for realizing large-scale energy storage.

[0005] One of the main factors contributing to the cost of manufacturing metal-hydrogen batteries is the cost of the container housing the batteries and the additional cost of the connectors used in battery stacking. Therefore, there is interest in providing container and battery configurations with fewer components that reduce overall cost and simplify the manufacturing of metal-hydrogen batteries. Summary of the Invention

[0006] According to some embodiments of this disclosure, a metal-hydrogen battery is proposed. The metal-hydrogen battery includes: a bridgeless CPV superstack having K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes; a pressure vessel encapsulating the bridgeless CPV superstack; and an electrolyte within the pressure vessel.

[0007] In some embodiments, each end anode in the end anodes includes one or more layers of anode material connected to an anode tab. In some embodiments, each end cathode in the end cathodes includes one or more layers of cathode material connected to a cathode tab and a diaphragm material covering the cathode material, wherein the diaphragm material includes a wall core. In some embodiments, each intermediate anode-cathode in the intermediate anode-cathodes includes: an anode having one or more layers of anode material connected to one or more layers of cathode material via a metal sheet; and a diaphragm material covering the cathode material, wherein the diaphragm material includes a wall core. In some embodiments, the bridgeless CPV super stack also includes a first cell plate and a second cell plate, the first cell plate and the second cell plate being on either side of the K cells and connected by an arm. In some embodiments, the K cells are compressed before the first cell plate and the second cell plate are connected to the arm. In some embodiments, the end anode includes an anode tab and the end cathode includes a cathode tab, and also includes an anode end bridge engaging with the anode tab of each of the K cells and a cathode end bridge engaging with the cathode tab of each of the K cells. In some embodiments, each of the anode end bridge and the cathode end bridge includes a feedthrough conductor extending through the pressure vessel.

[0008] Furthermore, this disclosure proposes a method for providing a battery. In some embodiments, the method includes: forming a bridgeless CPV superstack of K cells by alternately stacking K first layers and K second layers, each separated by a separator, wherein each first layer includes L / 2 anode-cathode pairs and each second layer includes L / 2-1 anode-cathode pairs, an end anode, and an end cathode; encapsulating the bridgeless CPV superstack in a pressure vessel; and adding an electrolyte to the pressure vessel.

[0009] In some embodiments, the method further includes forming K end anodes, wherein each end anode includes one or more layers of anode material connected to an anode tab. In some embodiments, the method further includes forming K end cathodes, wherein each end cathode includes one or more layers of cathode material connected to a cathode tab, and wherein a diaphragm material covers the cathode material, the diaphragm material including a wall core. In some embodiments, the method further includes forming K*(L-1) intermediate anode-cathodes, wherein each intermediate anode-cathode includes: an anode having one or more layers of anode material connected to one or more layers of cathode material via a metal sheet, and wherein a diaphragm material covers the cathode material, the diaphragm material including a wall core. In some embodiments, forming a stack of K units includes: providing a first cell plate on which K first layers and K second layers are stacked; and providing a second cell plate above the K first layers and K second layers. In some embodiments, forming a stack of K units includes: compressing between the first cell plate and the second cell plate; and connecting the first cell plate to the second cell plate via an arm extending between the first cell plate and the second cell plate. In some embodiments, each of the K end anodes includes an anode tab, and each of the K end cathodes includes a cathode tab, and the system further includes: engaging an anode end bridge to the anode tab of each of the K units; and engaging a cathode end bridge to the cathode tab of each of the K units. In some embodiments, each of the anode end bridge and the cathode end bridge includes a feedthrough conductor extending through the pressure vessel.

[0010] In addition, a bridgeless CPV super stack is proposed. The bridgeless CPV super stack includes K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

[0011] In some embodiments, the bridgeless CPV super stack includes a first cell plate and a second cell plate separated by K cells. In some embodiments, the bridgeless CPV super stack includes bushings between the first cell plate and the K cells and between the second cell plate and the K cells. In some embodiments, the end anode and end cathode each include tabs, and further include a cathode end bridge coupled through the tab of the end cathode and an anode end bridge coupled through the tab of the end anode.

[0012] In addition, a method for forming a bridgeless CPV superstack is also included. In some embodiments, the method includes stacking K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

[0013] In some embodiments, stacking K cells includes stacking K cells between a first cell plate and a second cell plate. In some embodiments, the method further includes providing bushings between the first cell plate and the K cells and between the second cell plate and the K cells. In some embodiments, the end anode and the end cathode each include tabs, and the method further includes connecting a cathode end bridge through the tab of the end cathode and connecting an anode end bridge through the tab of the end anode.

[0014] In some embodiments, a metal-hydrogen battery includes: an assembled cell chain including an overmolded cell tray; a superstack having K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes, and wherein each end cathode includes a cathode tab and each end anode includes an anode tab, the superstack being assembled on the overmolded cell tray; an overmolded end plate separated by an overmolded cell plate, the overmolded end plate being positioned above the superstack; and a cell arm connecting the overmolded cell tray to the overmolded end plate and the overmolded cell plate to compress the superstack; and a first bridge and a second bridge, the first bridge being connected to all cathode tabs and the second bridge being connected to all anode tabs.

[0015] In some embodiments, a diaphragm is inserted between the anode of the end cathode and the anode of the intermediate anode-cathode, and between the cathode material and the anode material in the intermediate anode-cathode. In some embodiments, a first diaphragm is disposed between the overmolded cell tray and the super-stack, and a second diaphragm is disposed between the super-stack and the overmolded end plate and the overmolded cell plate. In some embodiments, one or both of the first bridge and the second bridge include a spring portion for providing stress relief. In some embodiments, the first bridge includes a burst pressure relief feeder. In some embodiments, the second bridge includes a filler feeder that allows for annular filler filling.

[0016] In some embodiments, the battery includes a bushing into which an assembled cell chain is inserted. In some embodiments, the bushing is a tube formed of a material having an ethyl vinyl alcohol (EVOH) layer sandwiched between polymer layers, the EVOH layer impeding hydrogen transport. In some embodiments, the battery also includes caps located on each side of the assembled cell chain, wherein the caps and the assembled cell chain are laser-welded to the bushing.

[0017] The battery also includes electrolyte applied via an annular filling portion. In some embodiments, a feedthrough filling portion sleeve is applied over the feedthrough filling portion. In some embodiments, an insulating ring is also applied over the feedthrough. In some embodiments, the battery includes a wrapping layer around a bushing and a cap.

[0018] A method for manufacturing a battery according to some embodiments of the present disclosure includes: assembling a component including an end anode, an end cathode, an intermediate anode-cathode, a molded cell tray, a molded end plate, and a molded cell plate; assembling a cell chain by stacking the end anode, end cathode, and intermediate anode-cathode on the molded cell tray to form a super-stack having K units, and placing molded end plates separated by molded cell plates on top of the super-stack, each unit including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes L / 2-1 intermediate anodes. - Cathode-separated end anodes and end cathodes, wherein each end cathode includes a cathode tab and each end anode includes an anode tab, super-stacked and assembled on an overmolded cell tray; compressing the cell chain and securing the overmolded cell tray to the overmolded end plate and overmolded cell plate via cell arms; applying a top support to the cell chain; applying bridges to the cell chain to form an assembled cell chain; inserting the assembled cell chain together with a cap into a bushing; welding the cap and the assembled cell chain to the bushing; wrapping the bushing and the assembled cell chain; injecting electrolyte through an annular filling section; adding a feedthrough filling section sleeve; crimping feedthroughs onto each bridge in the bridges; and adding feedthrough insulating rings.

[0019] Other embodiments are envisioned and described below. Attached Figure Description

[0020] Certain features of various embodiments of the present technology are specifically described in the appended claims. The features and advantages of the present technology will be better understood by referring to the following detailed description and accompanying drawings, which set forth illustrative embodiments utilizing the disclosed principles, in which:

[0021] Figure 1A , Figure 1B , Figure 1C , Figure 1D and Figure 1E The previously disclosed Individual Pressure Vessel (IPV) is depicted.

[0022] Figure 2A and Figure 2B A bridgeless CPV superstack according to an embodiment of the present disclosure is shown.

[0023] Figure 3A , Figure 3B , Figure 3C and Figure 3D It shows Figure 2A The components shown are bridgeless CPV super-stacked components.

[0024] Figure 4A and Figure 4BA first example of a bridgeless CPV super-stacked cell board and cell board structure according to some embodiments of the present disclosure is shown.

[0025] Figure 5 The assembly of an assembly of a bridgeless CPV superstack using the cell board shown in FIG4 is illustrated according to some embodiments of the present disclosure.

[0026] Figure 6A , Figure 6B , Figure 6C and Figure 6D The various steps in constructing a bridgeless CPV superstack according to some embodiments of this disclosure are illustrated.

[0027] Figure 7 The process for constructing a bridgeless CPV superstack according to some embodiments of the present disclosure is illustrated.

[0028] Figure 8A , Figure 8B , Figure 8C , Figure 8D and Figure 8E It shows the use of Figures 2A to 7 The performance of the first example battery in the bridgeless CPV super stack is shown.

[0029] Figure 9A , Figure 9B , Figure 9C , Figure 9D and Figure 9E It shows the use of Figures 2A to 7 The second example battery shown is a bridgeless CPV super stack.

[0030] Figure 10A , Figure 10B , Figure 10C , Figure 10D , Figure 10E , Figure 10F and Figure 10G It shows the use of Figures 2A to 7 The third example battery of a bridgeless CPV super stack is shown.

[0031] Figure 11A , Figure 11B , Figure 11C and Figure 11D The use of, as shown Figures 2A to 7 The fourth example battery of the bridgeless CPV superstack embodiment shown.

[0032] Figure 12A , Figure 12B , Figure 12C , Figure 12D , Figure 12E and Figure 12F Another example end anode is shown according to some embodiments of the present disclosure.

[0033] Figure 13A , Figure 13B , Figure 13C , Figure 13D , Figure 13E , Figure 13F and Figure 13G Another example of an end cathode with a diaphragm bag according to some embodiments of the present disclosure is shown.

[0034] Figure 14A ,picture Figure 14B , Figure 14C , Figure 14D , Figure 14E , Figure 14F , Figure 14G , Figure 14H , Figure 14I , Figure 14J , Figure 14K , Figure 14L , Figure 14M and Figure 14N Another example of an intermediate anode-cathode with a diaphragm bag on the cathode, according to some embodiments of the present disclosure, is shown.

[0035] Figure 15A and Figure 15B The use of some embodiments according to this disclosure is illustrated. Figures 11A to 14M The assembly of the super-stacked electrodes is shown.

[0036] Figure 16 An assembly of a battery cell chain according to some embodiments of the present disclosure is shown.

[0037] Figure 17A , Figure 17B , Figure 17C and Figure 17D Examples of battery cells according to some embodiments of the present disclosure are shown.

[0038] Figure 18A , Figure 18B , Figure 18C , Figure 18D , Figure 18E and Figure 18F Examples of overmolded battery cells according to some embodiments of the present disclosure are shown.

[0039] Figure 19A , Figure 19B , Figure 19C , Figure 19D , Figure 19E and Figure 19F Examples of overmolded end cells according to some embodiments of the present disclosure are shown.

[0040] Figure 20A , Figure 20B , Figure 20C , Figure 20D , Figure 20E , Figure 20F , Figure 20G , Figure 20H and Figure 20I An example of an overmolded battery cell tray according to some embodiments of the present disclosure is shown.

[0041] Figure 21A , Figure 21B , Figure 21C , Figure 21D , Figure 21E , Figure 21F and Figure 21G Examples of forming a cell tray according to some embodiments of the present disclosure are shown.

[0042] Figure 22A , Figure 22B , Figure 22C , Figure 22D , Figure 22E and Figure 22F An assembly of a battery cell chain according to some embodiments is shown.

[0043] Figure 23A , Figure 23B , Figure 23C , Figure 23D and Figure 23E An assembly of a battery cell chain according to some embodiments of the present disclosure is shown.

[0044] Figure 24A , Figure 24B , Figure 24C , Figure 24D , Figure 24E and Figure 24F This disclosure illustrates some embodiments that can be applied to Figures 23A to 23E The top support of the battery cell chain shown.

[0045] Figure 25A and Figure 25B This disclosure illustrates some embodiments that can be applied to Figures 23A to 23E An example of a bridge in a battery cell chain is shown.

[0046] Figure 26A , Figure 26B , Figure 26C , Figure 26D , Figure 26E , Figure 26F , Figure 26G , Figure 26H , Figure 26I , Figure 26J , Figure 26K , Figure 26L and Figure 26M It shows Figure 25AThe components and construction of the example bridge are shown.

[0047] Figure 27A , Figure 27B , Figure 27C , Figure 27D , Figure 27E , Figure 27F , Figure 27G , Figure 27H and Figure 27I As shown Figure 25B The components and construction of an example bridge with stress relief are shown.

[0048] Figure 28A , Figure 28B , Figure 28C , Figure 28D , Figure 28E , Figure 28F , Figure 28G , Figure 28H , Figure 28I and Figure 28J This disclosure illustrates some embodiments of the ability to interact with... Figure 25A and Figure 25B The bridge shown is used together with a feeder that provides overvoltage protection.

[0049] Figure 29A , Figure 29B , Figure 29C , Figure 29D , Figure 29E , Figure 29F , Figure 29G and Figure 29H This disclosure illustrates some embodiments of the ability to interact with... Figure 25A and Figure 25B The bridge shown is used together to provide a feed passage for the annular filling section of the pressure vessel.

[0050] Figure 30A , Figure 30B , Figure 30C , Figure 30D and Figure 30E The above illustrates the use of some embodiments according to this disclosure. Figures 12A to 29H The assembly of the battery structure shown.

[0051] Figure 31A , Figure 31B , Figure 31C and Figure 31D Examples of bushings according to some embodiments of this disclosure are shown.

[0052] Figure 32A and Figure 32B Examples of end caps according to some embodiments of the present disclosure are shown.

[0053] Figure 33A , Figure 33B , Figure 33C , Figure 33D , Figure 33E , Figure 33F , Figure 33G and Figure 33H It shows Figure 32B The example shown is an overmolded end cap.

[0054] Figure 34A , Figure 34B , Figure 34C and Figure 34D An example of welding the bushing to the end cap is shown.

[0055] Figure 35A , Figure 35B , Figure 35C and Figure 35D An example of a feedthrough filling sleeve according to some embodiments of the present disclosure is shown.

[0056] Figure 36A , Figure 36B , Figure 36C and Figure 36D An example of a feedthrough insulating ring according to some embodiments of the present disclosure is shown.

[0057] Figure 37 Assembly methods according to some embodiments of the present disclosure are shown. Detailed Implementation

[0058] In the following description, specific details are set forth in order to provide a thorough understanding of various embodiments of the present disclosure. However, those skilled in the art will understand that the present disclosure may be practiced without these details. Furthermore, while various embodiments of the present disclosure are disclosed herein, many adjustments and modifications may be made within the scope of the present disclosure based on common general knowledge known to those skilled in the art. Such modifications include replacing any aspect of the present disclosure with known equivalents in order to achieve the same results in substantially the same manner.

[0059] Unless the context otherwise requires, throughout this specification and the claims, the word “comprising” and its variations (e.g., “including” and “contains”) shall be interpreted in an open, inclusive sense (i.e., “including but not limited to”). Throughout this specification, descriptions of numerical ranges of values ​​are intended as a convenient way of referring separately to each individual value falling within that range (including the value defining the range), and each individual value is incorporated herein as if it were described separately herein. Furthermore, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” include plural indicators.

[0060] Throughout this specification, references to "an embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of this disclosure. Therefore, throughout this specification, the phrases "in one embodiment" or "in an embodiment" appearing in various places do not necessarily refer to the same embodiment, but may refer to the same embodiment in some cases. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0061] Terms such as “top,” “bottom,” “left,” “right,” “above,” “below,” or other directional references are relative to the accompanying drawings and are not intended to be absolute. These references should be interpreted as relative to the accompanying drawings in question and are not intended to be limiting.

[0062] Metal-hydrogen batteries can be configured in various ways. In each case, the battery itself includes one or more electrode stacks, each electrode stack having a series of electrodes (alternating layers of cathode and anode materials) separated by an electrically insulating membrane. The electrode stacks filled with electrolyte are housed in one or more pressure vessels. The electrode stacks can provide an array of cells (i.e., cathode and anode electrode pairs) capable of being electrically coupled in series or parallel. Each electrode stack can be arranged such that the cells formed in the array of electrodes are coupled in parallel. According to embodiments of this disclosure, an electrode stack formed by a stacked arrangement of series-coupled components and housed in a common pressure vessel (CPV) is proposed.

[0063] The common pressure vessel (CPV) described herein refers to a large battery in which multiple electrodes connected in series, in parallel, or both are stacked and encapsulated within a common pressure vessel. (Similar to...) Figure 1A Compared to a single pressure vessel (IPV) or a group of IPVs with the same energy capacity, a CPV has fewer components (such as end caps, feedthroughs, filling ports, buses, wiring, BMS, etc.) and fewer solder joints, exhibiting lower weight and cost. Although inter-stack bridge connections can be used in series coupling to the underlying cells... Figure 1A The stack shown is different, but embodiments of this disclosure provide a more efficient arrangement. An embodiment of the CPV according to this disclosure includes a stack formed by a combination of series and parallel-oriented anode / cathode combinations, which eliminates the need for inter-stack bridging connections. This further reduces weight and material used in battery production, thereby simplifying superelectrode stack production while improving performance.

[0064] Figures 1A to 1DIPV and a prior IPV-based CPV configuration are illustrated, which was previously proposed in U.S. Patent Application 17 / 898,098, filed August 29, 2022, entitled “Nickel-Hydrogen Battery Configurations for Grid-Scale EnergyStorage,” which is incorporated herein by reference in its entirety. The embodiments disclosed herein eliminate the bridges shown in that patent application that couple a series of individually parallel-oriented stacks in series.

[0065] Figure 1A A schematic diagram of a stand-alone pressure vessel (IPV) metal-hydrogen battery 100 is depicted. The metal-hydrogen battery 100 includes an electrode stack assembly 101 comprising stacked electrodes spaced apart by a separator 106. The electrodes include an anode 102 and a cathode 104. The separator 106 is located between the cathode 102 and the anode 104. Each pair of cathode 102 and anode 104 electrodes can be considered as a cell or a power source. The electrode stack 101 may also include a frame 110 that holds the cathode 102, anode 104, and separator 106 in place. Figure 1A In the specific example shown, there are anodes 104 adjacent to frame 106 on the top and bottom of stack 101; however, other arrangements may also be formed.

[0066] Electrode stack 101 can be housed in pressure vessel 108. Pressure vessel 108 can contain electrolyte 126 and hydrogen gas. Cathode 102, anode 104, and diaphragm 106 are porous to allow electrolyte 126 to flow between cathode 102 and anode 104. Electrode stack 101 is filled with electrolyte 126. In some embodiments, diaphragm 106 can be omitted, as long as cathode 102 and anode 104 can be isolated from each other. For example, the space occupied by diaphragm 106 can be filled with electrolyte 126. Metal-hydrogen battery 100 may also include a filling tube 122 configured to exchange electrolyte or gas (e.g., hydrogen gas) with pressure vessel 108.

[0067] like Figure 1A As shown, the electrode stack 101 includes multiple stacked layers of alternating anodes 102 and cathodes 104 separated by diaphragms 106 in separate pressure vessels (IPVs). The electrode stack 101 includes at least one pair of anodes 102 and cathodes 104. Cells can be formed in pairs from the cathode 102 and anode 104 layers. Although the cells in the electrode stack assembly 101 can be coupled in parallel or in series, Figure 1A In the example of battery 100 shown, the cells are coupled in parallel. Specifically, each cathode in cathode 102 is coupled to bridge conductor 118, and each anode in anode 104 is coupled to bridge conductor 116. Although Figure 1AThe filling tube 122 is shown located on one side of the anode bridge conductor 116, but it may alternatively be placed on one side of the cathode bridge conductor 118, or placed in the side wall of the pressure vessel 108. The filling tube 122 may include one or more valves (not shown), or may be otherwise sealed after the pressure vessel 108 has been filled with electrolyte 126 at the working level.

[0068] In addition, Figure 1A In the example, pressure vessel 108 is shown as a cylindrical container housing a single electrode stack 101. According to embodiments of this disclosure, pressure vessel 108 can be of any shape large enough to accommodate multiple electrode stacks 101 and maintain the pressures involved during operation. Furthermore, in Figure 1A In the diagram, electrode stack 101 is shown oriented along the length of pressure vessel 108. However, electrode stack 101 can be arranged such that the electrodes are alternatively oriented laterally. Thus, electrode stack 101 can be of any shape, have any number of cells, and have any orientation relative to pressure vessel 108.

[0069] like Figure 1A As further shown, the bridge conductor 116, coupled to the anode 104, is electrically coupled to an anode feedthrough terminal 120, which may represent the negative terminal of the battery 100. Terminal 120 may include an insulating feedthrough to allow extension of terminal 120 to the outside of the pressure vessel 108, or the bridge conductor 116 may be directly connected to the pressure vessel 102. Similarly, the cathode conductor 118, coupled to the cathode 102, may be coupled to a cathode feedthrough terminal 124, which represents the positive side of the battery 100. Terminal 124 also extends through an insulating feedthrough to allow extension of terminal 124 to the outside of the pressure vessel 108.

[0070] As discussed above, each cell included in the electrode stack 101 includes a cathode 102 and an anode 104 separated by a diaphragm 106. The electrode stack 101 is located in a pressure vessel 108, wherein an electrolyte 126 can flow between the cathode 102 and the anode 104. As discussed further below, the cathode 102 is formed of a conductive substrate coated with a metal compound. Similarly, the anode 104 is formed of a porous conductive substrate coated with a porous catalyst. The diaphragm 106 is a porous insulator that separates the alternating layers of the cathode 102 and the anode 104 and allows the electrolyte 126 to flow between the cathode 102 and the anode 104. In some embodiments, the electrolyte 126 is an alkaline (pH greater than 7) aqueous electrolyte. Each of the anode 104 and the cathode 102 can be formed as an electrode assembly with a multilayer structure.

[0071] Figure 1AA schematic diagram of an IPV-configured metal-hydrogen battery 100 including an electrode stack 101 is depicted. The electrode stack 101 includes at least one layer comprising an anode 102, a cathode 104, and a separator 106 disposed between the anode 102 and the cathode 104. The layer 101 is housed within a housing 108. An electrolyte 126 is disposed within the housing 108. The cathode 102, anode 104, and separator 106 are porous to allow the electrolyte 126 to flow between the cathode 102 and the anode 104. The pressure vessel 108 of the metal-hydrogen battery 100 also includes a filling tube 122 configured to exchange hydrogen and electrolyte 126 with the interior of the housing 108.

[0072] According to some embodiments, a configuration of the battery layer entirely contained within a container is proposed. As further discussed below, some embodiments may include a Ni-H2 cell comprising a nickel hydroxide cathode, an H2 catalytic anode, and a porous membrane impregnated in 5% to 50% potassium hydroxide, all sealed within a metal pressure vessel, although other configurations as discussed above are also possible. A typical cell design includes multiple pairs of cathodes and anodes separated by porous membranes, with each pair connected in parallel, such as... Figure 1A As shown. This configuration is known as a separate pressure vessel or IPV design. The IPV design allows for high capacity, but under typical conditions only achieves a nominal discharge voltage of 1.25V. The pressure vessel 108 is leak-free and can withstand pressures greater than 1000psi, which is a major cost factor for Ni-H2 cells.

[0073] An embodiment of the electrode stack 101 shown above, used in a standalone pressure vessel (IPV) configuration, is described in more detail in U.S. Patent Application 17 / 830,193, filed June 1, 2022, entitled “Electrode Stack Assembly for a Metal Hydrogen Battery,” which is incorporated herein by reference. Another embodiment of the electrode stack 101 is described in U.S. Patent Application 17 / 687,527, filed March 4, 2022, entitled “Electrode Stack Assembly for a Metal Hydrogen Battery,” which is also incorporated herein by reference in its entirety. These and other electrode stacks can be used in embodiments of this disclosure as discussed below.

[0074] like Figure 1AThe multiple electrode stacks 101 shown can be electrically coupled in series via bridges and housed in a CPV pressure vessel to form a CPV-configured cell. Specifically, each electrode stack in the electrode stacks 101 includes bridge conductors that can be easily soldered to corresponding bridge conductors of adjacent electrode stacks 101 when the electrode stacks 101 are aligned. These bridge conductors between adjacent stacks 101 act as bipolar plates (i.e., the anode bridge of one stack is connected to the cathode bridge of the adjacent stack). Figure 1B A construction using multiple stacks 101 connected in series is shown.

[0075] Figure 1B The above shows about Figure 1A The alignment of N electrode stacks 101 (electrode stacks 101-1 to 101-N) is described. Figure 1B As shown, electrode stacks 101-1 to 101-N are arranged in series to form a stack arrangement 130, wherein the anode of one electrode stack 101 is coupled to the cathode of an adjacent electrode stack 101 using a bridge 140. Figure 1B In the example shown, bridge 134-1 is coupled to terminal bar 138. Bridge 132-N is coupled to terminal bar 136.

[0076] Figure 1C A bridge conductor 140 is shown, which is an example of one of bridge conductors 134 or 132. In the example embodiment shown here, bridge conductor 140 includes a bridge frame 142 that can be configured to cooperate with an isolator that helps to isolate bridge conductor 140 from the components of stack 101. Additionally, bridge frame 144 is configured to be mechanically connected (e.g., welded) to bridge frames 144 of adjacent electrode stacks 101 within the electrode stack 101, or as such. Figure 1B Terminal bars such as the terminal bars shown. In some embodiments, bridge frame 144 is configured to stack with other bridge frames 144.

[0077] exist Figure 1C In the embodiment of the bridge conductor 140 shown, a slot 142 is formed in the bridge conductor 140. The slot 142 is configured to receive a tab formed in the anode or cathode of the stack 101. The tab is inserted into the slot 142 to form a bridge 134 or bridge 132, as... Figure 1B As shown.

[0078] like Figure 1B As shown, the stacked arrangement 130 can be formed by soldering bridge conductor 134 to bridge conductor 132 to form a series arrangement 130. Feed conductors can be soldered to bridge conductor 134-1 and bridge conductor 132-N.

[0079] Figure 1D As shown Figure 1BThe CPV configuration of battery 150 is shown. As shown, N stacks 101-1 to 101-N are assembled such that bridge conductors 134 and 132 are soldered to form inter-stack connections 152-1 to 152-(N-1), as... Figure 1B As shown in the figure, configuration 130 is encapsulated within a pressure vessel 154, wherein feedthrough conductors 138 and 136 extend through the pressure vessel 154. Figure 1D As shown, there are N stacked units connected in series. Figure 1D In the specific example shown, N=6.

[0080] Figure 1E As shown Figure 1D The electrical representation of battery 150 shown is 160. (As shown) Figure 1E As shown and as above regarding Figure 1A The stacks discussed, each in stack 101, include multiple pairs of cathodes 102 and anodes 104, represented as sources 162 coupled in parallel. N stacks 101 are coupled in series at inter-stack connections 152 and to feedthroughs 138 and 136. However, the configuration of this cell 150 requires the presence of inter-stack connections 152, which necessitates significant construction resources.

[0081] According to embodiments of this disclosure, inter-stack connections 152 are eliminated by constructing a bridgeless CPV superstack according to some embodiments of this disclosure. Individual stacks 101 are not assembled. This eliminates the need to manufacture inter-stack connections 152, thereby reducing both the cost and weight of the resulting battery. Embodiments of this disclosure eliminate the need to weld bridges together, thereby reducing production costs and increasing production efficiency. Since the individual electrodes are now directly bonded together, the overall resistance of the superstack is also much lower, which improves the energy efficiency of the resulting battery using a bridgeless CPV superstack.

[0082] Figure 2A A bridgeless CPV superstack 200 (also referred to as stack 200) according to some embodiments of this disclosure is shown. Figure 2A As shown, the bridgeless CPV super stack 200 is formed by a combination of the following three components: intermediate anode-cathode 206, end anode 208, and end cathode 210. The intermediate anode-cathode 206 is formed by welding the anode 212 and cathode 214 together using a metal sheet 216. To prevent electrolyte bridging (which can cause short circuits between electrodes), one or more of the following methods can be used: 1) making the metal sheet 216 between the anode 212 and cathode 214 sufficiently wide to prevent the formation of electrolyte bridging; 2) applying plastic tape to the metal sheet 216 to prevent the formation of electrolyte bridging; and / or 3) controlling the amount of electrolyte to prevent the formation of electrolyte bridging.

[0083] The end anode 208 includes one or more layers of anode material welded to the tab 222. The tab 222 can engage with the slot 142 of the bridge conductor 140, such as... Figure 1C As shown. Bridge conductor 140 can be connected to feedthrough conductor, which can engage with a feedthrough in a pressure vessel. Similarly, end cathode 210 includes cathode material coupled to tab 214, which can engage with slot 142 of bridge conductor 140. Likewise, bridge conductor 140 engaged with end cathode 210 can include feedthrough conductor engaged with a feedthrough in a pressure vessel.

[0084] like Figure 2A As shown, the bridgeless CPV super stack 200 can be formed in layers. Cell 202 can be formed as a first layer 218, which includes L / 2 intermediate anode-cathodes 206 placed adjacently but separated by a space equivalent to the width of a metal sheet 216. A second layer 220 has an end anode 208 at one end and an end cathode 210 at the other end, wherein L / 2-1 intermediate anode-cathodes 206 separate the end anode 208 and the end cathode 210. The first layer 218 and the second layer 220 are aligned such that the cathode in layer 218 is adjacent to the anode in layer 220 (e.g., the end anode 208 is aligned with the cathode 214 of the intermediate anode-cathode 206, and the end cathode 210 is aligned with the anode 212 of the intermediate anode-cathode 206) to form L cells in each of K cells. K repeating cells 202 stacked and aligned with each other can exist in the bridgeless CPV super stack 200. The following discussion further examines four example batteries: Example 1 has L=6 and K=20, Example 2 has L=6 and K=30, Example 3 has L=12 and K=25, and Example 4 has L=12 and K=33. These examples are illustrated below with reference to Table 1 and some of the example properties listed.

[0085] like Figure 2A As shown, L can be any even number. Furthermore, any number of K units 202 can be stacked to form a bridgeless CPV superstack 200. Therefore, to form a bridgeless CPV superstack 200, the assembly contains K end anodes 208, K end cathodes 210, and K*(L-1) intermediate anode-cathodes 206. For example, if K=20 and L=6, then 20 end anodes 208, 20 end cathodes 210, and 100 intermediate anode-cathodes 206 will be arranged, as follows. Figure 2A As shown.

[0086] Figure 2B As shown Figure 2A The equivalent electrical depiction 230 of the bridgeless CPV super stack 200 is shown. (See diagram 230.) Figure 2BAs shown, each stacked anode / cathode layer forms a cell or source 232. Because... Figure 2A The stack shown has L series-coupled sources 232 in each cell 202. The cells 202 are coupled in parallel, so that the bridgeless CPV super stack 200 has K parallel-coupled sources 232 and L series-coupled sources 232.

[0087] Structure 1

[0088] Figure 3A , Figure 3B , Figure 3C and Figure 3D A component of a first bridgeless CPV using a super stack 200 is shown according to some embodiments. Figure 3A An end anode 208 is shown. As illustrated, the end anode 208 may be formed of multiple layers 302 of anode material. In some embodiments, the multiple layers 302 may include two layers of anode material, although three or more layers may also be used. The multiple layers 302 are welded to tab 222.

[0089] Figure 3B The end cathode 210 is shown. (See figure) Figure 3B As shown, the end cathode 210 includes cathode material 310 connected to tab 224. In some embodiments, the cathode material 310 is encapsulated in a separator material. Furthermore, the separator material includes a core that facilitates alignment of components during assembly and serves to draw electrolyte from the sidewalls of the pressure vessel in the finished battery.

[0090] Figure 3C Intermediate anode-cathode 206 is shown. As shown and as discussed above, intermediate anode-cathode 206 includes an anode 212 welded to cathode 214 via a metal sheet 216. Anode 212 may include, for example... Figure 3A Multiple layers 302 are shown. The cathode 214 includes a cathode material 314, which may be encapsulated in a diaphragm material having a wall core. Similarly, the wall core can facilitate alignment and the extraction of electrolyte from the sidewalls of the pressure vessel.

[0091] Figure 3D A diaphragm bag 306 according to some embodiments of the present disclosure is shown. The diaphragm bag 306 is formed of a diaphragm material and can be placed over the cathode material 310 of the end cathode 210 or the cathode material 314 of the anode-cathode 206 to provide a diaphragm in the cell formed in the stack 200. Figure 3DAs shown, the diaphragm bag 306 may include a wall core 308. As discussed above, the wall core 308 may facilitate alignment of components during assembly and draw electrolyte from the sidewall of the pressure vessel. In some embodiments, diaphragm material may be loosely disposed between the cathode material of the end cathode 210 and the anode material 212 of the anode-cathode 206, between the cathode material 314 of the end cathode 206 and the anode material 212 of the anode-cathode 206, or between the cathode material 314 of the anode-cathode 206 and the anode material 302 of the end anode 208 to provide a diaphragm in the cell formed in the stack 200, without forming the diaphragm bag 306.

[0092] Figure 4A Cell boards 412 and 414 are shown according to some embodiments as components used in constructing a bridgeless CPV SuperStack 200 battery. As discussed further below, in assembly, the bridgeless CPV SuperStack 200 is packaged between cell boards 412 and 414. Figure 4A In the diagram, cell boards 412 and 414 show both sides of the cell board, with cell board 414 showing a "bottom" orientation and cell board 412 showing a "top" orientation. Specifically, cell boards 412 and 414 can be identical and oriented according to their intended use. Figure 4B Another structure 400, capable of assembling a super stack 200, is shown. (See diagram.) Figure 4B As shown, the battery cell boards are assembled and supported by brackets 416 to provide further structural integrity. Furthermore, structure 400 can be assembled from individual battery cell board assemblies 418, which are held together by brackets 416 and battery cell board arms, as discussed further below.

[0093] Figure 5 The assembly of a battery assembly with a bridgeless CPV stack 200 is shown. As illustrated, the assembly and alignment are performed in a manner that ensures all components are correctly aligned to form a stack. Specifically, the components of the stack 200 are located between cell plates 412 and 414, and L cells are aligned with each other. As shown, the wall core 308 can facilitate the alignment of each cell 202 in the K repeating cells of the bridgeless CPV super stack 200.

[0094] Figures 6A to 6D The assembly stack and assembly into a battery are shown according to some embodiments. Figure 6A As shown, once as Figure 5As shown, assembling the stack 200 involves inserting the resulting structure with the stack 200 into a press 602 and applying pressure to compress the stack 200. Once compressed, arms 604 are welded to mechanically connect the cell boards 412 and 414, thereby firmly securing the compressed stack 200. Arms 604 can be welded to the cell board 414 before assembly, allowing arms 604 to help maintain the alignment of the stack 200 during transfer to the press 602.

[0095] Figure 6B An insertion bridge 610 is shown to engage with tab 608. An isolator 606 may be included between stack 200 and bridge 610. Tab 608 refers to tab 222 or tab 224, depending on the orientation of stack 200. Figure 6C In the process, the tabs 608 are welded to the end bridges 610 using a welding machine 612. The end bridges 610 are assembled on each side of the stack 200 in this manner.

[0096] Figure 6D As shown Figures 6A to 6C The bridgeless CPV superstack 200 shown is inserted into a liner 622, which can then be placed within a metal pressure vessel 624. The pressure vessel into which the bridgeless CPV superstack 200 is inserted can be made of any material with sufficient strength to withstand the generated pressure and prevent escape of the gas and liquid contained within the pressure vessel. In some cases, the pressure vessel may be metallic; however, in others, it may be encased in plastic, epoxy resin, or fiberglass composite material.

[0097] Figure 7 A process 700 for forming a battery according to some embodiments of the present disclosure is shown. For example... Figure 7 As shown, process 700 begins at step 702, where the various components are produced. Specifically, as... Figure 3A The end anode 208 shown is as follows: Figure 3B and Figure 3C The end cathode 210 shown is as follows: Figure 3D The intermediate anode-cathode 206 is shown in Figure 4, the end bridges 402 and 404 are shown in Figure 4, the bushings 410 are shown in Figure 4, and the cell plates 412 and 414 are shown in Figure 4. As further discussed above, there need to be K end anodes 208, K end cathodes 210, K*(2L-1) intermediate anode-cathodes 206, one end bridge 402 and one end bridge 404, two bushings 410, and one cell plate 412 and one cell plate 414. Once all components are obtained, process 700 is performed according to step 704.

[0098] In step 704, as Figure 5As shown, a bridgeless CPV super stack 200 is assembled. Specifically, the wall core 308 is used as a placement indicator, such as... Figure 5 The diagram shows the end anode 208, cathode end 210, and intermediate anode-cathode 206 assembly stacked on the cell plate 414. Once the K layered units 202 are arranged, the cell plate 412 is placed on top. In some embodiments, bushings may be placed between the cell plates 412 and 414 and the components of the stack 200.

[0099] In step 706, as Figure 6A As shown, the assembly stack 200 is inserted into the press 602 and the stack 200 is compressed. In step 708, the arms 604 are welded to rigidly connect the cell boards 412 and 414, thereby rigidly fixing the bridgeless CPV super stack 200 in place.

[0100] In step 710, as Figure 6B As shown, the end bridge 610 is engaged with tabs from the assembled bridgeless CPV super stack 200. The tabs are inserted into slots passing through the end bridge 610 and folded, as illustrated. It should be noted that multiple tabs can be inserted into a single slot passing through the end bridge 610. Figure 6C As shown, the tabs are soldered to the end bridge 610. In step 710, an end bridge 610 is attached to each side of the assembled bridgeless CPV super stack 200.

[0101] In step 712, the assembled stack 200 is placed into a pressure vessel, such as... Figure 6D The device may include an inner bushing 622 and an outer container 624, such that feeder conductors 406 and 408 extend through the feeder in the pressure vessel. Then, in step 714, the pressure vessel is welded and sealed to form the finished battery.

[0102] In step 716, battery electrolyte can be added to the battery. This can be done via a filling tube by alternately adding and draining electrolyte from the pressure vessel until a suitable amount of electrolyte remains in the battery, or by adding an optimized amount of potassium hydroxide at once without draining. A fully charged battery will allow the stack 200 to absorb a suitable amount of electrolyte, and during battery cycling, liquid-phase ion transport and hydrogen diffusion throughout the electrodes will reach equilibrium. Then, in step 718, the battery can be charged and operated in charge / discharge cycles.

[0103] As discussed above, four example batteries that have been assembled and characterized are discussed below. In Example 1, the battery comprises a stack 200 with L=6 and K=20. In Example 2, the battery comprises a stack 200 with L=6 and K=30 placed in a pressure vessel of the same size as the battery in Example 1. In Example 3, the battery comprises a stack 200 with L=12 and K=2. In Example 4, the battery comprises a stack 200 with L=12 and K=3. As discussed below, each of these example batteries exhibits stable operation throughout the entire period of multiple battery cycles. Table 1 summarizes the four examples of CPVs with different cell (L) and unit (K).

[0104] Table I – Test Examples

[0105]

[0106] Figures 8A to 8E The following is an example formed according to Example 1 in Table 1. Figures 2A to 7 The performance of the battery. Figure 8A and Figure 8B The diagram illustrates the relationship between the discharge energy (in watt-hours) and the C-rate of the battery in Example 1 (L=6, K=20). The C-rate is a measure of the current used for charging and discharging the battery, measured against the capacity of a fully charged battery. As shown in the figure... Figure 8A The relationship between discharge energy and C-rates at C / 12, C / 10, C / 8, C / 6, C / 4, C / 2, and 1C is shown. Figure 8B The energy efficiency is shown at the same set of C rates. The data were collected at a battery temperature of 30°C.

[0107] Figure 8C The efficiency characteristics of Example 1 battery with CPV stack 200 (L=6, K=20) as described above are shown. Coulombic efficiency (CE) 810, voltage efficiency (VE) 812, and energy efficiency (EE) 814 are shown based on the number of battery cycles (i.e., charge / discharge cycles). The battery is continuously cycled at C / 2 at room temperature. Figure 8C As shown, the resulting battery is very stable.

[0108] Figure 8D The energy capacity of the battery with a bridgeless CPV stack 200 (L=6, K=20) as described above is shown. The charging energy 816 and discharging energy 818 also exhibit stability after repeated cycling. Similarly, the battery was continuously cycled at room temperature at C / 2.

[0109] Figure 8E The long-term performance of the battery with a CPV stack of 200 (L=6, K=20) as described above is shown. Specifically, Figure 8EThe voltage versus capacity performance is shown under cycles #50 820 and #445 822. The charge / discharge cycles were performed continuously at C / 2. As shown, after 400 cycles, there are very small differences between these performance characteristics, indicating very stable long-term performance.

[0110] Figures 9A to 9C Another example of stack 200 is shown. Except that K is increased from 20 to 30 (which provides 50% more capacity than the battery in Example 1), Example 2 (L=6, K=30) has similar characteristics to Example 1 shown in Table 1. Figure 9A As shown Figure 5 The side view of the assembled stack 200 with L=6 and K=30 is shown. As shown, the bridgeless stack 200 includes cell boards 412 and 414. (The text also mentions...) Figure 3D The core 308 is discussed. Additionally, tabs 902 and 906 are shown; they are... Figure 3A The tab 222 of the end anode 208 shown Figure 3B and Figure 3C The tab 224 of the end cathode 210 shown.

[0111] Figure 9B As shown Figure 6A The press 602 shown in the figure Figure 9A The stack shown is 200. Figure 9B The tab 902 is further shown, as well as end plates 412 and 414. Specifically, the bridgeless stack 200 can be compressed in the press 602 via end plates 412 and 414. Figure 9C One end of the stack 200 is further shown, which further shows the arrangement of the bushing 904, the components of the stack 200, and the tab 902 located between the cell boards 412 and 414.

[0112] Figure 9D and Figure 9E Further examples are shown, such as Figures 9A to 9C The characteristics of Example 2 battery are shown, produced by stacking 200 cells with L=6 and K=30. Figure 9D As shown Figures 9A to 9B The efficiency of a 200-cell stack with L=6 and K=30 is shown as a function of the number of cycles. Figure 9D Example batteries CE 910, VE 912, and EE 914 are shown. Figure 9E The use of, as shown Figures 9A to 9C The example battery in the stack 200 shown has a charging energy of 918 and a discharging energy of 918. Figure 9D and Figure 9E The data was collected by continuously cycling at a charging rate of C / 2 at room temperature.

[0113] Figures 10A to 10G A third example (Example 3) is shown, where L=12 and K=25. Figure 10A A bridgeless CPV super stack 200 is shown, which is placed in a portion of the compressor 602 prior to compression, according to Example 3. Figure 10B Compression in press 602 of bridgeless CPV super stack 200 according to Example 3 is shown.

[0114] Figure 10C The image shows the bridgeless CPV superstack 200 after it has been pressed into press 602 and the welding of arms 604 has been completed. End plates 610 are then mounted and welded as described above. Figure 10D The finished battery is shown, wherein the stack 200 is inserted into a pressure vessel 1004, and the pressure vessel 1004 is sealed and welded. Electrolyte can then be injected into the pressure vessel 1004, and the resulting battery is tested.

[0115] Figure 10E The relationship between voltage and capacity charge / discharge characteristics of the battery in Example 3 at C / 2 is shown. Figure 10F The energy efficiency of the battery in Example 3 varies with the number of cycles. Figure 10G The discharge energy of the battery in Example 3 varies with the number of cycles. Table 2 below shows... Figures 10E to 10G The characteristics described in the document.

[0116] Table 2: Battery characteristics of Example 3 (stack 200 with L=12 and K=25)

[0117]

[0118] like Figures 10A to 10G As shown, the cells with the stack 200 of Example 3 are also very stable over time. Therefore, each cell produced according to this disclosure by the example bridgeless CPV super stack 200 has fewer internal components, especially no internal bridges, and performs very well.

[0119] Figures 11A to 11D The fourth example (Example 4) is shown, where L=12 and K=33. Figure 11A The bridgeless CPV super stack 200 before compression is shown. Figure 11B A bridgeless CPV superstack 200 is shown, which has been compressed and welded together by cell plates 412 and 414 and arm 604. As discussed above, the assembled and welded bridgeless CPV superstack 200 is completed by adding end plates, placing the components in a pressure vessel, and adding an appropriate amount of electrolyte to form a cell.

[0120] Figure 11C The relationship between voltage and capacity charge / discharge characteristics of the battery in Example 3 at C / 2 is shown. Figure 11D The round-trip energy efficiency 1102 of the battery in Example 4 is shown as a function of the number of cycles. Figure 11D The discharge energy 1104 of the battery in Example 4 is also shown as a function of the number of cycles. Table 3 below illustrates this. Figures 11C to 11D The characteristics described in the document.

[0121] Table 3: Battery characteristics of Example 4 (stack 200 with L=12 and K=33)

[0122]

[0123] Therefore, in all four examples shown, the resulting batteries exhibit high efficiency. Furthermore, the resulting batteries remain stable after a large number of cycles. Specifically, the batteries formed according to the embodiments of this disclosure exhibit high stability and high efficiency. Moreover, the production of these batteries uses fewer components and eliminates the need for multiple bridges between components.

[0124] Structure 2

[0125] Some embodiments of the battery use a different structure than structure 1 shown above. In some embodiments, the advantages of structure 2 include lighter components, better hydrogen sealing, stress relief, fewer components, and other benefits. Therefore, each of the following components is sized to work together collaboratively throughout the battery formation. The benefits of these components are further discussed below, as in the description of the components themselves.

[0126] Figures 12A to 12F An example end anode 208 and its assembly according to some embodiments are shown. The end anode 208 includes a single tab 1204 that engages with a corresponding slot of a bridge conductor, as discussed further below. In some embodiments, the tab 1204 may include multiple individual tabs capable of engaging with corresponding slots of the bridge conductor. As shown, the end anode 208 includes an anode layer 302, which may be a multilayered anode material. In some embodiments, the anode layer 302 may be embossed to provide more channels for electrolyte flow. As shown, a metal strip 1202 may be used to weld the layers of anode material together and to the tab 1204. Furthermore, the tab 1204 may include a notch 1208 that facilitates bending when inserted into a slot through the bridge, as discussed further below. Additionally, an adhesive strip 1206 may cover the material of the tab 1204 near the anode layer 302 for further isolation.

[0127] Figure 3Cand Figure 3D An example is shown where two anodic material layers 302 are positioned and welded together relative to a metal strip 1202. When the layers 302 are embossed, the embossed surfaces bond together. An electrode tab 1204 can be welded to one of the metal strips 1202, as shown. Figure 12E The cross-sectional view is shown below. Figure 12F As shown, insulating strip 1210 can be applied to each side of strip 1202 and tab 1204 to cover the weld. Insulating strip 1210 extends the entire length of end anode 208.

[0128] Figures 13A to 13D The end cathode 210 is shown. (See figure) Figure 13A and Figure 13B As shown, the end cathode 210 includes cathode material 310 connected to a single tab 1302. Additionally, in some embodiments, the tab 1302 may include multiple tabs that engage with slots in the bridge. For example... Figure 13A and Figure 13B As further shown, tab 1302 may include a notch 1306. In some embodiments, tape 1304 is applied to either side of tab 1302.

[0129] Figure 13C The assembly of cathode material 310 with metal strip 1308 is shown. As shown, two cathode material layers 310 are welded to each side by strip 1308. Figure 13D The electrode 1302 is shown being soldered to the metal strip 1308. Additionally, tape 1304 can be applied to either side of the electrode 1302.

[0130] Figures 13E to 13G The diagram shows the end cathode 210 encapsulated within a diaphragm bag 1310. In some embodiments, the diaphragm material may be loosely placed around the cathode 210 instead of forming a diaphragm bag 1310, thus not forming a diaphragm bag 1310. Figure 13E As shown, two diaphragms 1310 are applied to either side of the cathode material 310. Figure 13F As shown, the diaphragm 1310 is joined at the connector 1312 to form as shown. Figure 13G The bag 1316 is shown. Furthermore, the separator bag 1316 includes a liquid-absorbing tab 1314 for drawing electrolyte from the side wall of the pressure vessel into the finished battery. Therefore, the separator layer 1310 is sized to completely cover the cathode material 310, while also forming the liquid-absorbing tab 1314. Additionally, the separator layer 1310 may include slots 1318 that facilitate the formation around the tab 1302, thereby forming... Figure 13F The connector 1312 is shown. (As shown) Figure 13F As shown, in some embodiments, the end of the absorbent sheet 1314 may be kept open to facilitate electrolyte flow.

[0131] Figures 14A to 14N An example of an intermediate anode-cathode 206 is shown. (e.g.) Figure 14A As shown and discussed above, the intermediate anode-cathode 206 includes an anode 212 welded to the cathode 214 via a metal sheet 216. The anode 212 may include, for example... Figure 3A as well as Figures 12A to 12F Multiple layers 302 are shown. The cathode 214 includes a cathode material 314, which may be encapsulated in a diaphragm material having a wall core. Similarly, the wall core can facilitate alignment and the extraction of electrolyte from the sidewalls of the pressure vessel.

[0132] Figures 14B to 14E The fabrication of anode 212 according to some embodiments is shown. For example... Figure 14B As shown, the anode layer 1424 is positioned and soldered to the metal strip 1426. As previously discussed, the anode layer 1424 can be patterned, and the patterned surfaces are adjacent to each other in the anode 212, as... Figure 14B and Figure 14C As shown. Figure 14C Also shown is tab 1428, which is welded to metal strip 1426 to form anode 212. This structure is... Figure 14D A plan view of anode 212 and Figure 14E The cross-sectional view along line AA is shown in the diagram.

[0133] Figures 14F to 14H The fabrication of cathode 214 according to some embodiments is shown. Figure 14F The cathode layer material 1450 from which the cathode 214 is formed is shown. For example... Figure 14F As shown, the cathode layer 1430 is positioned and welded to the metal strip 1432. Figure 14G The diagram shows a planar view of the obtained cathode material. Figure 14H The image shows a cross-sectional view of the cathode 214 obtained by cutting from cathode material 1450.

[0134] Figures 14I to 14K An assembly of an intermediate anode-cathode 206 according to some embodiments is shown. As shown in FIG12O, cathode 214 and anode 212 are positioned such that metal strip 1432 is welded to tab 1428 to form metal sheet 216. Figure 14J In this process, tape 1434 can be applied to metal sheet 216 to provide insulation between anode material 1424 and cathode material 1430. Figure 14K A plan view of the resulting intermediate anode-cathode 206 is shown.

[0135] Figures 14L to 14N It shows the direction as Figure 14KThe cathode 214 of the intermediate anode-cathode 206 shown provides a diaphragm bag 1442. As discussed above, in some embodiments, the diaphragm material is loosely stacked around the cathode 214 instead of forming a diaphragm bag 1442. Figure 14L As shown, diaphragm material 1436 is located around cathode 214. As illustrated, the multilayered diaphragm material 1436 is cut large enough to form a liquid-absorbing sheet 1438 and positioned to cover cathode 214. In some embodiments, diaphragm 1436 may include slots 1437 shaped to fit a metal sheet 216. Figure 14M As shown, the multilayered membrane material layers 436 are then joined via connector 1440 to form a bag 1442 with absorbent tabs 1438. In some embodiments, membrane material 1436 and membrane material 1310 may be the same. Figure 14M As shown, the connector 1440 is formed in the shape of a metal sheet 216. Figure 14N A bagged intermediate anode-cathode 206 according to some embodiments is shown.

[0136] Figure 15A and Figure 15B An assembly of a superstack 200 with K repeating units 202 is shown. (As shown) Figure 15A As shown, repeating units 202 are formed by appropriately spacing and stacking the intermediate anode-cathode 206 with the end anodes 208 and end cathodes 210. Figure 15A As shown, for example, the first layer of unit 202 includes all intermediate anode-cathodes 206 spaced apart by a spacing 1502 that is substantially equal to the width of the metal sheet 216 of the intermediate anode-cathode 206. The second layer includes end anodes at one end and end cathodes 210 at the opposite end, with intermediate anode-cathodes 206 spaced apart in between. Figure 15B A top view shows the diaphragm bags 1442 and 1310 of the display unit 202, which are equidistantly spaced apart.

[0137] Figure 16 The construction of a battery cell chain 1600 according to some embodiments is shown. For example... Figure 16 As shown, the cell chain 1600 includes a cell tray 1602 to which cell plate arms 1604 have been welded. A separator 1606 is placed at each position on the cell tray 1602. Figure 16 As shown, the separator 1606 extends into the stacked two layers to cover the entire surface of the bottom of the cell tray 1602. The separator 1606 can be the same as the separator 1310 used to form the pouch 1316 for the end cathode 210 or the separator 1436 used to form the pouch 1442 for the intermediate anode-cathode 206 described above. Figure 16As shown, the diaphragm 1606 includes slots 1616, which in some embodiments are each positioned to correspond to a cathode bag (e.g., bag 1316 or 1442).

[0138] like Figure 16 As further shown, the electrode stack 200 is laminated into the cell tray 1602, as described above regarding... Figure 15A and Figure 15B As discussed. In some embodiments, such as regarding Figures 12A to 14N The electrodes being discussed are manufactured in the local area. For example... Figure 16 As shown, two or more layers of diaphragms 1608 are placed above the electrode stack 200. Similarly, diaphragms 1608 can be the same diaphragms 1310 or 1436 described above. Also, each diaphragm 1608 includes a slot 1616 aligned with the slots of diaphragms 1310 and 1436 in the electrode stack 200.

[0139] like Figure 16 As further shown, the cell plate 1610 is positioned above the diaphragm 1608. End plates 1612 and 1614 are also disposed above the diaphragm 1608 on opposite sides of the cell plate 1610. Once assembled, the cell chain 1600 can be placed in a press and compressed to a specific pressure, and under pressure, the arms 1604, which have already been welded to the cell tray 1602, can be welded to the end plates 1612 and 1614 and the cell plate 1610. In some embodiments, the cell plate 1610 may be a separate plate that is individually connected under pressure.

[0140] In some embodiments, the cell tray 1602, cell plate 1610, and end plates 1612 and 1614 can be overmolded assemblies. According to the overmolding process, the cell tray 1602, cell plate 1610, and end plate 1612 are formed by injection molding material onto a sufficiently rigid substrate. The rigid substrate can be any material with sufficient structural integrity and corrosion resistance, such as stainless steel, aluminum, copper, nickel, other metallic materials, or other sufficiently rigid materials. Stainless steel, for example, provides good rigidity and corrosion resistance; however, any sufficiently rigid and corrosion-resistant material that can easily bond with other materials during assembly can be used. A wide variety of insulating materials can be used for injection molding. For example, acrylonitrile butadiene styrene (ABS), nylon, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polycarbonate (PC), polyoxymethylene (POM), polymethyl methacrylate (PMMA), thermoplastic polyurethane (TPU), thermoplastic rubber (TPR), polypropylene (PP), or other suitable materials. Alternatively, rigid composites or high-performance polymers, such as Garolite and polysulfone, can be used.

[0141] Figures 17A to 17DAn example of a substrate cell board 1700 according to some embodiments is shown. The substrate cell board 1700 can be used as a substrate in an overmolding process to produce, for example, Figure 16 The various components of the 1600 battery cell chain are shown. For example... Figures 17A to 17D As shown, the base cell board 1700 can be formed of metal (e.g., stainless steel).

[0142] Figure 17A A plan view of the substrate cell board 1700 is shown. (As shown) Figure 17A As shown, the base cell board 1700 includes a base 1702, the dimensions of which are accordingly designed to accommodate the intermediate anode-cathode 206 as discussed above. As shown, tabs 1706 are formed on both sides of the base 1702. The tabs 1706 are vertically oriented relative to the base 1702 and include two tabs 1706 on each side. As discussed further below, the tabs 1706 will be used to construct the cell chain 1600, wherein the arms 1604 will ultimately be connected to the tabs 1706.

[0143] Figure 17A Also shown is a support 1708, which extends vertically in the direction opposite to that of the tab 1706 and is located on both sides of the tab 1706. In other words, the tab 1706 is located on each of a set of opposite sides of the base 1702, while the support 1708 is located on each of another set of opposite sides of the base 1702. Figure 16 As shown, the base cell plate 1700 is oriented in the cell chain 1600 such that the tab 1706 is oriented along the side (i.e., oriented in the direction between the cathode and anode of the intermediate anode-cathode 206), while the support member 1708 is oriented perpendicular to the direction defined by the intermediate anode-cathode 206.

[0144] Figure 17A It is further shown that feature 1704 can be formed in substrate 1702. Feature 1704, formed in the material of substrate 1702, provides additional strength to the substrate cell board 1700. Figure 17A As shown, feature 1704 can be two parallel elongated grooves formed in the substrate 1702.

[0145] Figure 17B A side view of the base cell plate 1700 is shown from the angle of the support member 1708. (See attached image.) Figure 17B As shown, the support 1708 is partially molded into a hemispherical shape to ultimately mate with the bushing, as will be discussed further below. Additionally, the tab 1706 is shown extending from the side of the substrate 1702. It should be noted that the substrate cell board 1700 may be formed from a single sheet of metal material, or it may be formed as a separate assembly soldered to the substrate 1702.

[0146] Figure 17C The image shown is as seen from the angle of the electrode 1706. Figure 17A The figure shows a side view of the substrate cell plate 1700. As shown, the substrate cell plate 1700 shows two individual tabs 1706 extending through the substrate 1702. The tabs 1706 can be coupled to the mounting base 1710 to facilitate stacking and improve ease of handling and packaging. A support member 1708 extends from the substrate 1702 in the opposite direction to the tabs 1706 and is located on the side of the substrate 1702 opposite to the side from which the tabs 1706 extend. Furthermore, feature 1704 is shown extending from the bottom of the substrate 1702 (the side from which the support member 1708 extends) and parallel to the support member 1708. Figures 17A to 17D As shown, tab 1706 and support 1708 extend from base 1702 at right angles. Figure 17D A cross-section of feature 1704 is shown, illustrating a semi-circular notch in base 1702 that extends at least partially across base 1702, as... Figure 17A As shown.

[0147] Figures 18A to 18F An example of an overmolded battery cell board 1800 is shown. As discussed above, the overmolded battery cell board 1800 can be formed by injection molding using the battery cell board 1700 as a substrate. Therefore, many features shown in the battery cell board 1700 are continued in the overmolded battery cell board 1800.

[0148] Figure 18A A plan view of an example overmolded battery cell 1800 according to some embodiments is shown. The features shown in the overmolded battery cell 1800 can be formed by injection molding over a battery cell 1700. In some examples, the injection molding material is HDPE. The molding thickness can be adjusted to obtain an overmolded battery cell 1800 of appropriate dimensions.

[0149] like Figure 18A As shown, the overmolded battery cell board 1800 includes a substrate 1802, a feature 1804, a tab 1806, and a support member 1808. Figure 18B A side view of the overmolded battery cell 1800 along the direction of the support member 1808 is shown, and the side support member 1808 and the tab 1806 are also shown. As shown, the support member 1808 is molded to have the following characteristics: Figure 17B The support member 1708 shown is adapted to a curved shape with a flat top. Injection molding is performed above the tab 1706 to form 1806, which is arranged to expose a section of the tab 1706 for attachment of an additional support member. This also... Figure 18C As shown in the figure, Figure 18C One of the pole lugs 1806 is shown (e.g.) Figure 18B(as shown in circle A) and the exposure of a section of the electrode 1706.

[0150] Figure 18D The overmolded battery cell board 1800 is shown along the edge as shown. Figure 18A The cross-sectional view is shown in the direction CC. Thus, the cell board 1700 is shown. Furthermore, feature 1804 is filled by injection molding to provide a flat base 1802 on which the components of the stack 200 can be supported.

[0151] Figure 18E A side view of the overmolded battery cell plate 1800, as seen at tab 1802, is shown. Therefore, feature 1804 and the resulting flat substrate 1802 are shown. A support member 1808 and a mounting base 1810 are also shown, which mounts the battery cell plate 1800 at... Figure 18F The details are shown in more detail below. Mounting base 1810 is overmolded from mounting base 1710, which is used to connect tab 1706 and helps to facilitate stacking as well as easy handling and packaging.

[0152] Multiple overmolded battery cells 1800 can be connected in series (with support members 1808 adjacent to each other) to form a structure such that... Figure 16 The battery cell 1610 is shown. Therefore, during the compression step, each overmolded battery cell 1800 in the battery cell 1610 can be individually compressed to a specified pressure.

[0153] Figures 19A to 19F An example of an overmolded end cell plate 1900 according to some embodiments is shown. The end cell plate 1900 may be... Figure 16 End plates 1612 and 1614 are shown. As shown, the overmolded end cell board 1900 includes a cell board 1700 that serves as a substrate in the overmolding process. Figures 19A to 19F As further shown, the overmolded end cell board 1900 includes Figures 18A to 18F Most of the components of the battery cell board 1800 are shown. However, one of the support members 1808 in the battery cell board 1800 is replaced with... Figure 19A The support member 1908 shown has protrusions 1902 and 1904. Protrusions 1902 and 1904 help align the resulting cell chain 1600 with the bridge structure.

[0154] Figure 19AA plan view of an overmolded end cell plate 1900 is shown, including a tab 1806, a feature 1804, a substrate 1802, and a support member 1808. However, the overmolded end cell plate 1900 includes a support member 1908 opposite to the support member 1808. The support member 1908 includes protrusions 1902 and 1904. In some embodiments, protrusions 1902 and 1904 may be substantially identical; however, in other embodiments, they have different dimensions, thereby achieving a certain effect when compared with... Figure 16 The battery cell board 1610 shown achieves better alignment during assembly. This asymmetry also facilitates the use of a material pick-and-place box, in which the battery cell board 1900 can be reliably inserted in a defined orientation.

[0155] Figure 19B A side view of the overmolded end cell plate 1900 as seen at the support 1908 is shown. As shown, protrusions 1904 and 1902 extend from the surface of the cell plate 1908 and have different dimensions. Figure 19B It is shown that during the overmolding process, the tab 1806 was not fully overmolded, resulting in the tab 1706 from the cell board 1700 being exposed. Figure 19D As shown Figure 19A The cross-sectional view of the overmolded end cell plate 1900 shown by the cutting line CC in the figure. Figure 19D Protrusion 1902 is further shown. Figure 19E and Figure 19E A side view of the overmolded end cell plate 1900 is further shown, which shows the protrusion 1904.

[0156] Figures 20A to 20I An example of an overmolded battery cell tray 2000 is shown. The overmolded battery cell tray 2000 can be used as... Figure 16 The battery cell tray shown is 1602. (As shown...) Figure 20A As shown, the overmolded battery cell tray 2000 includes a plurality of battery cell plates 1700, which are arranged such that the supports 1708 of adjacent battery cell plates are spaced apart from each other. Figure 16 The spacing between adjacent electrodes in the stack 200 shown corresponds to the distance. The arrangement of the cell boards 1700 is then overmolded using injection molding, for example, using HDPE, to form an overmolded cell tray 2000. Figure 20A As shown, the cell tray 200 includes an overmolded support 2008, a feature 2004, a structure 2010, and an exposed tab 1702.

[0157] Figure 20A A side view of the overmolded battery cell tray 2000 is shown, while Figure 20BA plan view of the bottom of the cell tray 2000 (i.e., seen at the support 2008) is shown. As shown, the cell tray 2000 includes exposed tabs 1706, supports 1708, and pairs of adjacent supports 2008 connected by overmolding. A support structure 2010 is provided for holding the array of cell plates 1700 after overmolding. Each end of the cell tray 2000 includes a separate overmolded support 2009 formed together with the supports 1708 of the cell plates 1700. These ends are also provided with structures 2016 and 2018, which provide alignment with other components. As further shown, support is provided by overmolding over feature 1704 to form feature 2004. Figure 16 The electrode stack 200 shown provides a flat substrate 2002.

[0158] The overmolded support structure 2010 provides structural support and is flexible, providing structural support between adjacent cell plates 1700 in the cell plate 1700. The curvature is set to fit the bushing, which is discussed further below. Parts of the support structure 2010 engage with the overmolded portion on each cell plate 1700 in the cell plate 1700. It is also noted that although the structure 2010 is fixed to the overmolded portion on the cell plate 1700 at the end of the overmolded cell tray 2000, it does not extend the entire length of the cell tray 2000 and leaves both ends of the overmolded cell tray 2000 open.

[0159] Figure 20C The support member 2008 is further shown, specifically, Figure 20B The portion shown is from 2012. (As shown) Figure 20C As shown, the support 2008 is formed by two adjacent supports 1708 and an overmolded diaphragm 2020. The spacing formed is consistent with the width of the metal sheet 216 in the intermediate anode-cathode 206. Figure 20D It shows the following: Figure 20C The figure shows a cross-sectional view along the DD direction. As shown, adjacent cell boards 1700 are overmolded to form a support member 2008 with a diaphragm 2020. Furthermore, a support structure 2010 is shown, and the support structure 2010 is formed as part of the substrate. Additionally, the tabs 1702 remain exposed. Figure 20E As shown Figure 20B The portion 2014 shown illustrates that tab 1706 extends through the bottom of the overmolded cell tray 2000 and is overmolded to form tab 2006, which facilitates positioning and improves ease of handling and packaging.

[0160] Figure 20F and Figure 20GAn end view of the overmolded cell tray 2000 is shown. As shown, the mounting structure 2022 includes mounting holes 2026. This structure facilitates the mounting of the end conductors, as further shown below.

[0161] Figure 20H As shown Figure 20B End view 2026 of the overmolded cell tray 2000 shown. Figure 20H More detailed structures 2016 and 2018 that can be formed are shown. As shown, structure 2016 can be a protrusion, and structure 2018 can be a groove. As discussed further below, the positions of structures 2016 and 2018 are interchanged on opposite sides of the overmolded cell tray 2000, such that multiple overmolded cell trays 2000 can be aligned to form a shape such as... Figure 16 The battery cell chain shown is 1600. Figure 20I It shows the following: Figure 20H The cross-sectional view in the FF direction is shown.

[0162] Figures 21A to 21G An example of forming a cell tray 2100 according to some embodiments is shown. Figure 21A As shown, multiple cell board arms 2102 are welded to the above... Figures 20A to 20H The electrode tab 1706 of the overmolded cell tray 2000 described in the text. See below for reference. Figures 21E to 21G Describes cell plate arm 2102. (e.g.) Figure 21E As shown, the cell plate arm 2102 includes a shaft portion 2118 and a tip 2110. (As...) Figure 21A As shown, the cell plate arm 2102 is welded to each of the exposed tabs 1706 via a shaft portion 2118. Each cell plate arm in the cell plate arm 2102 is parallel and aligned.

[0163] Figure 21B An end view of the cell tray 2100 is shown. (As shown) Figure 21B As shown, each of the cell plate arms 2102 is welded to the tab 1706 such that it extends vertically from the surface of the substrate 2002. Figure 21C As shown Figure 21A The portion 2104 is shown, and it is shown that the width of the shaft portion 2118 is slightly smaller than the width of the tab 1706 and the center of the shaft portion 2118 is welded to the tab 1706. Figure 21D As shown Figure 21B View 2106 is shown, and further illustrates how the shaft portion 2118 is welded to the tab 1706 on the side opposite to the base 2002 of the overmolded cell tray 2000.

[0164] Figures 21E to 21GAn example of cell plate arm 2102 is further shown. As discussed above and as... Figure 21E As further shown, the cell plate arm 2102 includes a shaft portion 2118 and a tip 2110. Figure 21F The battery cell plate arm 2102 is shown to be formed from a sheet of a metallic material (e.g., stainless steel). Figure 21G Further shown Figure 21E View 2112 is shown. View 2112 further shows tip 2110. As shown in this example, tip 2110 includes a narrow shaft 2114 that couples shaft portion 2118 to semi-circular connector 2116. As discussed below, tip 2110 is used to connect other components.

[0165] Figures 22A to 22F The assembly of the battery cell chain 2200 is shown, which is as follows: Figure 16 The shown diagram illustrates the completion of the 1600 battery cell chain. (As...) Figure 22A As shown, the battery cell chain 2200 includes a battery cell tray 1602, which can be used... Figures 20A to 20I The overmolded battery cell tray 2000 shown is from... Figures 21A to 21G The battery cell tray is formed by one or more cell trays 2100 as shown. The cell chain 2200 also includes end plates 1612 and 1614 located at either end, and a cell plate 1610. As discussed above, each of the end plates 1612 and 1614 can be as follows: Figures 19A to 19C The overmolded end plate 1900 is shown. Furthermore, it can be placed as follows... Figures 18A to 18F One or more overmolded cell boards 1800 are shown to form cell board 1610. Some embodiments may use all-metal components instead of the overmolded components described above.

[0166] As further shown, the super stack 200 and the additional layers of separators 1606 and 1608 are arranged as follows: Figure 15A and Figure 15B as well as Figure 16 On the cell chain 1602 shown. As discussed, the super stack 200 includes the intermediate anode-cathode 206, end anode 208 and end cathode 210 as described above.

[0167] Each end anode 208 includes a single tab 1204, and each end cathode 210 includes a single tab 1302. The cathode portion of the intermediate anode-cathode 206 and the end cathodes 210 all include diaphragm bags with absorbent tabs 1438 and 1314, respectively. Figure 22A As shown, the absorbent sheet 2202 is a stack of absorbent sheets 1438 and 1314 and absorbent sheets formed on diaphragms 1606 and 1608.

[0168] Once such Figure 22A As shown, after stacking all components, the cell chain 2200 is placed in a press and compressed under pressure. Then, the cell plate arm 2102 is aligned with the exposed tabs 1706 on the overmolded end plate 1900 and the overmolded cell plate 1800, and welded into place or compressed to a specific thickness under pressure P, as described below. Figure 22F Further discussion is needed. For example... Figure 22A As shown, each of the end plates 1612 and 1614 and each part of the cell plate 1610 can be pressed or pressed to a specified height individually or collectively using a specified force 2204.

[0169] Figure 22B A plan view is shown, viewed from the top of the cell tray 1602 of the cell chain 2200. (See diagram below.) Figure 22B As shown, tab 2210 is shown on one side, while tab 2212 is shown on the other side. One of tabs 2210 and 2212 is a stack of end cathode tab 1302 or end anode tab 1204, as discussed above. Figure 22C Further shown Figure 22B The region 2214 is shown. As shown in the figure, the tab 2210 is a monopole structure as discussed above. Figure 22D Further shown Figure 22B The area 2216 is shown. Similarly, the tab 2212 can be a monopole structure, or in some embodiments, the tab 2212 can include multiple individual tabs. Figure 22E As shown Figure 22A The region 2206 is shown, and the stacking of tabs 2210 is further shown.

[0170] Figure 22F As shown Figure 22A The area shown is 2208. (As shown in the image) Figure 22F As shown, the shaft portion 2118 of the cell arm 2102 is welded to the tab 1706 of the end cell plate 1614. Tab 2212 is also shown.

[0171] Figures 23A to 23E An assembled battery cell chain 2300 according to some embodiments of the present disclosure is shown. For example... Figure 23A As shown, bridges 2302 and 2304 are attached to cell chain 2200. (Reference) Figures 22A to 22F The cell chain 2200 is described. As previously discussed, tabs 2210 and 2212 on the cell chain 2200 extend through slots in bridges 2302 and 2304, respectively, and are soldered into place. Bridges 2302 and 2304 can be secured to the cell chain 2200. Bridges 2302 and 2304 will be discussed further below.

[0172] Figure 23BThe installation of a top bracket 2306 according to some embodiments is shown. The top bracket 2306 may be formed from one or more separate top brackets 2310, which will be discussed below. Figure 23C A top bracket 2306 is shown attached to the battery cell chain 2200. In some embodiments, a pin 2308 may be inserted through the top bracket 2306 for further attachment to the battery cell chain 2200. Figure 23D and Figure 23E Line drawings showing the top and side views of the assembled battery cell chain 2300 are shown respectively.

[0173] Using the overmolded parts as described above Figure 23A , Figure 23D and Figure 23E The frame structure of the shown cell chain 2200 provides with Figure 4B The advantages of the frame structure 400 shown are as follows: First, the resulting battery structure requires fewer components for assembly, thus reducing overall cost. In some cases, the number of components is reduced from 214 to 98. Furthermore, overall assembly is greatly simplified. Additionally, electrical isolation between the frame structure of the stack 200 and the cell chain 2200 is increased. Furthermore, the inner diameter of the cell chain 2200 can be increased, thereby reducing internal pressure, accommodating a larger super-stack 200, and further increasing the gap between most of the cell chain 2200 and the walls of the pressure vessel bushing.

[0174] Figures 24A to 24F It shows the ability to interact with, for example Figures 23A to 23E A separate top bracket 2310 is attached to the adjacent tip 2110 of the cell plate arm 2102 on the cell plate 1610 of the shown cell chain 2200. The separate top bracket 2310 can be formed by injection molding using any suitable material (e.g., HDPE). Figure 24A A side view of the split top bracket 2310 is shown, and Figure 24B A top view of the split-type top bracket 2310 is shown.

[0175] like Figure 24A and Figure 24B As shown, the split top bracket 2310 is a structural support member with a support structure 2402, which may have inclined supports and top and side brackets 2408. Furthermore, a mounting structure 2404 is configured to engage with the tip 2110 of the cell plate arm 2102. An additional mounting structure 2412 is also formed to accommodate, for example... Figure 23C The pin 2308 shown can be a screw. Furthermore, a pick-and-place structure 2406 can be formed, which allows for convenient subsequent removal and removal of the core chain 2200 combined with the top support 2306, which is made of, for example... Figure 23BOne or more split-type top supports 2310 are formed as shown.

[0176] Figure 24C An end view of the split top support 2310 is shown, and the pick-and-place structure 2306 is further shown. Figure 24D Showing more details Figure 24C The area 2410 is shown. As shown, the pick-and-place structure 2406 provides a notch in the surface of the split top bracket 2310 that allows for easy gripping (using the structures on both sides of the split top bracket 2310) and pick-and-place of the split top bracket 2310.

[0177] Figure 24E and Figure 24F This illustrates attaching the split top bracket 2310 to the battery cell chain 2200. (As shown) Figure 24E and Figure 24F As shown, mounting structure 2404 engages with tip 2110 of cell plate arm 2102 to secure each of the split top brackets in split top bracket 2310 to cell chain 2200.

[0178] Figure 25A and Figure 25B An example of a bridge 2500 according to some embodiments of the present disclosure is shown. Figure 25A The example of bridge 2500 shown is a rigid, fixed structure, while Figure 25B An example of bridge 2500 is a spring that is loaded to provide stress relief to the resulting battery when the charge-discharge cycle of assembling the cell chain 2300 causes the structure to expand and contract. Furthermore, in any example of bridge structure 2500, components can be adapted to allow for annular filling sections as discussed below, or to allow pressure blowout in the event of overpressure in a pressure vessel containing the cell chain 2300. Bridges 2302 and 2304 can each be as follows: Figure 25A and Figure 25B Bridge 2500 is shown. For example, bridges 2302 and 2304 can both be as follows: Figure 25A The example shown is bridge 2500. In some examples, one or both of bridges 2302 and 2304 may be as follows: Figure 25B An example of a bridge 2500 with stress relief is shown. Furthermore, one of bridges 2302 and 2304 can be sized and configured to fit the annular filling section, and one of bridges 2302 and 2304 can be sized and configured to fit pressure relief.

[0179] exist Figure 25A In the example of the bridge 2500 shown, the bridge 2500 includes a base 2502, a crossbar 2504 engaged with the base 2502, and a feeder 2510 mounted on the crossbar 2504. Figure 25BIn the example of bridge 2500 shown, feeder 2510 is mounted to spring portion 2514, which is mounted to base 2512.

[0180] Figures 26A to 26M It shows Figure 25A The components and construction of an example of bridge 2500 are shown in the figure. Figures 26A to 26D An example of substrate 2502 is shown. Figures 26E to 26H An example of crossbar 2504 is shown. Figures 26I to 26K The formation of a crossbar 2504 with a feeder 2510 is shown. Figure 26L and Figure 26M This example shows a crossbar 2504 and a feeder 2510 attached to a base 2502 to form a bridge 2500.

[0181] Figure 26A As shown Figure 25A An example of the base 2502 of the bridge 2500 is shown. Figure 26A As shown, the base 2502 includes a support 2602 having two sidewalls 2606 attached to opposite sides of the support 2602. A slot 2604 is formed in the support 2602 and partially formed in the sidewalls 2606. A mounting base 2608 is formed on the side of the support 2602 without the sidewalls 2606. The mounting base 2608 includes a recess 2610. The mounting base 2608 and the recess 2610 are configured to mechanically attach the base 2502 to the end of the battery cell chain 2200, for example, using screws. The slot 2604 is configured to receive, for example... Figure 22A One or more tabs 2210 or 2212 are shown. Specifically, slot 2604 accommodates one of tabs 2210 or 2212 (depending on which side of the cell chain 2200 the bridge 2500 is mounted on). Each slot in slot 2604 can accommodate one or more individual tabs, and these tabs are soldered to support 2602 during the mounting process.

[0182] When bridge 2500 is installed, sidewall 2606 extends vertically from support 2602 in a direction away from cell chain 2200. Sidewall 2606 includes slot 1612, which accommodates, for example... Figure 26A The crossbar 2504 is shown. In some embodiments, the crossbar 2504 may be welded to the sidewall 2606.

[0183] Figure 26B As shown Figure 26A The plan view of the base 2502 is shown. Figure 26C It shows the following: Figure 26A A view of the edge of the base 2502 shown. Figure 26D It shows the orientation as Figure 26AA view of the sidewall 2606 of the substrate 2502 is shown. The number of slots 2604 and the physical dimensions of various aspects of the substrate 2502 are configured to match the dimensions of the cell chain 2200 and the number of tabs in the cell chain 2200. The substrate 2502 can be formed from a monolithic material of sufficient thickness to provide adequate rigidity. The substrate 2502 can be formed from any conductive material sufficient to conduct current into and out of the cell chain 2200. For example, the substrate 2502 can be formed from stainless steel, carbon steel, or any other suitable material.

[0184] Figures 26E to 26H As shown Figure 25A The crossbar 2504 shown is component 2620. (See example...) Figure 26E As shown, component 2620 includes slot 2622, which is connected to, as shown in the diagram... Figure 26A The slot 2612 of the base 2502 shown engages. Furthermore, an additional tip 2632 may extend from the edge adjacent to the slot 2622, thereby allowing for further structural support when engaged with the slot 2612 of the base 2502. Component 2620 may have a top edge capable of being shaped to save material. Edge 2630 may be configured to engage with feedthrough 2510. Furthermore, on edge 2630, a notch 2624 may be formed to adapt to the shape of feedthrough 2510 and any protrusions (e.g., bursting discs or shields). Figure 26F A plan view of component 2620 is shown, which further shows slot 2622 and groove 2624. Figure 26G The area 2626 is indicated, and the slot 2624 is further shown. It should be noted that the slot 2626 is adapted to receive the feedthrough 2510, and its dimensions (width and length) will vary depending on the characteristics of the feedthrough 2510. In some embodiments, the slot 2626 is not required. Figure 26H An edge view of component 2620 is shown. Component 2620 can be formed of any conductive material sufficient to carry the current in the cell chain 2200 and provide sufficient rigidity for the bridge 2500. In some embodiments, component 2620 can be formed of stainless steel, carbon steel, or any other suitable material.

[0185] Figures 26I to 26K The diagram shows the connection of component 2620 to feeder 2510 to form crossbar 2504. (See diagram for reference.) Figure 26I As shown, two components in assembly 2620 are attached to feedthrough 2510 in opposite ways, such that a slot 2622 on each component in assembly 2620 will engage with a corresponding slot 2612 on base 2502 to form crossbar 2504. Figure 26IAs shown, the feedthrough 2510 includes an inner conductor 2642 disposed within a feedthrough sheath 2640. An end portion 2644 is then attached to the sheath 2640 opposite the exposed portion of the inner conductor 2642. In some embodiments, the end portion 2644 has a diameter larger than the diameter of the sheath 2640; however, in some cases, the diameter of the end portion 2640 may be equal to or smaller than the diameter of the sheath 2640. A slot 2624 on each component of the assembly 2620 is arranged to receive the end portion 2644 such that the slot 2624 can receive the end portion 2644 if the diameter of the end portion 2644 is larger than the diameter of the sheath 2640. In some embodiments, the assembly 2620 may be soldered to the sheath 2640 of the feedthrough 2510. Figure 26J As shown Figure 26I The planar cross-sectional view of the crossbar 2504 and the feeder 2510 is shown. Figure 26K As shown Figure 26I The edge view of the crossbar 2504 and feeder 2510 shown.

[0186] Figure 26L and Figure 26M It shows Figure 25A The example assembly of the bridge 2500 shown. As shown, a crossbar 2504 formed by welding the component 2620 on either side of the feedthrough 2510 is mounted on the base 2502, such that the slot 2622 of the component 2620 engages with and is welded into place with the slot 2612 of the base 2502. Figure 26M As shown Figure 26L The plan view of Bridge 2500 is shown.

[0187] Figures 27A to 27I As shown Figure 25B The example shown is of bridge 2500. Figure 25B As shown, bridge 2500 may include spring portion 2514, which can provide stress relief when battery cell chain 2200 is installed inside the pressure vessel. Figure 25B As shown, bridge 2500 includes base 2512 and spring portion 2514. Spring portion 2514 is connected to feeder 2510 and connects feeder 2510 to base 2512. Figures 27A to 27D It shows the same as Figure 25B The bridge 2500 shown is an example of a base 2512 consistent with the base 2512. Figures 27E to 27H Spring blade 2720 is shown, while Figure 27I The formation of a spring portion 2514 having multiple spring blades 2720 is shown.

[0188] like Figure 27AAs shown, the substrate 2512 includes a support 2702 having two sidewalls 2706 attached to opposite sides of the support 2602. A slot 2704 is formed in the support 2702 and partially formed in the sidewalls 2706. A mounting base 2708 is formed on the side of the support 2702 without the sidewalls 2706. The mounting base 2708 includes an access point 2710. The mounting base 2708 and the access point 2710 are configured to mechanically attach the substrate 2512 to the end of the battery cell chain 2200, for example, by screws or welding (e.g., welding to electrode tabs). The slot 2704 is configured to receive, for example, Figure 22A One or more tabs 2210 or 2212 are shown. Specifically, slot 2704 accommodates one of tabs 2210 or 2212 (depending on which side of the cell chain 2200 the bridge 2500 is mounted on). Each slot in slot 2704 can accommodate one or more individual tabs, and these tabs are soldered to support 2702 during the mounting process.

[0189] When the bridge 2500 is installed, the sidewall 2706 extends vertically from the support 2702 in a direction away from the battery cell chain 2200. The sidewall 2706 includes a lug 2712 forming an opening. The opening formed by the lug 2712 is internally a structure 2714 capable of accommodating a spring portion 2514. In some embodiments, the spring portion 2514 may be welded to the structure 2714.

[0190] Figure 27B A plan view of the base 2512 is shown, and the mounting base 2708 is shown even more clearly. Figure 27C A side view of the base 2512 is shown, and the formation of the slot 2704 is further shown. Figure 27D An end view of the substrate 2512 is shown. The substrate 2512 can be integrally formed using a conductive material with sufficient strength, conductivity, and chemical resistance. For example, the substrate 2512 can be formed from stainless steel, low-carbon steel, or other conductive metallic materials.

[0191] Figures 27E to 27H A spring blade 2720 capable of forming the spring portion 2514 is shown. The spring blade 2720 is U-shaped, with two arms 2724 extending at right angles from the central portion 2722. The central portion 2722 includes a hole 2726 at its center, which is configured to receive the feed passage 2510. Therefore, the diameter of the hole 2726 matches the cross-sectional diameter of the feed passage 2510. Additionally, a curved portion 2728 is formed on either side of the hole 2726. Figure 27G As shown, Figure 27GA side view of the central portion 2722 is shown, and the curved portion 2728 is formed as a triangular portion that contributes to the spring action of the spring leaf 2720. Each arm of the arms 2724 also includes a triangular curved portion 2730, as shown... Figure 27H The side view is further shown. Furthermore, as... Figure 27F As shown in the plan view, the end of arm 27624 includes slot 2732, which is configured to engage with... Figure 27A and Figure 27C The lug 2712 of the base 2512 shown is joined to the structure 2714.

[0192] like Figure 27I As shown, the spring portion 2514 is formed by a plurality of opposing spring leaves 2720. (As...) Figure 27I As shown, the spring blades 2720 are arranged opposite each other (i.e., arms 2724 point in opposite directions). Feedthrough members 2510 are inserted into the holes 2726 of each spring blade 2720 and welded in place. The number of pairs of spring blades 2720 used to form the spring portion 2514 determines the resulting spring constant of the spring portion 2514. Figure 25B As shown, the slot 2732 of the spring leaf 2720 is then engaged with the lug 2712 using structure 2714 and welded to the lug 2712.

[0193] Feeders 2510 can take various forms and have different functions. The assembled cell chain 2200 includes two bridges 2302 and 2304, each having a feeder 2510 (one bridge is electrically coupled to all end anodes, and the other is electrically coupled to all end cathodes). The two feeders provide the primary function of externally connecting the assembled cell chain 2300 to the pressure vessel housing it. However, each feeder 2510 can be sized and configured for auxiliary functions, as discussed further below. As discussed above, bridges 2500 are tailored to accommodate the specific feeder 2510 used. In some embodiments according to the invention, the assembled cell chain 2300 includes a feeder 2510 configured to facilitate annular filling and another feeder 2510 configured to accommodate pressure bursts. As discussed below, these two configurations, although structurally very similar, can have different diameters, different end units 2644, and different internal conductor configurations. These features are discussed further below. In some embodiments, one of bridges 2302 or 2304 is configured to provide pressure relief to overpressure, while the other of bridges 2302 or 2304 is configured to allow annular filling. These two configurations have different dimensions and arrangements.

[0194] Figures 28A to 28J It shows that it can be used as such Figure 25AOr feeder 2800 of feeder 2510 shown in 25B. Feeder 2800 provides a pressure rupture function that allows pressure release in the event of overpressure in the pressure vessel. Figure 28A As shown, the feedthrough 2800 includes a conductor 2802 extending through a sheath 2804. A bursting disc 2806 is fixed above a base of the sheath 2804. The conductor 2802 extends from the sheath 2804, thus exposing it to provide electrical connection to the outside of the pressure vessel. Furthermore, the conductor 2802 includes a groove 2812 formed in its surface along its length to allow gas to flow from the bursting disc 2806 along the conductor 2802.

[0195] Conductor 2802 can be formed of any conductor (e.g., copper), while sheath 2804 can be formed of another conductor (e.g., carbon steel). The outer diameter of conductor 2802 is configured relative to the inner diameter of sheath 2804 such that a tight seal is formed between conductor 2802 and sheath 2804 when they are joined. In some embodiments, conductor 2802 can be joined to sheath 2804 in a heat treatment that heats sheath 2804, cools conductor 2802, and inserts conductor 2802 through sheath 2804. After temperature equilibrium is reached, the resulting structure provides a tight fit between conductor 2802 and sheath 2804. Sheath 2804 also provides corrosion resistance to conductor 2802.

[0196] Figure 28B The assembled conductor 2802 and the sheath 2804 are shown. Figure 28C It shows along Figure 28B The cross-sectional view along the AA direction is shown. Figure 28C The cross-sectional view shown illustrates that conductor 2802 fills the interior of sheath 2804, except for groove 2812.

[0197] Figure 28D Further shown Figure 28C The area shown is 2810, which is Figure 28B The substrate of the combined conductor 2802 and sheath 2804 structure is shown. Figure 28D As shown, when conductor 2802 does not fully extend to the bottom of the sheath 2804, a small cavity 2814 is formed. The cavity 2814 contains the bursting disk 2806.

[0198] Figure 28E As shown Figure 28C The area shown is 2808. (As shown in the image) Figure 28E As shown, when the feeder 2800 extends through the pressure vessel, the conductor 2802 extends through the top of the sheath 2804 to provide direct contact with the conductor 2802.

[0199] Figure 28F It shows from such Figure 28B The top view of the combined sheath 2804 and conductor 2802 structure shown. Figure 28D and Figure 28E As further shown, the edges of the sheath 2804 can be chamfered to reduce sharp edges. For example... Figure 28F As shown, groove 2812 is formed into conductor 2802. Any number of grooves extending along the length of conductor 2802 can exist. Figure 28F In the example shown, there are four grooves 2812, each with a width W and a depth D, which are evenly spaced around the periphery of the conductor 2802.

[0200] Figure 28G An example of the bursting disc 2806 is shown. Figure 28A As shown, the bursting disk 2806 is attached to the bottom of the sheath 2804 (i.e., the end of the sheath 2804 opposite to the end of the conductor 2802 extending from it). Figure 28G As shown, the bursting disc 2806 consists of a disc housing 2824, a disc flange 2822, and a disc cover 2820. The disc housing 2824, disc flange 2822, and disc cover 2820 can be formed from any material (e.g., carbon steel).

[0201] Figure 28H A top view of the disk housing 2824 is shown. Figure 28H The disc housing 2824 is also shown, with a disc flange 2822 inserted inside the disc housing 2824. The disc cover 2820 is coupled to the disc flange 2822 and the disc housing 2824. Figure 28I A side view of the bursting disc 2806 is shown, and specifically, the weld 2826 between the disc cover 2820 and the disc housing 2824 is shown. Figure 28J It shows the following: Figure 28H The cross-sectional view along the AA direction is shown. Figure 28J The diagram further illustrates the welding of the disc cover 2820 to both the disc flange 2822 and the disc housing 2824 via weld 2826. When the pressure difference across the disc cover 2820 exceeds a threshold, the disc cover 2820 is capable of bursting and allowing pressure release.

[0202] Figures 29A to 28H It shows that it can be used as such Figure 25A Or feeder 2900 of feeder 2510 shown in 25B. For example... Figure 29AAs shown, the feedthrough 2900 includes a conductor 2902 extending through a sheath 2904. A feedthrough cover 2906 is fixed to a base of the sheath 2904. The conductor 2902 extends from the sheath 2904, thus exposing it to provide electrical connection to the outside of the pressure vessel.

[0203] Conductor 2902 can be formed of any conductor (e.g., copper), while sheath 2904 can be formed of another conductor (e.g., carbon steel). The outer diameter of conductor 2902 is configured relative to the inner diameter of sheath 2904 such that a tight seal is formed between conductor 2902 and sheath 2904 when they are joined. In some embodiments, conductor 2902 can be joined to sheath 2904 in a heat treatment that heats sheath 2904, cools conductor 2902, and inserts conductor 2902 through sheath 2904. When the temperature reaches equilibrium, the resulting structure provides a tight fit between conductor 2902 and sheath 2904.

[0204] Figure 29B The assembled conductor 2902 and the sheath 2904 are shown. Figure 29C It shows along Figure 29B The cross-sectional view along the BB direction is shown. Figure 29C The cross-sectional view shown illustrates the interior of conductor 2902 filling the sheath 2904.

[0205] Figure 29D As shown Figure 29A The connection between the feeder cover 2906 and the sheath 2904 in region 2908 is shown. As shown, the feeder cover 2906 can be welded to the sheath 2904 at weld 2912.

[0206] Figure 29E The region 2910 extending from the sheath 2904 to the conductor 2902 is shown. As shown, the edges of the sheath 2904 can be chamfered.

[0207] Figure 29F , Figure 29G and Figure 29H A feedthrough shield 2906 is shown. The feedthrough shield 2906 may be a disk with the same diameter as the covering sheath 2904. The feedthrough shield 2906 may be formed of a conductive material (e.g., carbon steel). In some embodiments, the feedthrough shield 2906 may be cup-shaped, in which case its diameter may be larger than the diameter of the covering sheath 2904.

[0208] Figures 30A to 30E An assembly of a battery structure according to some embodiments of the present disclosure is shown. Figure 30A The assembly of structure 3000 is shown. (As shown) Figure 30AAs shown, the assembled battery cell chain 2300 is inserted into the bushing 3002. End caps 3004 are inserted into the bushing on each side. Figure 30A As shown, the battery cell chain 2300 includes one side (e.g., the cathode side) as... Figure 28A The feedthrough 2800 shown and the opposite side (e.g., the anode side) are as follows Figure 29A The feedthrough 2900 is shown. An end cap 3004 is inserted above the feedthrough 2800, and another end cap 3004 is inserted above the feedthrough 2900. The end caps 3004 and the assembled cell chain 2300 can then be welded to the bushing 3002 to form structure 3000.

[0209] Figure 30B The final assembly is shown. Structure 3000 is wrapped with a wrapping layer 3010, and then an electrolyte is injected into structure 3000, as discussed above. In some embodiments, the wrapping layer 3010 may be a composite material consisting of a substrate (resin) and fibers, such as glass fiber and epoxy resin or other such materials.

[0210] like Figure 30B As further shown, the feeder filling sleeve 3006 is inserted above the feeder 2900. As discussed further below, the outer diameter of the feeder 2900 is smaller than that of the feeder 2800, but the end caps 3004 on each side are the same. The feeder filling sleeve 3006 is used such that the outer diameters of the feeder 2900 and the feeder filling sleeve 3006 match the diameter of the feeder 2800. As further shown, a feeder insulating ring 3008 is applied to each side. It should also be noted that the bushing 3002 can be welded to the assembled cell chain 2300 and the two caps 3004 using laser welding technology before the wrapping layer 3010 and the addition of electrolyte, as discussed further below.

[0211] Figure 30C An assembled battery structure 3012 without the encapsulation layer 3010 is shown. Figure 30C The area 3014 shown is in Figure 30D As shown in the figure, region 3016 is... Figure 30E As shown in the image. Figure 30D As shown, feedthrough 2800 extends through cap 3004. Insulating ring 3008 is inserted over feedthrough 2800 and into end cap 3014. Bridge 2500 is also shown. Feedthrough 2800 is sealed to cap 3004, as discussed in further detail below. Figure 30D The bridge 2500 is also shown, which may include, for example... Figure 25B The stress relief is shown. As discussed above, the feedthrough 2800 provides a pressure relief function and can be coupled to the cathode side of the assembled cell chain 2300.

[0212] Figure 30E As shown Figure 30C The area shown is 3016. (As shown...) Figure 30E As shown, the feedthrough 2900 extends through the cap 3004. The gap between the feedthrough 2900 and the cap 3004 allows electrolyte to be injected into the structure 3012. After injection, a feedthrough filling sleeve 3006 can be inserted between the feedthrough 2900 and the cap 3004, as discussed below, and the assembly is sealed, as further discussed below. Additionally, an insulating ring 3008 is inserted above the feedthrough 2900 and into the cap 3004. Figure 30E The bridge 2500 is also shown, which may include, for example... Figure 25B The stress relief is shown. The feedthrough 2900 can be coupled to the anode side of the assembled cell chain 2300.

[0213] Figures 31A to 31D An example of bushing 3002 is shown. Figure 31A As shown, bushing 3002 is formed in the tube. Figure 31B A cross-sectional view of bushing 3002 is shown. The inner diameter of bushing 3002 is sufficient to accommodate the diameter of the assembled battery cell chain 2300 and the end cap 3004. Specifically, the diameter of the battery cell chain 2300, the inner diameter of bushing 3002, and the outer diameter of end cap 3004 are configured such that end cap 3004 and the assembled battery cell chain 2300 are tightly fitted within bushing 3002. Furthermore, the length of bushing 3002 can be arranged to extend beyond the length of structure 3012 during assembly.

[0214] Bushing 3002 is designed to prevent hydrogen permeation as much as possible. This feature can be used in applications such as... Figure 31C This is achieved through the composite material structure shown. Figure 31C It shows Figure 31B The area shown is 3100. (As shown...) Figure 31C As shown, bushing 3002 is formed of a layered material surrounded by polymer layers 3102 and 3106, which includes an ethyl vinyl alcohol (EVOH) layer 314. Polymer layers 3102 and 3106 can be, for example, high-density polyethylene (HDPE), polyamide (PA), or polypropylene (PP). In one example, layers 3102 and 3106 can be HDPE. EVOH 3104 provides a barrier against air, including hydrogen. Layers 3102, 3104, and 3106 are bonded together using an adhesive or bonding layer. The bonding layer can be, for example, a different grade of polyethylene, such as HDPE. Bushing 3002.

[0215] Figure 31DThe illustration shows the laser welding of bushing 3102 to a structure such as end cap 3004 or a support structure for assembling the battery cell chain 2300. The HDPE used to form the assembled battery cell chain 2300 in the overmolding process can be colored to absorb laser light from laser 3112. The HDPE layer 3102 and EVOH layer 3104 can be arranged to transmit laser light from laser 3112. Therefore, bushing 3002 can be laser welded to the underlying structure 3110 using laser light from laser 3112. In some examples, the HDPE used in the assembled battery cell chain 2300 is colored black, while the HDPE and EVOH layers in bushing 3002 can remain in their natural state (e.g., uncolored) to transmit laser light.

[0216] Figure 32A and Figure 32B An example of an end cap 3004 according to some embodiments is shown. Figure 32A A sliding engagement end cap 3004 is shown, into which a bushing 3002 can slide after being properly trimmed and sized. (See diagram.) Figure 32A As shown, end cap 3004 includes a cylindrical body 3202 through which feeder 2510 can be inserted and sealed. End cap 3004 also includes a base 3204 extending therefrom from the cylindrical body 3202, the cylindrical body 3202 engaging with bushing 3002.

[0217] Figure 32B The overmolded end cap 3004 is shown. (Example) Figure 32B The overmolded end cap 3004 shown also includes a cylinder 3208 and an integrally formed base 3206. The integrally formed base 3206 can be fully inserted into the bushing 3002, thereby eliminating the need for pre-sizing of the bushing 3002. Furthermore, the overmolded end cap 3004 eliminates gap requirements, thus eliminating the need for insulation of the cylinder 3004 and its structure. Moreover, due to the overmolding process, the resulting feedthrough can be more reliably crimped to seal the cylinder 3208 to the inserted feedthrough 2510.

[0218] Figures 33A to 33H As shown Figure 32B The example shown is the overmolded end cap 3004. Figure 33A A pole post boss 3300 according to some embodiments of the present disclosure is shown. The pole post boss 3300 may be formed of steel (e.g., SAE 1018) and, in some cases, may be zinc-plated or nickel-plated. However, any material with sufficient strength may be used.

[0219] like Figure 33AAs shown, the pole post boss 3300 includes a base 3302, a chuck mount 3304, a cylinder 3306, and a lip 3308 on the top of the cylinder 3306. The base 3302 may be formed of a large-diameter plate having formed holes 3310. A support spacer 3312 may be formed between the base 3310 and the chuck mount 3304. The support spacer 3312 also acts as a resin baffle to protect the mount 3302 from epoxy / resin during the winding process. Furthermore, the chuck mount 3304 may have a flat portion 3316 and a threaded portion 3314, which allows easy access to the pole post boss 3300. The flat portion 3316 may also be used to mount strain gauges to monitor pressure in a pressure vessel. An opening 3318 extends through the center of the pole post boss (i.e., extends through the cylinder 3306 and extends to the outside of the base 3302), through which a feedthrough 2510 may extend.

[0220] Figure 33B The diagram shows a view of the pole post boss 3300 looking into the opening 3318 from the top of the pole post boss 3300. Figure 33B Further shown are the lip 3308, the threaded portion 3314, the support spacer 3312, and the base 3302 with the hole 3310. Figure 33C A side view of the pole post boss 3300 is shown, which also shows the base 3302, hole 3310, support partition 3312, chuck mount 3304 with flat portion 3316 and threaded portion 3314, cylinder 3306, lip 3308 and opening 3318.

[0221] Figure 33D The pole post boss 3300 is shown along Figure 33B The cross-sectional view along the AA direction is shown. Figure 33D The opening 3318 is shown extending through the entire pole post boss 3300. Figure 33D The image also shows a lip 3308, a cylinder 3306, a support partition 3312, and a base 3302. Furthermore, a structure 3320 formed in the cylinder 3306 is also shown. Figure 33E The structure 3320 is further illustrated below. (As shown in the image...) Figure 33E As shown, protrusions 3322 are formed on the inner wall of the cylindrical body 3306. After overmolding, protrusions 3322 will form bumps on the inner wall, which can help prevent polymer from flowing downwards during the crimping process, thereby preventing the overmolded HDPE from delaminating from the post boss substrate 3302.

[0222] Figure 33F and Figure 33GThe diagram illustrates overmolding to form a cap 3004, with the pole boss 3300 serving as a substrate. In some embodiments, the overmolding can be HDPE, and as discussed above, it can be black HDPE to facilitate... Figure 31D The laser welding is illustrated. Specifically, HDPE may include a specific weight percentage of carbon black or other additives to promote laser welding and maintain chemical compatibility with the electrolyte.

[0223] Figure 33F A view of the bottom of the overmolded cap 3004 is shown. (See attached image.) Figure 33F As shown, overmolding 3318 can be disposed within opening 3318. Furthermore, overmolding can provide sidewalls 3340 and 3334 that allow mating with bushing 3002. In some embodiments, a protrusion exists between sidewalls 3340 and 3334 that is trimmed during subsequent operations, thereby allowing a smooth transition between bushing 3002 and end cap 3004. Additionally, alignment structure 3330 can be formed. Structure 3332 can also be formed to facilitate guiding feedthrough 2510 through opening 3318. Furthermore, structure 3336 is formed that allows for the containment of HDPE during the crimping process.

[0224] Figure 33H A finished overmolded cap 3004 according to some embodiments of the present disclosure is shown. For example... Figure 33H As shown, the overmolding portion 3350 exposes the support partition 3312, the cylinder 3306, and the lip 3308. Furthermore, the overmolding portion 3338 is also provided in and extends from the opening 3318. It should be noted that the diameter of the opening 3318 is fixed. Therefore, as... Figure 30B As shown, the combination of the diameter of the feeder 2800 and the diameters of the feeder 2900 and the filling sleeve 3006 is arranged to match the diameter of the opening 3318 and to provide a seal when the cylinder 3306 is crimped.

[0225] Figures 34A to 34D The example shows the bushing 3002 being welded to the end cap 3004. (See diagram.) Figure 34A As shown, the assembled cell chain 2300 with cap 3400 is fully inserted into the tubular bushing 3002. Feedthroughs 2800 and 2900 extend through cap 3400, as shown above. Figure 34B As shown, a weld 3404 is formed between bushing 3002 and cap 3004. Figure 34B As further shown, bushing 3002 can be trimmed at trimming point 3406 to achieve the following: Figure 34D The resulting battery structure 3012 shown provides a clean surface. It should be noted that, at this stage, the overmolded components of the assembled cell chain 2300 can also be welded.

[0226] Figure 34C Further examples are shown, such as Figure 34A The area shown is 3402. Figure 34C Weld 3404 and trimmed portion 3406 are further shown. (See attached image.) Figure 30B As further shown, once the welding process is completed, it can be wrapped with a structural cladding layer 3010. Figure 34D The battery structure 3012 shown is used to complete the battery.

[0227] Figure 35A Figure 35 shows, for example Figure 30B An example of the feedthrough filling sleeve 3006 is shown. As discussed above, after the electrolyte is injected into the battery structure 3012 through the cap 3400 and around the feedthrough 2900, the feedthrough filling sleeve 3006 is inserted around the feedthrough 2900. The barrel portion 3306 can then be press-fitted around the combination of the feedthrough filling sleeve 3006 and the feedthrough 2900 to seal the battery structure 3012. The feedthrough filling sleeve 3006 can be formed of, for example, HDPE.

[0228] like Figure 35B As shown in the plan view, the feeder filling sleeve 3006 has a length L. The length L of the feeder filling sleeve 3006 matches the length of the cylinder portion 3306. Figure 35C A cross section along the AA direction is shown, and the side wall 3506 of the feeder filling sleeve 3006 is also shown. Figure 35D A view along the length of the feeder filling sleeve 3006 is shown, indicating the inner diameter 3502 and the outer diameter 3504. As discussed above, the outer diameter 3504 is configured to match the inner diameter of the cylindrical portion 3306 of the cap 3400. The inner diameter 3502 is configured to match the outer diameter of the feeder 2900. Therefore, when the cylindrical portion 3306 is crimped, the feeder 2900 is sealed.

[0229] Figures 36A to 36D An example of a feedthrough insulating ring 3008 is shown. The feedthrough insulating ring 3008 can be configured as follows: Figure 30B The feedthrough 2900 or feedthrough 2800 shown is insulated from the cap 3400 and can conform to standards such as IEC 60644. Therefore, the insulating ring 3008 can be formed of HDPE. Figure 36AAs shown, the HDPE includes a tubular portion 3604 and a lip portion 3602. The inner diameter of the lip portion 3602 is sized to fit the outer diameter of the feeder 2800 or the outer diameter of the feeder filling sleeve 3006. The outer diameter of the feeder 2800 can be inserted into the cylindrical portion 3306 of the cap 3304 until the lip 3602 fits against the lip 3308 of the cap 3304.

[0230] Figure 36B A side view of the feedthrough insulating ring 3008 is shown. The feedthrough is shown as follows: Figure 36A The tubular portion 3604 and the lip 3602 are shown. Figure 36C It shows the following: Figure 36B The cross-sectional view along the AA direction is shown. (As shown) Figure 36B As shown, the tubular portion 3604 and the lip 3602 are formed from a single injection molded part. Figure 36D A plan view of the feedthrough insulating ring 3008 is shown.

[0231] Figure 37 The use of some embodiments according to this disclosure is illustrated. Figures 12A to 36D The method for assembling the battery of the components shown is 3700. It should be understood that... Figure 37 The steps shown can be performed in different orders.

[0232] Method 3700 begins with step 3702, in which components for producing the finished battery are manufactured and assembled. This includes... Figures 12A to 14N The electrodes, Figures 17A to 22F The production of the aforementioned overmolded battery cell tray assembly, Figures 24A to 24F The production of the split-type top bracket 2310 shown Figures 25A to 29H The production of the bridge components, Figures 31A to 31D The production of the bushing shown Figures 32A to 33H The production of the cap, Figures 35A to 35C The production of the feedthrough filling sleeve shown, and Figures 36A to 36D The production of the insulating ring for the feedthrough component shown.

[0233] In step 3704, the battery cell chain 1600 is assembled, as follows: Figures 15A to 16 As shown. In step 3706, the battery cell chain 1600 is compressed and fixed with the battery cell arm 2102, as... Figures 22A to 22F As shown, a battery cell chain 2200 is generated. In step 3708, the top bracket 2306 is attached, as shown... Figure 23B As shown, and in step 3710, the attached bridge, as... Figures 23A to 23E As shown, this forms an assembled battery cell chain 2300. In step 3712, the assembled battery cell chain 2300 and the cap 3004 are inserted into the bushing 3002, as shown. Figures 34A to 34DAs shown. In step 3714, the laser welding process attaches the bushing 3002 to the cap 3004 and welds it to the internal components of the assembled battery cell chain 2300, as shown. Figure 34A and Figure 34C As shown. In step 3716, the battery is wrapped with a wrapping layer 3010, as follows. Figure 30B As shown. In step 3718, electrolyte is injected into the assembled battery cell chain 2300 inside the bushing 3002, and in step 3720, as... Figure 30B As shown, the feeder filling sleeve 3006 is inserted, and the cylinder 3208 is crimped to seal with the feeder 2510. In step 3722, the feeder insulating ring 3008 is applied to each side.

[0234] For further clarity, the following aspects of embodiments of this disclosure are provided. It should be understood that the invention should not be limited to these aspects, which are merely used to further illustrate these embodiments.

[0235] Aspect 1: A metal-hydrogen battery comprising: a bridgeless CPV superstack having K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes; a pressure vessel encapsulating the bridgeless CPV superstack; and an electrolyte within the pressure vessel.

[0236] Aspect 2: The battery according to aspect 1, wherein each end anode in the end anodes includes one or more layers of anode material connected to the anode tab.

[0237] Aspect 3: The battery according to aspect 1 or 2, wherein each end cathode in the end cathode includes one or more layers of cathode material connected to a cathode tab and a separator material covering the cathode material, wherein the separator material includes a core.

[0238] Aspect 4: The battery according to any one of aspects 1 to 3, wherein each intermediate anode-cathode in the intermediate anode-cathode comprises: an anode having one or more anode materials connected to one or more cathode materials by means of a metal sheet; and a separator material covering the cathode material, wherein the separator material comprises a core wall.

[0239] Aspect 5: The battery according to any one of Aspects 1 to 4, wherein the bridgeless CPV super stack further includes a first cell plate and a second cell plate, the first cell plate and the second cell plate being on either side of the K cells and connected by an arm.

[0240] Aspect 6: The battery according to aspect 5, wherein K cells are compressed before the first cell plate and the second cell plate are connected to the arm.

[0241] Aspect 7: The battery according to any one of aspects 1 to 6, wherein the end anode includes an anode tab and the end cathode includes a cathode tab, and further includes an anode end bridge engaged with the anode tab of each of the K cells and a cathode end bridge engaged with the cathode tab of each of the K cells.

[0242] Aspect 8: The battery according to aspect 7, wherein each of the anode bridge and the cathode bridge includes a feed conductor extending through the pressure vessel.

[0243] Aspect 9: A method of providing a battery, comprising forming a bridgeless CPV superstack of K cells by alternately stacking K first layers and K second layers, each separated by a separator, wherein each first layer includes L / 2 anode-cathode pairs and each second layer includes L / 2-1 anode-cathode pairs, an end anode, and an end cathode; encapsulating the bridgeless CPV superstack in a pressure vessel; and adding an electrolyte to the pressure vessel.

[0244] Aspect 10: The method according to aspect 9 further includes forming K end anodes, wherein each end anode includes one or more layers of anode material connected to an anode tab.

[0245] Aspect 11: The method according to any one of aspects 9 to 10 further includes forming K end cathodes, wherein each end cathode includes one or more layers of cathode material connected to a cathode tab, and wherein a diaphragm material covers the cathode material, the diaphragm material including a wall core.

[0246] Aspect 12: The method according to any one of aspects 9 to 11 further includes forming K*(L-1) intermediate anode-cathodes, wherein each intermediate anode-cathode comprises: an anode having one or more anode materials connected to one or more cathode materials by a metal sheet, and wherein a diaphragm material covers the cathode material, wherein the diaphragm material comprises a wall core.

[0247] Aspect 13: The method according to any one of aspects 9 to 12, wherein forming a stack of K cells comprises: providing a first cell board on which K first layers and K second layers are stacked; and providing a second cell board above the K first layers and K second layers.

[0248] Aspect 14: The method according to aspect 13, wherein forming a stack of K cells comprises: compressing between a first cell plate and a second cell plate; and connecting the first cell plate to the second cell plate by an arm extending between the first cell plate and the second cell plate.

[0249] Aspect 15: The method according to aspect 12 or 13, wherein each of the K end anodes includes an anode tab and the K end cathodes includes a cathode tab, and the method further includes: engaging an anode end bridge to the anode tab of each of the K units; and engaging a cathode end bridge to the cathode tab of each of the K units.

[0250] Aspect 16: The method according to any one of aspects 12 to 15, wherein each of the anode bridge and the cathode bridge includes a feed conductor extending through the pressure vessel.

[0251] Aspect 17: A bridgeless CPV super stack comprising K cells, each cell comprising a first layer and a second layer, wherein the first layer comprises L / 2 intermediate anode-cathodes, and wherein the second layer comprises end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

[0252] Aspect 18: The bridgeless CPV super stack according to aspect 17 further includes a first cell board and a second cell board separated by K cells.

[0253] Aspect 19: The bridgeless CPV super stack according to aspect 17 or 18 further includes bushings between the first cell board and the K cells and between the second cell board and the K cells.

[0254] Aspect 20: A bridgeless CPV super stack according to any one of aspects 17 to 19, wherein the end anode and the end cathode each include tabs, and the bridgeless CPV super stack further includes a cathode end bridge coupled through the tabs of the end cathode and an anode end bridge coupled through the tabs of the end anode.

[0255] Aspect 21: A method for forming a bridgeless CPV superstack, comprising stacking K cells, each cell comprising a first layer and a second layer, wherein the first layer comprises L / 2 intermediate anode-cathodes, and wherein the second layer comprises end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

[0256] Aspect 22: According to the method of aspect 21, stacking K units includes stacking K units between a first cell board and a second cell board.

[0257] Aspect 23: The method according to aspect 21 or 22 further includes providing bushings between the first cell plate and the K cells and between the second cell plate and the K cells.

[0258] Aspect 24: The method according to any one of aspects 21 to 23, wherein the end anode and the end cathode each include a tab, and the method further includes connecting a cathode end bridge through the tab of the end cathode and connecting an anode end bridge through the tab of the end anode.

[0259] Aspect 25: A metal-hydrogen battery comprising: an assembled cell chain including an overmolded cell tray; a superstack having K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes, and wherein each end cathode includes a cathode tab, and each end anode includes an anode tab, the superstack being assembled on the overmolded cell tray; an overmolded end plate separated by overmolded cell plates, the overmolded end plate being positioned above the superstack; and a cell arm connecting the overmolded cell tray to the overmolded end plate and the overmolded cell plates to compress the superstack; and a first bridge and a second bridge, the first bridge being connected to all cathode tabs, the second bridge being connected to all anode tabs.

[0260] Aspect 26: The battery according to aspect 25, wherein a separator is inserted between the end cathode and the anode of the intermediate anode-cathode and between the cathode material and the anode material in the intermediate anode-cathode.

[0261] Aspect 27: The battery according to aspect 25 or 26, wherein a first separator is disposed between the overmolded cell tray and the super stack, and a second separator is disposed between the super stack and the overmolded end plate and the overmolded cell plate.

[0262] Aspect 28: The battery according to any one of aspects 25 to 27, wherein one or both of the first bridge and the second bridge include a spring portion for providing stress relief.

[0263] Aspect 29: The battery according to any one of aspects 25 to 28, wherein the first bridge includes a burst pressure relief feedthrough.

[0264] Aspect 30: The battery according to any one of aspects 25 to 29, wherein the second bridge includes a filling feeder that allows the annular filling portion to pass through.

[0265] Aspect 31: The battery according to any one of aspects 25 to 30 further includes a bushing into which the assembled cell chain is inserted.

[0266] Aspect 32: The battery according to 25 to 31, wherein the bushing is a tube formed of a material having an ethyl vinyl alcohol (EVOH) layer sandwiched between polymer layers, the EVOH layer impeding the transport of hydrogen.

[0267] Aspect 33: The battery according to any one of aspects 25 to 32 further includes caps located on each side of the assembled cell chain, wherein the caps and the assembled cell chain are laser welded to the bushing.

[0268] Aspect 34: The battery according to any one of aspects 25 to 33 further includes an electrolyte applied through an annular filling portion.

[0269] Aspect 35: The battery according to any one of aspects 25 to 34 further includes a feeder feeder sleeve applied above the feeder feeder.

[0270] Aspect 36: The battery according to any one of aspects 25 to 35 further includes an insulating ring.

[0271] Aspect 37: The battery according to any one of aspects 25 to 36 further includes a wrapping layer around the bushing and cap.

[0272] Aspect 38: A method of producing a battery, comprising: assembling an assembly including an end anode, an end cathode, an intermediate anode-cathode, an overmolded cell tray, an overmolded end plate, and an overmolded cell plate; assembling a cell chain by stacking the end anode, end cathode, and intermediate anode-cathode on the overmolded cell tray to form a super-stack having K units, and placing overmolded end plates separated by overmolded cell plates on top of the super-stack, each unit including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes L / 2-1 intermediate anode-cathodes. The process includes: cathode-separated end anodes and end cathodes, wherein each end cathode includes a cathode tab and each end anode includes an anode tab; super-stacked assembly on an overmolded cell tray; compression of the cell chain; securing the overmolded cell tray to an overmolded end plate and an overmolded cell plate via cell arms; application of a top support to the cell chain; application of bridges to the cell chain to form an assembled cell chain; insertion of the assembled cell chain, along with a cap, into a bushing; welding the cap and the assembled cell chain to the bushing; wrapping the bushing and cap; injecting electrolyte through an annular filling section; adding a feedthrough filling section sleeve; crimping feedthroughs onto each bridge in the bridges; and adding feedthrough insulating rings.

[0273] Aspect 39: The method according to aspect 38, wherein the cathodes of the end cathode and the intermediate anode-cathode are separated from the anode material by a diaphragm.

[0274] Aspect 40: The method according to aspect 38 or 39 further includes stacking a first separator between the overmolded cell tray and the super stack, and stacking a second separator between the super stack and the overmolded end plate and the overmolded cell plate.

[0275] Aspect 41: The method according to any one of aspects 38 to 40, wherein the bridge includes a first bridge and a second bridge, wherein one or both of the first bridge and the second bridge include a spring portion for providing stress relief.

[0276] Aspect 42: The method according to any one of aspects 38 to 41, wherein the bridge includes a first bridge and a second bridge, and wherein the first bridge includes a burst pressure relief feeder.

[0277] Aspect 43: The method according to any one of aspects 38 to 42, wherein the second bridge includes a filling section feeder that allows the annular filling section to pass through.

[0278] Aspect 40: The method according to any one of aspects 38 to 43, wherein the bushing is a tube formed of a material having an ethyl vinyl alcohol (EVOH) layer sandwiched between polymer layers, the EVOH layer impeding the transport of hydrogen.

[0279] The foregoing description of this disclosure has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the precise form of the disclosure. The breadth and scope of this disclosure should not be limited to any of the exemplary embodiments described above. Many modifications and variations will be apparent to those skilled in the art. These modifications and variations include any related combinations of the disclosed features. The embodiments were chosen and described in order to best explain the principles of this disclosure and its practical application, thereby enabling others skilled in the art to understand the various embodiments of this disclosure and the various modifications suitable for the particular purpose contemplated. It is intended that the scope of this disclosure be defined by the appended claims and their equivalents.

Claims

1. A metal-hydrogen battery, comprising: A bridgeless CPV super stack has K cells, each cell including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes; Pressure vessel, encapsulating the bridgeless CPV super stack; and Electrolyte, inside the pressure vessel.

2. The battery according to claim 1, wherein, Each of the end anodes comprises one or more layers of anode material connected to the anode tab.

3. The battery according to claim 1, wherein, Each of the end cathodes includes one or more layers of cathode material connected to a cathode tab and a diaphragm material covering the cathode material, wherein the diaphragm material includes a wall core.

4. The battery according to claim 1, wherein, Each intermediate anode-cathode in the intermediate anode-cathode includes: an anode having one or more layers of anode material connected to one or more layers of cathode material by a metal sheet; and a diaphragm material covering the cathode material, wherein the diaphragm material includes a wall core.

5. The battery according to claim 1, wherein, The bridgeless CPV super stack also includes a first cell board and a second cell board, which are located on either side of the K cells and connected by an arm.

6. The battery according to claim 5, wherein, The K units are compressed before the first and second cell boards are connected to the arm.

7. The battery according to claim 1, wherein, The end anode includes an anode tab and the end cathode includes a cathode tab, and also includes an anode end bridge engaged with the anode tab of each of the K units and a cathode end bridge engaged with the cathode tab of each of the K units.

8. The battery according to claim 7, wherein, Each of the anode bridge and the cathode bridge includes a feed conductor extending through the pressure vessel.

9. A method of providing a battery, comprising: A bridgeless CPV super stack of K units is formed by alternately stacking K first layers and K second layers separated by a diaphragm, wherein each first layer includes L / 2 anode-cathode pairs and each second layer includes L / 2-1 anode-cathode pairs, an end anode, and an end cathode; Encapsulating the bridgeless CPV super stack into a pressure vessel; and Electrolyte is added to the pressure vessel.

10. The method of claim 9, further comprising forming K end anodes, wherein, Each of the end anodes comprises one or more layers of anode material connected to the anode tab.

11. The method of claim 9, further comprising forming K end cathodes, wherein, Each of the end cathodes includes one or more layers of cathode material connected to a cathode tab, and wherein a diaphragm material covers the cathode material, the diaphragm material including a wall core.

12. The method of claim 9, further comprising forming K*(L-1) intermediate anode-cathodes, wherein, Each of the intermediate anode-cathodes comprises: an anode having one or more layers of anode material connected to one or more layers of cathode material by a metal sheet, and wherein a diaphragm material covers the cathode material, wherein the diaphragm material comprises a wall core.

13. The method according to claim 9, wherein, The stack forming the K cells includes: Provides a first cell board on which the K first layers and the K second layers are stacked; and A second cell board is provided above the K first layers and the K second layers.

14. The method according to claim 13, wherein, The stack forming the K cells includes: Compressing between the first battery cell plate and the second battery cell plate; The first battery cell plate and the second battery cell plate are connected by an arm extending between the first battery cell plate and the second battery cell plate.

15. The method according to claim 14, wherein, Each of the K end anodes includes an anode tab, and each of the K end cathodes includes a cathode tab, and the method further includes: Connect the anode end bridge to the anode tab of each of the K units; and The cathode end bridge is connected to the cathode tab of each of the K units.

16. The method according to claim 15, wherein, Each of the anode bridge and the cathode bridge includes a feed conductor extending through the pressure vessel.

17. A bridgeless CPV superstack, comprising: K units, each unit comprising a first layer and a second layer, wherein the first layer comprises L / 2 intermediate anode-cathodes, and wherein the second layer comprises end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

18. The bridgeless CPV super stack according to claim 17, further comprising a first cell board and a second cell board separated by the K cells.

19. The bridgeless CPV super stack of claim 18, further comprising bushings between the first cell board and the K cells and between the second cell board and the K cells.

20. The bridgeless CPV superstack according to claim 18, wherein, The end anode and the end cathode each include tabs, and the bridgeless CPV super stack also includes a cathode end bridge coupled through the tabs of the end cathode and an anode end bridge coupled through the tabs of the end anode.

21. A method for forming a bridgeless CPV superstack, comprising: K units are stacked, each unit including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes.

22. The method according to claim 21, wherein, Stacking K cells involves stacking the K cells between a first cell board and a second cell board.

23. The method of claim 22, further comprising providing bushings between the first cell plate and the K cells and between the second cell plate and the K cells.

24. The method according to claim 22, wherein, The end anode and the end cathode each include a tab, and the method further includes connecting a cathode end bridge through the tab of the end cathode and connecting an anode end bridge through the tab of the end anode.

25. A metal-hydrogen battery, comprising: Assemble a battery cell chain, the assembled battery cell chain comprising: Overmolded battery cell tray; A super stack having K units, each unit including a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes, and wherein each end cathode includes a cathode tab, and each end anode includes an anode tab, the super stack being assembled on the overmolded cell tray; A molded end plate, separated by a molded cell plate, is located above the super stack; and The cell arm connects the overmolded cell tray to the overmolded end plate and the overmolded cell plate to compress the super stack; and A first bridge and a second bridge, wherein the first bridge is connected to all the cathode tabs and the second bridge is connected to all the anode tabs.

26. The battery according to claim 25, wherein, A diaphragm is inserted between the anode of the end cathode and the anode of the intermediate anode-cathode, and between the cathode material and the anode material in the intermediate anode-cathode.

27. The battery according to claim 26, wherein, The first separator is disposed between the overmolded cell tray and the super stack, and the second separator is disposed between the super stack and the overmolded end plate and the overmolded cell plate.

28. The battery according to claim 25, wherein, One or both of the first bridge and the second bridge include a spring portion for providing stress relief.

29. The battery according to claim 25, wherein, The first bridge includes a burst pressure relief feeder.

30. The battery according to claim 29, wherein, The second bridge includes a filling feeder that allows the annular filling section to pass through.

31. The battery of claim 30, further comprising a bushing into which the assembled cell chain is inserted.

32. The battery according to claim 31, wherein, The bushing is a tube formed of a material having an ethyl vinyl alcohol (EVOH) layer sandwiched between polymer layers, the EVOH layer hindering the transport of hydrogen.

33. The battery of claim 32, further comprising caps located on each side of the assembled cell chain, wherein, The cap and the assembled battery cell chain are laser welded to the bushing.

34. The battery according to claim 32, further comprising an electrolyte applied through the annular filling portion.

35. The battery according to claim 34, further comprising a feeder filling sleeve applied above the filling feeder.

36. The battery according to claim 35, further comprising an insulating ring.

37. The battery of claim 36, further comprising a wrapping layer around the bushing and the cap.

38. A method for producing a battery, comprising: Assemble the components, which include end anodes, end cathodes, intermediate anode-cathode, coated cell trays, coated end plates, and coated cell boards; The battery cell chain is assembled by stacking the end anodes, end cathodes, and intermediate anode-cathodes on the overmolded battery cell tray to form a super stack with K units, and placing the overmolded end plates separated by the overmolded battery cell plates on top of the super stack. Each unit includes a first layer and a second layer, wherein the first layer includes L / 2 intermediate anode-cathodes, and wherein the second layer includes end anodes and end cathodes separated by L / 2-1 intermediate anode-cathodes, and wherein each end cathode includes a cathode tab, and each end anode includes an anode tab. The super stack is assembled on the overmolded battery cell tray. The cell chain is compressed, and the overmolded cell tray is fixed to the overmolded end plate and the overmolded cell plate by the cell arm; Apply a top support to the battery cell chain; Bridges are applied to the battery cell chain to form an assembled battery cell chain; Insert the assembled battery cell chain, along with the cap, into the bushing; The cap and the assembled battery cell chain are welded to the bushing; Enclose the bushing and the cap; Electrolyte is injected through the annular filling section; Add a feedthrough filling sleeve; Feeders are press-fitted onto each of the bridges; and Add an insulating ring to the feedthrough component.

39. The method according to claim 38, wherein, The end cathode and the intermediate anode-cathode are separated from the anode material by a diaphragm.

40. The method of claim 38, further comprising: A first separator is stacked between the overmolded cell tray and the super stack, and a second separator is stacked between the super stack and the overmolded end plate and the overmolded cell plate.

41. The method according to claim 38, wherein, The bridge includes a first bridge and a second bridge, wherein one or both of the first bridge and the second bridge include a spring portion for providing stress relief.

42. The method according to claim 38, wherein, The bridge includes a first bridge and a second bridge, wherein the first bridge includes a burst pressure relief feeder.

43. The method according to claim 42, wherein, The second bridge includes a filling feeder that allows the annular filling section to pass through.

44. The method according to claim 38, wherein, The bushing is a tube formed of a material having an ethyl vinyl alcohol (EVOH) layer sandwiched between polymer layers, the EVOH layer hindering the transport of hydrogen.

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