Electrochemical Cell

Abstract

The electrochemical cell includes a housing defining an interior space of the electrochemical cell and a lid disposed on a first side of the electrochemical cell defined by a length and a thickness of the housing. A dimension of the housing extending perpendicular to the first side of the electrochemical cell is a height of the housing, and the length of the housing is greater than the height of the housing. An anode and a cathode are disposed in the interior space of the electrochemical cell, and at least one of the anode or cathode is connected to the lid.

Description

[Technical field]

[0001] Claiming priority

[0001] This application claims priority to U.S. patent application Ser. No. 63 / 301,237, filed Jan. 20, 2022, the contents of which are incorporated by reference in their entirety into this specification.

[0002] Field of Disclosure This disclosure relates to electrochemical cells. [Background technology]

[0003] background

[0003] An electrochemical cell is a current source that converts chemical energy into electrical energy and vice versa. An electrochemical cell includes a positive terminal and a negative terminal through which current flows in and out during the charging and discharging process of the electrochemical cell. For example, lithium-ion, sodium-ion, nickel-metal hydride, lithium-air, lithium-sulfur and other electrochemical cells are widely used in vehicles, personal computers and laptops because they are lightweight and provide improved energy and power density. Summary of the Invention [Means for solving the problem]

[0004] overview

[0004] Here, electrochemical cells, such as prismatic electrochemical cells, in which anode and cathode layers are arranged, are described. For example, the anode and cathode layers can be arranged as an electrode stack or jelly roll including alternating anode and cathode layers. The anode and cathode layers are connected to terminals, for example, on respective lids at opposite ends of the electrochemical cell. The lids are arranged at opposite ends of the electrochemical cell separated by the height of the cell. The length of the cell perpendicular to the height is greater than the height. These electrochemical cells operate quickly and efficiently because the current flows in the direction of the smaller height.

[0005]

[0005] The anode layer and the cathode layer are connected to the terminals of the lid through a direct physical and electrical connection, such as a tabless connection. For example, the anode layer is formed of a metal substrate (e.g., foil) coated with an anode active material. Similarly, the cathode layer is formed of a metal substrate (e.g., foil) coated with a cathode active material. The uncoated portion of the foil is in direct physical and electrical contact with the inner surface of the respective lid. This direct connection provides low resistance, facilitating rapid charging and discharging of the electrochemical cell.

[0006]

[0006] The electrochemical cells described herein may include a thermal management module formed on an inner surface of one or both lids, e.g., the lid connected to the anode layer, the lid connected to the cathode layer, or both. The thermal management module includes one or more fluid flow paths defined in the inner surface of the lid. Fluid flowing through the fluid flow paths regulates the thermal environment of the electrochemical cell, e.g., to cool or heat the electrochemical cell.

[0007] In a first aspect, the electrochemical cell includes a housing defining an interior space of the electrochemical cell and a lid disposed on a first side of the electrochemical cell defined by a length and a thickness of the housing. A dimension of the housing extending perpendicular to the first side of the electrochemical cell is a height of the housing, and the length of the housing is greater than the height of the housing. The electrochemical cell includes an anode and a cathode disposed in the interior space of the electrochemical cell, and at least one of the anode or the cathode is connected to the lid.

[0008]

[0008] Implementations may include any combination of one or more of the following features.

[0009]

[0009] The lid is a first lid, the electrochemical cell includes a second lid disposed on a second side of the electrochemical cell opposite the first side, the second lid is separated from the first lid by the height of the housing, the anode is connected to the first lid, and the cathode is connected to the second lid.

[0010]

[0010] The ratio between the length of the housing and the height of the housing is greater than 1 and less than 40.

[0011]

[0011] The height of the housing is less than 500 mm, for example less than 125 mm.

[0012]

[0012] The length of the housing is at least 100mm, for example greater than 500mm, for example greater than 1 meter.

[0013]

[0013] The electrochemical cell is configured such that current flow within the electrochemical cell is in a direction substantially parallel to the height of the electrochemical cell.

[0014]

[0014] The lid includes a plurality of conductive sections, each first section being electrically isolated from each other section. In some cases, the anode includes a plurality of anode elements, and a corresponding subset of the anode elements is connected to each section of the lid. In some cases, the cathode includes a plurality of anode elements, and a corresponding subset of the cathode elements is connected to each section of the lid. In some cases, a plurality of subcells are defined within the interior of the electrochemical cell space, each subcell including a respective subset of the anode elements and a respective subset of the plurality of cathode elements of the cathode. In some cases, each subcell is fluidly isolated from each other of the subcells. In some cases, at least one subcell has performance characteristics that are different from the performance characteristics of one or more other of the subcells. In some cases, at least one subcell is independently controllable from one or more other of the subcells.

[0015]

[0015] A fluid flow path is defined on the inner surface of the lid.

[0016]

[0016] The anode includes a metal substrate extending along the height of the electrochemical cell and an anode material coated on a portion of a surface of the metal substrate, with the uncoated portion of the metal substrate contacting the inner surface of the lid.

[0017]

[0017] The cathode includes a metal substrate extending along the height of the electrochemical cell and a cathode material coated on a portion of a surface of the metal substrate, with the uncoated portion of the metal substrate contacting the inner surface of the lid.

[0018] In a second aspect, a battery pack includes an array of any of the electrochemical cells of the first aspect.

[0019]

[0019] Implementations may include any combination of one or more of the following features.

[0020]

[0020] The electrochemical cells in the array are arranged such that the largest surface of each electrochemical cell faces the largest surface of an adjacent electrochemical cell.

[0021]

[0021] The lids include a first lid to which the anode is connected, and each electrochemical cell includes a second lid disposed on a second side of the electrochemical cell opposite the first side, and the cathode is connected to the second lid. The electrochemical cells in the array are arranged such that the first lid of a first electrochemical cell in the array faces a first direction, and the first lid of an adjacent first electrochemical cell in the array faces a second direction opposite the first direction.

[0022]

[0022] The battery pack is positioned within the vehicle. In some cases, the battery pack is positioned within the vehicle such that the lengths of the electrochemical cells within the battery pack are oriented parallel to the axles of the vehicle.

[0023]

[0023] In a third aspect that can be combined with the first or second aspect, an electrochemical cell includes a housing defining an interior space of the electrochemical cell, the housing defining one or more side surfaces of the electrochemical cell. An inner surface of each of the one or more side surfaces faces the interior space of the electrochemical cell. The electrochemical cell includes an anode and a cathode disposed in the interior space of the electrochemical cell, a lid having an inner surface facing the interior space of the electrochemical cell, the anode, the cathode, or both being connected to the lid, and a thermal management module disposed on the inner surface of one or more of the sides of the electrochemical cell, the inner surface of the lid, or both.

[0024]

[0024] Implementations may include any combination of one or more of the following features.

[0025]

[0025] The thermal management module includes a fluid flow path and an inlet and an outlet fluidly connected to the fluid flow path.

[0026]

[0026] The fluid flow path may have a serpentine or straight configuration.

[0027]

[0027] The fluid flow paths extend in a direction perpendicular to the height of the electrochemical cell or perpendicular to the length of the electrochemical cell.

[0028]

[0028] The fluid flow path is configured to receive a thermal management fluid.

[0029] The fluid flow path has a diameter of at least 100 μm.

[0030] The thermal management module includes a metal tube that defines a fluid flow path.

[0031]

[0031] The electrochemical cell includes a passive cooling element disposed external to the electrochemical cell, and the fluid flow path extends through the passive cooling element. In some cases, the passive cooling element includes fins.

[0032] The fluid flow paths are defined in an interior wall of the electrochemical cell, the interior wall including the interior surface of one of the sides of the electrochemical cell or the interior surface of a lid of the electrochemical cell.

[0033]

[0033] The inlet and outlet are defined on a side of the electrochemical cell in which the fluid flow path is defined or on a lid of the electrochemical cell. In some cases, the inlet and outlet are defined on the same end of the side or lid in which the fluid flow path is defined. In some cases, the inlet and outlet are defined on opposite ends of the side or lid in which the fluid flow path is defined.

[0034]

[0034] The thermal management module includes a second fluid flow path defined in a second inner wall of the electrochemical cell, the second inner wall including an inner surface of one of the sides of the electrochemical cell or an inner surface of the lid, the second inner wall being different from the first inner wall.

[0035] The thermal management module includes multiple fluid flow paths defined in the same interior wall.

[0036]

[0036] The inner wall comprises a metal.

[0037]

[0037] The area of ​​the inner wall occupied by the fluid flow paths is between 25% and 90% of the total surface area of ​​the inner wall.

[0038]

[0038] The fluid flow paths are defined in the inner surface of the lid, and the anode, cathode or both are directly connected to the inner surface of the lid.

[0039]

[0039] The thermal management module includes a thermoelectric cooling system.

[0040]

[0040] The lid includes a first lid, the electrochemical cell includes a second lid having an inner surface facing the interior space opposite the inner surface of the first lid, the anode is connected to the first lid, and the cathode is connected to the second lid.

[0041]

[0041] In a fourth aspect that can be combined with any one of the first to third aspects, a method of manufacturing an electrochemical cell includes disposing an anode and a cathode in an interior space defined by a housing that defines one or more sides of the electrochemical cell, an interior surface of each of the one or more sides facing the interior space of the electrochemical cell. The method includes connecting a lid to the housing such that the interior surface of the lid defines a wall of the interior space, including connecting the anode, the cathode, or both to the lid. A thermal management module is disposed on the interior surface of one or more of the sides of the electrochemical cell, the interior surface of the lid, or both.

[0042]

[0042] Implementations may include any combination of one or more of the following features.

[0043] The method includes forming a fluid flow path in one or more interior surfaces of a side of the electrochemical cell, an interior surface of the lid, or both. In some examples, forming the fluid flow path includes fabricating the housing, the lid, or both using an additive manufacturing process. In some examples, forming the fluid flow path includes fabricating the housing, the lid, or both using molding.

[0044]

[0044] In a fifth aspect that can be combined with any one of the fourth aspects, a method of operating an electrochemical cell includes generating an electric current from an electrochemical cell including an anode and a cathode disposed in an interior space of the electrochemical cell, where the anode, the cathode, or both are connected to a lid having an interior surface that defines a wall of the interior space of the electrochemical cell; and causing a fluid to enter the inlet and exit the outlet through a fluid flow path defined in one or more interior surfaces of a side of the electrochemical cell, an interior surface of the lid, or both.

[0045]

[0045] Implementations may include any combination of one or more of the following features.

[0046]

[0046] Flowing a fluid may include cooling the electrochemical cell or heating the electrochemical cell.

[0047]

[0047] Flowing a fluid includes flowing a liquid, a gas or a mixture of a liquid and a gas.

[0048]

[0048] In a sixth aspect which may be combined with any one of the first to fifth aspects, an electrochemical cell includes a housing defining an interior space of the electrochemical cell, a lid having an inner surface facing the interior space of the electrochemical cell, the lid extending along the length of the electrochemical cell, and an electrode disposed in the interior space of the electrochemical cell and electrically connected to the lid. The electrode includes a metal substrate extending along the height of the electrochemical cell and an anode material or a cathode material coated on a portion of a surface of the metal substrate, the uncoated portion of the metal substrate contacting the inner surface of the lid.

[0049]

[0049] Implementations may include any combination of one or more of the following features.

[0050]

[0050] The electrodes are welded to the inner surface of the lid.

[0051]

[0051] A groove is defined in the inner surface of the lid, and the uncoated portion of the metal substrate is disposed within the groove. In some cases, the groove extends along the length of the electrochemical cell. In some cases, the electrochemical cell includes multiple electrodes, and multiple grooves are defined in the inner surface of the lid, and the uncoated portion of the metal substrate of each electrode is disposed within a corresponding one of the grooves.

[0052]

[0052] The uncoated portion of the metal substrate includes a protrusion extending through a thickness of the electrical cell. In some cases, the protrusion defines a plane parallel to the plane of the inner surface of the lid. In some cases, the protrusion contacts the inner surface of the lid.

[0053]

[0053] The electrochemical cell includes a plurality of anodes, each of which includes an anode material coated on a portion of a surface of a respective anode substrate, and a plurality of cathodes, each of which includes a cathode material coated on a portion of a surface of a respective cathode substrate. In some cases, the plurality of anode substrates each include a protrusion extending in a first direction along the thickness of the electrochemical cell such that the protrusion of a given anode substrate is above the protrusion of an adjacent anode substrate, and the plurality of cathode substrates each include a protrusion extending in a second direction along the thickness of the electrochemical cell such that the protrusion of a given cathode substrate is above the protrusion of an adjacent cathode substrate. In some cases, the outermost protrusion of the plurality of anode substrates and the outermost protrusion of the plurality of cathode substrates contact the inner surface of the lid.

[0054]

[0054] The lid includes a first lid and a second lid having an inner surface facing the interior space of the electrochemical cell opposite the inner surface of the first lid. In some cases, the electrodes include an anode and a second electrode including a cathode, the anode being electrically connected to the first lid and the cathode being electrically connected to the second lid.

[0055]

[0055] A fluid flow path is defined on the inner surface of the lid.

[0056]

[0056] Particular implementations of the subject matter described in this specification can be implemented to realize one or more of the following technical advantages.

[0057]

[0057] The electrochemical cells described herein provide high power and energy density in single units and when these units are assembled to build larger units such as battery packs. For example, the electrochemical cells described herein can be assembled into packs to achieve power density improvements ranging from 100% to 1000% compared to conventional electrochemical cells of the same footprint and same energy density of the cell, and can also address deficiencies that arise in the cell-to-pack conversion. For example, the electrochemical cells described herein can be utilized to build batteries with high cell-to-pack ratios and high energy density at the pack level (e.g., anywhere from 10% to 100% by weight, 5% to 95% by volume).

[0058]

[0058] The electrochemical cells described herein have a lid that extends across the entire width of the cell unit, providing a high surface area for electron transfer and thermal equilibrium between the external and internal media of the electrochemical cell, for example, facilitating ultra-rapid charging and discharging, for example within a time frame ranging from 2 minutes to 45 minutes.

[0059]

[0059] The electrochemical cells described herein have direct, tab-less connections between the current collectors (e.g., anodes and cathodes) and the terminals. These direct, tab-less connections can accommodate, for example, 10% to 100% of the operating current without generating heat in excess of 100% of the operating temperature.

[0060]

[0060] In the electrochemical cells described herein, the current flow and heat dissipation flow are perpendicular to the longest dimension of the electrochemical cell, which allows for higher power and temperature control capabilities of the electrochemical cell while shortening the current and heat paths for an effective battery pack without sacrificing energy density. For example, these performance parameters can be achieved in a temperature range of 0°C to 200°C with less than 10% loss in cycle life of the battery cell. This configuration can also allow the battery to operate in a temperature range of -100°C to 400°C without sacrificing performance.

[0061]

[0061] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will become apparent from the description and drawings, and from the claims. [Brief description of the drawings]

[0062] [Figure 1A]

[0062] FIG. 1 is an exploded perspective view of an electrochemical cell. [Figure 1B]

[0062] FIG. 1 is an exploded perspective view of an electrochemical cell. [Figure 1C]

[0063] FIG. 2 is an exploded perspective view of an electrochemical cell. [Figure 1D]

[0063] FIG. [Diagram 2]

[0064] FIG. 1 is a cross-sectional view of an electrochemical cell. [Figure 3A]

[0065] FIG. 2 is an exploded perspective view of an electrochemical cell. [Figure 3B]

[0065] FIG. 1 is an exploded perspective view of an electrochemical cell. [Figure 4A]

[0066] FIG. 2 is an exploded perspective view of an array of electrochemical cells. [Figure 4B]

[0066] FIG. 1 is an exploded perspective view of an array of electrochemical cells. [Figure 5A]

[0067] FIG. 1 is a diagram of a pack of electrochemical cells. [Figure 5B] FIG. 1 is a diagram of a pack of electrochemical cells. [Figure 5C] FIG. 1 is a diagram of a pack of electrochemical cells. [Figure 6A]

[0068] FIG. 2 is an exploded perspective view of the lid of the electrochemical cell. [Figure 6B] FIG. 1 is an exploded side view of the lid of an electrochemical cell. [Figure 7]

[0069] FIG. 1 is a perspective view of an electrochemical cell. [Figure 8A]

[0070] FIG. 2 is a perspective view of a portion of a lid of an electrochemical cell. [Figure 8B]

[0071] FIG. 1 is a perspective view of an electrochemical cell. [Figure 9]

[0072] FIG. 1 is a perspective view of an electrochemical cell. [Figure 10]

[0072] FIG. 1 is a perspective view of an electrochemical cell. [Figure 11A]

[0073] FIG. 2 is an exploded end view of a portion of an electrochemical cell. [Figure 11B]

[0074] FIG. 2 is an end view of a portion of an electrochemical cell. [Figure 11C] FIG. 1 is a perspective view of a portion of an electrochemical cell. [Figure 12A]

[0075] FIG. 2 is a top view of a current collector of an electrochemical cell. [Figure 12B]

[0075] FIG. 1 is a perspective view of a current collector of an electrochemical cell. [Figure 13A]

[0076] FIG. 2 is a side view of a current collector of an electrochemical cell. [Figure 13B]

[0076] FIG. 1 is a perspective view of a current collector of an electrochemical cell. [Figure 14]

[0077] FIG. 1 is a diagram of an electrochemical cell and an array of electrochemical cells. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0063]

[0078] In the drawings, like reference numbers represent like elements.

[0064] Detailed Description

[0079] Here, electrochemical cells are described in which anode and cathode layers are disposed, e.g., prismatic cells. For example, the anode and cathode layers may be provided as an electrode stack or jelly roll including alternating anode and cathode layers. The anode and cathode layers are connected to terminals, e.g., on respective lids, at opposite ends of the electrochemical cell. The lids are disposed at opposite ends of the electrochemical cell separated by the height of the cell. The length of the cell perpendicular to the height is greater than the height. Because current flows in the direction of the smaller height, these electrochemical cells operate quickly and with high efficiency.

[0065]

[0080] These lids are defined by the largest dimension, i.e., length, of the cell and therefore provide a large surface area that facilitates electrical conduction between the electrodes (e.g., the anode and cathode layers) and external terminals, as well as facilitating regulation of the thermal environment of the electrochemical cell.

[0066]

[0081] The electrochemical cells described herein may include a thermal management module formed on an inner surface of the housing of the electrochemical cell. For example, the thermal management module may be incorporated into one or both lids, e.g., the lid connected to the anode layer, the lid connected to the cathode layer, or both, one or more sides of the housing, or a combination thereof. The thermal management module includes one or more fluid flow paths defined in the inner surface of the lid. Fluid flowing through the fluid flow paths regulates the thermal environment of the electrochemical cell, e.g., cooling or heating the electrochemical cell.

[0067]

[0082] The connection between the anode layer and the cathode layer and the respective lids is a direct connection without tabs. For example, the anode layer is formed of a metal substrate (e.g., foil) coated with an anode active material. Similarly, the cathode layer is formed of a metal substrate (e.g., foil) coated with a cathode active material. The uncoated portion of the foil is in direct physical and electrical contact with the inner surface of the respective lid. This direct connection provides low resistance and facilitates ultra-rapid charging and discharging of the electrochemical cell.

[0068]

[0083] As used herein, the following terms apply to the descriptive dimensions of an electrochemical cell: Height is defined as being in the direction of the terminals. Length and thickness (e.g., width) are orthogonal to the height, with thickness (e.g., width) being the smallest dimension. This rule applies regardless of which direction is the longest.

[0069]

[0084] 1A and 1B, an electrochemical cell 100, e.g., a prismatic cell, includes a cell housing 101 having orthogonal height H, length L, and thickness T. The length and height of the electrochemical cell 100 define a front face 106 and a rear face 106 of the cell, the front face 106 and the rear face 106 being the faces with the largest surface area. The length of the electrochemical cell is the largest dimension, e.g., the height and thickness are both less than the length.

[0070]

[0085] In some examples, the length L of the electrochemical cell 100 is the largest dimension of the cell and is 100 mm or more, e.g., 200 mm, 500 mm or more, or 1000 mm or more, e.g., 100 mm to 2000 mm, 200 mm to 1600 mm, or 200 mm to 800, e.g., about 100, about 200 mm, about 400 mm, about 600 mm, about 800 mm, about 1000 mm, or about 1600 mm. The height H, which is less than the length, is 500 mm or less, e.g., 250 mm or less, or 125 mm or less, e.g., 50 to 500 mm, 70 mm to 250 mm, or 80 mm to 125 mm, e.g., about 100 mm or about 125 mm. The ratio between the length L and the height H is greater than 1, e.g., 1 to 40. The thickness T is, for example, in the range of 18 mm to 26 mm.

[0071]

[0086] The electrochemical cell 100 includes two lids 102a, 102b (collectively referred to as lids 102) disposed at opposite ends of the electrochemical cell 100 and separated by a cell height H. An electrode stack 108 (see FIG. 1B) is disposed in the interior space of the housing 101. The electrode stack 108 includes at least one positive electrode and at least one negative electrode (cathode layer 201 and anode layer 203, respectively, shown in FIG. 2) and a non-conductive separator layer (e.g., layer 202 shown in FIG. 2) disposed between the positive and negative electrode layers.

[0072]

[0087] The electrode assembly 108 is electrically connected to the conductive terminals of one or both of the lids 102a, 102b. The connection of the electrode assembly 108 to one or both of the lids 102a, 102b means that the current flow in the electrochemical cell is in a direction that is generally parallel to the height H of the electrochemical cell. Because the height H is not the largest dimension of the electrochemical cell 100, the current in the cell has a short distance to travel before reaching the conductive terminals. This geometry allows for fast and efficient charging and discharging, and reduces the amount of heat generated in the electrochemical cell 100. Furthermore, the distance that the current travels is independent of the largest dimension of the electrochemical cell 100; for example, if the cell length L is increased, the current still only travels the height H of the cell. This configuration allows for fast and efficient operation of the cell, even with large cell volumes.

[0073]

[0088] In some examples, the negative electrode (e.g., the anode layer) is electrically connected to the lid 102a and the positive electrode (e.g., the cathode layer) is electrically connected to the lid 102b. In these examples, the conductive terminal on the lid 102a extends along substantially the entire length of the inner surface of the lid 102a and the conductive terminal on the lid 102b extends along substantially the entire length of the inner surface of the lid 102b.

[0074]

[0089] The lid 102 provides external electrical connections to the anode and cathode of the electrochemical cell, for example, electrical connections are made through the thickness of the lid between conductive terminals on the inner surface of the lid 102 and external terminals 112 on the outer surface. In some examples, the external terminals 112 extend through the thickness of the lid, thus also forming internal conductive terminals.

[0075]

[0090] 1C-1D, in some examples, both the negative and positive electrodes are electrically connected to the same lid, e.g., lid 102a. In these examples, the inner surface of lid 102a includes one or more negative conductive terminals to which the negative electrodes are connected and one or more positive conductive terminals to which the positive electrodes are connected, the negative and positive terminals being spaced apart from one another, e.g., along the length of the inner surface of the lid. Specifically, with reference to FIG. 1C, in electrochemical cell 130, negative conductive terminals 134 on lid 132 are adjacent to one another, and positive conductive terminals 136 are adjacent to one another and spaced apart from the negative conductive terminals 134. Specifically, with reference to FIG. 1D, in electrochemical cell 140, the terminals on lid 142 are alternating between positive conductive terminals 146 and negative conductive terminals 144.

[0076]

[0091] The lid 102 also provides a sealed environment within the housing 101. The lid 102 may be connected to the housing 101 using any suitable method, for example welding, such as laser welding, ultrasonic welding, adhesives, or other attachment methods.

[0077]

[0092] 2 shows an exemplary arrangement of a cathode layer 201, an anode layer 203, and a non-conductive separator layer 202 disposed inside a housing 101 of an electrochemical cell 100. The interior space of the housing 101 is filled with an ionically conductive material (e.g., electrolyte), such as a liquid or solid electrolyte material. The cathode layer 201 and the anode layer 203 are composed of active material coated on a metal substrate (e.g., aluminum, copper), such as a foil, mesh, foam, or other suitable substrate. The separator layer 202 is composed of a non-conductive material, e.g., a porous material, such as a polymer (e.g., plastic), such as polyethyl ethyl ketone (PEEK).

[0078]

[0093] 2, the cathode layer 201 is electrically connected to one or more conductive terminals (not shown) on the inner surface 210a of the lid 102a, and the anode layer 203 is electrically connected to one or more conductive terminals (not shown) on the inner surface 210b of the opposing lid 102b. In this configuration, the flow of current is along the height of the electrochemical cell. Because the height is not the largest dimension of the cell, the electrons do not have a long distance to travel, and therefore the electrochemical cell can operate quickly and efficiently, e.g., charge and discharge quickly, and generate little heat.

[0079]

[0094] In some examples, the cathode layer 201 and the anode layer 203 are both electrically connected to a conductive terminal on the same inner surface of the lid (e.g., inner surface 210a of lid 102a), and the conductive terminal to which the cathode layer 201 is connected is electrically isolated from the conductive terminal to which the anode layer 203 is connected.

[0080]

[0095] The lid 102 extends along a surface defined by the length and thickness of the electrochemical cell. Due to the long length L of the electrochemical cell, these surfaces provide a high surface area for, for example, electrical connections and heat dissipation. For example, this high surface area reduces contact resistance between the anode and cathode layers and the conductive terminals on the lid, allowing for efficient and fast operation. In addition, because the flow of current is in a direction parallel to the height and therefore not along the longest dimension of the cell, there is a short path for electron flow to the conductive terminals on the lid, also allowing for efficient and fast operation. In addition, as described further below, a thermal management module occupying one or both of the interior surfaces of the lid is provided with a large surface area that facilitates heat transfer to and from the interior of the electrochemical cell.

[0081]

[0096] The geometry of electrochemical cell 100 can be applied to cell shapes other than the rectangular solid shown. For example, the geometry can be applied to a cylindrical electrochemical cell with conductive terminals at one or both circular ends of the cylinder. In this example, the height of the cylinder (the distance between the circular ends) is less than the diameter of the cylinder.

[0082]

[0097] The electrochemical cell 100 of Figures 1A-1B includes a single electrode stack 108 that extends the entire length L of the electrochemical cell 100. With reference to Figures 3A-3B, in some examples, the electrochemical cell includes multiple electrode stacks disposed along the length of the electrochemical cell.

[0083]

[0098] Specifically, referring to FIG. 3A, the electrochemical cell 300 includes a plurality of electrode stacks 308 disposed in the interior space of the housing 301 and adjacent to one another along the length L of the cell. The electrode stacks 308 each have a structure such as that described above for the electrode stack 108, and each electrode stack 308 is electrically connected to a corresponding conductive terminal 312a on the lid 302a and a corresponding conductive terminal 312b on the lid 302b of the electrochemical cell, although in some examples, the electrode stack 308 is connected to only a single lid, for example, as described above. The conductive terminals 312a on the lid 302a are electrically isolated from one another, and the conductive terminals 312b on the lid 302 are also electrically isolated from one another. As with the electrochemical cell 100 of FIG. 1, the lids 302a, 302b are separated by a height H of the cell 300, which is less than the length L of the cell.

[0084]

[0099] Each electrode stack 308 can operate as an electrochemical cell. Multiple electrode stacks 308 can be connected in series to provide high voltage. For example, if an electrochemical cell 300 of length L has a single electrode stack, the electrochemical cell can generate a specified amount of voltage, for example, 3.7V. By incorporating multiple electrode stacks 308 in the same length L, the voltage available from the electrochemical cell is doubled. For example, the total voltage available is the voltage from an individual cell (e.g., 3.7V) multiplied by the number of electrode stacks 308 in the electrochemical cell 300. This configuration therefore allows for high voltage output even when space is limited.

[0085]

[0100] The presence of multiple electrode stacks 308 (rather than a single electrode stack such as that depicted in FIGS. 1A-1B) helps the electrochemical cell 300 operate quickly and efficiently. For example, the current generated in a given electrode stack 308 does not have to travel as far as the current generated in the single electrode stack 108 of FIG.

[0086]

[0101] The diagram in FIG. 3B shows an electrochemical cell 300 including eight electrode stacks 308, although other numbers of stacks are possible, such as 1, 2, 4, 8 or more than 8 stacks.

[0087]

[0102] 3B, electrochemical cell 350 includes multiple electrode stacks 358 disposed within the interior space of housing 351 and adjacent to one another along the length L of the cell. Electrode stacks 358 each have a structure such as that described above for electrode stack 108 and are electrically connected to respective conductive terminals 362a, 362b on lids 352a, 352b of the electrochemical cell or to a conductive terminal on a single lid. As with electrochemical cell 100 of FIG. 1, lids 352a, 352b are separated by height H of cell 300, which is less than length L of the cell. Electrode stack 358 provides similar advantages as those described above for electrochemical cell 300 of FIG. 3A.

[0088]

[0103] Each electrode stack 358 is disposed within a respective compartment 360 defined in the interior space of the housing 351. The compartments 360 are separated by walls 362 that provide fluidic and electrical isolation between adjacent compartments 360. This isolation allows subcells with distinct characteristics to be housed within a single electrochemical cell 350. For example, some electrode stacks 358 may be designed for rapid discharge, while others may be designed for energy storage. In addition, the electrode stacks 358 may be individually controlled, e.g., turned off if overheated, or turned on if the characteristics are suitable for the environmental conditions. This isolation and individual control contribute to efficient operation. Furthermore, the isolation between the electrode stacks may facilitate the generation of high voltages from multiple stacks, e.g., by avoiding the potential adverse effects of high voltages in a single electrolyte (e.g., similar to the configuration of FIG. 3A).

[0089]

[0104] In the example of Figures 3A and 3B, the orientation of the multiple electrode stacks 308, 358 may be the same across the entire length of the cell, or may alternate between adjacent electrode stacks. For example, the electrode stacks 308, 358 may be oriented such that the cathode layers of all the electrode stacks are electrically connected to the top lid 302a, 352a, and the anode layers of all the electrode stacks are electrically connected to the bottom lid 302b, 352b. This alternating arrangement may be advantageous, for example, when connecting the electrode stacks 308, 358 in series, for example, to provide a shorter distance for current to flow between the stacks.

[0090]

[0105] The electrochemical cells described herein can be assembled into arrays for use, for example, in battery packs.

[0091]

[0106] 4A, in one example, a series array 400 includes a plurality of electrochemical cells 100 arranged in an array and electrically connected in series. Although electrochemical cell 100 is shown in FIG. 4A, any of the electrochemical cells described herein can be used in such an array.

[0092]

[0107] The electrochemical cells 100 are arranged such that the front surface 106 of one cell faces the rear surface of an adjacent cell. The elongated geometry of the electrochemical cells 100 allows the cells to be closely packed in the array 400, e.g., allowing a large number of cells to be included in a relatively compact space, e.g., allowing a battery pack including the array 400 to have a high energy density.

[0093]

[0108] The external terminals 112 of the electrochemical cells are electrically connected via the series bus bars 402a, 402b. The electrochemical cells 100 in the array 100 are arranged in an alternating orientation, for example, such that both the lid 102a (e.g., the lid connected to the cathode layer) of one cell and the lid 102b (e.g., the lid connected to the anode layer) of an adjacent cell abut the same series bus bar 402. This configuration allows the array to operate efficiently, for example, because the distance that the current must travel is negligible. In some examples, when both the positive and negative poles of the electrochemical cells are connected to the same lid of the cell, only a single series bus bar is used.

[0094]

[0109] Referring to Figure 4B, in one example, a parallel array 450 includes a plurality of electrochemical cells 100 arranged in an array and electrically connected in parallel. Although the electrochemical cell 100 is shown in Figure 4A, any of the electrochemical cells described herein may be used in such an array. The external terminals 112 of the electrochemical cells are electrically connected via parallel connection bus bars 452a, 452b. The arrangement of the electrochemical cells 100 may be, for example, as described above for the array 400.

[0095]

[0110] 5A-5C, multiple arrays (e.g., series arrays 400 or parallel arrays or a combination of both, not shown) are themselves assembled into an array to form a pack assembly 500. The pack assembly 500 includes a base 502 having a compartment 504 for receiving the electrochemical cell array 400, and a lid 506 configured to fit over the base 502, thereby defining an interior space in which the array 400 of electrochemical cells 100 is disposed.

[0096]

[0111] The pack assembly 500 may be used in a variety of situations where the high energy density, rapid charging and discharging, and / or other advantageous properties of the electrochemical cell 10 are relevant. In one example, the pack assembly 500 may be used as a power source for an electric vehicle, such as an automobile. For example, the pack assembly 500 may be installed in the chassis of the automobile and oriented such that the length L of the electrochemical cell 100 is parallel to the axles of the automobile. Due to the length of the electrochemical cell 100, the cell and / or pack assembly 500 may be sized similar to the width of the chassis, thereby providing structural support in addition to electrical power.

[0097]

[0112] 6A and 6B, in some examples, the electrochemical cells described herein have thermal management features integrated into one or both lids. For example, the exemplary lid 602 includes a thermal management module 603 on its inner surface 601. The thermal management module 603 includes one or more fluid flow paths 604 defined on the inner surface 601 of the lid 602, such that, for example, the fluid flow paths 604 extend along a plane perpendicular to the height of the electrochemical cell (e.g., the height H of the electrochemical cell 100 in FIG. 1). To provide thermal management, for example, fluid can be circulated through the fluid flow paths to condition (e.g., cool or heat) materials within the electrochemical cell's housing (e.g., the housing 101 of the electrochemical cell 100 in FIG. 1). For example, in a warm environment, fluid is flowed through the thermal management module 603 to dissipate heat generated by the electrochemical cell, whereas in a cold environment, fluid is flowed through the thermal management module 603 to heat the electrochemical cell, for example, to enable efficient start-up operation of the electrochemical cell.

[0098]

[0113] The thermal management module 603 is constructed of a thermally and electrically conductive material, e.g., a metal such as steel, aluminum, copper, or alloys thereof. Forming the thermal management module 603 of an electrically conductive material allows for direct connection of the cathode layer (e.g., the cathode layer 201 and anode layer 203 of FIG. 2) with the respective thermal management module 603, and provides an electrical path between the anode or cathode and the external terminal 612 on the exterior surface of the lid 602.

[0099]

[0114] 6B, fluid flow paths 604 defined in an inner surface 601 of the lid 602 are positioned such that fluid circulating through the fluid flow paths 604 is in physical proximity to the contents (e.g., electrolyte) within the electrochemical cell housing. The fluid flow paths 604 are fluidly isolated from the interior of the electrochemical cell, e.g., no fluid exchange occurs between the fluid flow paths 604 and the cell interior. One end of each of the fluid flow paths 604 is connected to a corresponding outlet 606 while the other end is connected to a corresponding inlet 605.

[0100]

[0115] A heat exchange fluid, such as a liquid, gas, or combination thereof, can be supplied into the fluid flow passages 604 through an inlet 605 and removed from the fluid flow passages 604 through an outlet 606. Some examples of heat exchange fluids include water, air, or other suitable fluids (e.g., glycol, mineral oil). In some examples, the heat exchange fluid can be a slurry of particles suspended in a fluid, for example, to allow for rapid heat removal.

[0101]

[0116] The number and configuration of the fluid flow channels 604 may depend, for example, on the level of thermal management desired within the electrochemical cell. For example, the flow channels 604 may follow a serpentine path, a straight path, or a combination of serpentine and straight paths. The configuration of the fluid flow channels 604 may be such that the fluid flow channels 604 occupy a majority of the surface area of ​​the inner surface 601 of the lid 602, thereby facilitating efficient heat exchange between the interior of the electrochemical cell and the fluid within the fluid flow channels 604. For example, the area of ​​the inner surface 601 of the lid 602 occupied by the fluid flow channels 604 may be, for example, 25% to 90% of the total surface area of ​​the inner surface 601 of the terminals within the lid 602. The size (e.g., length, inner diameter, or both) of the fluid flow channels may be sized to allow a desired amount of fluid to flow through the fluid flow channels, for example, depending on the desired level of thermal management. For example, the fluid flow channels 604 may have a diameter of at least about 100 μm, such as from about 100 μm to about 1 mm. The size of the fluid flow paths can be determined based on factors such as thermal management requirements, cost, and the size of the electrochemical cell.

[0102]

[0117] The example inlet 605 and outlet 606 in Figure 6A include threaded connections, although in alternative examples, one or more other reversible (e.g., compression connections) or irreversible (e.g., welded) connections may be made. The type of connection provided by the inlet 605 and outlet 606 may depend on the type of exchange fluid. A liquid-tight connection may be used for liquid exchange fluids, while an air-tight connection may be used for gas exchange fluids.

[0103]

[0118] In some examples, the thermal management module 603 is a separate plate that is connected (e.g., by welding, brazing, adhesive, or another suitable connection method) to a plate including the external terminals 612 to form the lid 602. In some examples, the thermal management module 603 is integrally formed with the external terminals 612, for example, by molding (e.g., injection molding, compression molding, or another suitable molding technique), co-molding, additive manufacturing, or another suitable manufacturing technique. In some examples, the inlet 605 and / or the outlet 606 are welded to the thermal management module 603, and in some cases the thermal management module 603 is co-molded or otherwise fabricated (e.g., by additive manufacturing, injection molding, casting, or another suitable fabrication technique) to include the inlet 605 and the outlet 606.

[0104]

[0119] A thermal management module including flow paths for fluid flow can be incorporated into other portions of the electrochemical cell, e.g., in addition to or instead of the lid. For example, the thermal management module can be incorporated into one or both of the largest faces of the cell, e.g., the inside surface of the side 106 defined by the length L and height H of the cell (see FIG. 1 ). Including a thermal management module on the side of the cell can help reduce heat flow from an overheated cell to other adjacent cells in the array, e.g., because the largest faces of the cells face each other in the array.

[0105]

[0120] In some examples, the thermal management module can provide thermal management through actions other than heat transfer to or from the fluid. For example, the thermal management module can be a thermoelectric module that converts waste heat into electrical current. The thermoelectric module can be located on one or both lids of the electrochemical cell, on one or both largest sides of the electrochemical cell, or both.

[0106]

[0121] 7 is a perspective view of an electrochemical cell 700 including a lid 602' with the thermal management module 603 of FIGS. 6A-6B. An inlet 605a and an outlet 606a are provided in the "A" position, and a second inlet 605b and an outlet 606b are provided in the "B" position. In this configuration, fluid flows in both directions through the fluid flow paths along the entire length L of the cell unit, e.g., from "A" to "B" and from "B" to "A". This configuration provides a smooth, substantially symmetrical thermal gradient along the length L of the electrochemical cell 700.

[0107]

[0122] FIG. 8A is a perspective view of a lid 602″ of an electrochemical cell with the thermal management module 603 of FIGS. 6A-6B, showing an example arrangement of the inlet 605c and the outlet 606c of the thermal management module 603. In FIG. 8A, the inlet 605c5 and the outlet 606c are provided at the same end of the lid 602″, such that the fluid flows through the fluid flow path along all or a portion of the length L and then turns around to exit on the same side as the fluid entered. In some examples of this configuration, the fluid flow path is configured such that the fluid flows along the entire length L of the electrochemical cell before turning around. In some examples, multiple fluid flow paths are defined, a first flow path defining a flow path that starts at one end of the lid, reaches approximately the midpoint of the length, and returns to the same end, and a second flow path defining a flow path that starts at the other end of the lid, reaches approximately the midpoint of the length, and returns to the same other end. This configuration can be useful, for example, to manage high heat loads.

[0108]

[0123] FIG. 8B is a perspective view of an electrochemical cell 800 including a lid 602′″ with the thermal management module 603 of FIGS. 6A-6B, showing an example arrangement of the inlets 605d and outlets 606d of the thermal management module 603. In this configuration, the inlets 605d and outlets 606d are adjacent to one another at approximately the midpoint of the length of the electrochemical cell. In some examples of this configuration, a single fluid flow path extends from the inlet 605d to one end of the cell unit, then doubles back to the outlet 606d at the opposite end of the electrochemical cell. In some examples, multiple pairs of inlets and outlets can be arranged along the length L of the electrochemical cell such that the flow path between each pair of inlets and outlets is short, allowing for management of high heat loads, for example.

[0109]

[0124] The positioning of the inlets and outlets is based on, for example, anticipated thermal management needs, electrochemical cell dimensions, or other design criteria. Other locations of the inlets and outlets and other configurations of the fluid flow paths are possible.

[0110]

[0125] 6A-6B, the fluid flow paths of the thermal management module 603 are defined within the body of the lid 602 such that the inner surface 601 of the lid 602 is planar, although other configurations are possible. For example, with reference to FIG. 9, an electrochemical cell lid 902 includes a thermal management module 903 including a tube 912, such as a metal tube (e.g., copper tube), that is attached to the inner surface of the lid 902. The tube 912 extends along the length of the electrochemical cell and between conductive terminals 914 to which the anode and cathode layers in the electrochemical cell are attached. Fluid enters and exits the tube 912 through inlets and outlets, for example as described above.

[0111]

[0126] In some examples, both the lid to which the cathode layer is connected and the lid to which the anode layer is connected include a thermal management module. In some examples, only one lid includes a thermal management module, e.g., relevant for applications where a relatively low thermal load is expected. In some examples, when both the cathode layer and the anode layer are connected to the same lid, the wall of the housing opposite the lid includes the thermal management module 3.

[0112]

[0127] During operation (e.g., when the electrochemical cell is generating an electrochemical current during use), a fluid (e.g., a liquid, a gas, or a combination thereof) flows into each of the one or more inlets, through a fluid flow path connected to each inlet, and out a corresponding outlet. As the fluid flows through the fluid flow paths, heat is transferred between the fluid and an electrolyte inside the electrochemical cell. For example, if the fluid is a cooling fluid, heat is transferred from the electrolyte to the fluid and heat is removed from the electrochemical cell as the fluid flows out of the outlet. If the fluid is a heating fluid, the fluid provided to the fluid flow paths is at a higher temperature than inside the electrochemical cell. As the fluid flows through the fluid flow paths, heat is transferred from the fluid to an electrolyte inside the electrochemical cell, for example, to heat the electrolyte and enable efficient start-up or operation of the electrochemical cell.

[0113]

[0128] Referring to Fig. 10, in some examples, the passive cooling system is integrated with a thermal management module. Fig. 10 illustrates an electrochemical cell 120 including a passive cooling system 134 integrated with a lid 902 of Fig. 9. The lid 122 has a thermal management module 123 including a tube 132 and a passive cooling system 134, for example, as described above with respect to Fig. 9, although the passive cooling system is also applicable to other types of thermal management modules, for example, the thermal management module 603 of Fig. 6. The tube 132 extends along the passive cooling system 134 such that a fluid flowing through the tube 132 can be cooled or heated by heat transfer using the passive cooling system 134. For example, the passive cooling system 134 can be a fin structure.

[0114]

[0129] Referring again to FIG. 2, the cathode layer 201 and the anode layer 203 are each formed from a metal substrate (e.g., foil) coated with a cathode or anode active material, respectively, on one or both sides of the substrate. In some examples, to allow direct connection between the cathode layer 201 and the lid 102a and between the anode layer 203 and the lid 102b, the ends of the cathode and anode layers closest to the inner surface 210a of the lid 102 to which the cathode and anode layers are connected are uncoated, e.g., the ends of the cathode and anode layers are metal substrates having substantially no anode or cathode active material coated thereon. This direct tab-less connection between the anode and cathode layers and the inner surface 210a of the respective lids provides a configuration with low electrical resistance and high current conductivity between each of the cathode and anode and the respective lid, e.g., allowing for rapid charging and discharging of the electrochemical cell. For example, electrochemical cells with this tab-less direct connection are more efficient than electrochemical cells with welded or non-welded tabs. The tab-less connection arrangement described herein may be used in conjunction with the fluid management module 3 described above, or may be used without a fluid management module.

[0115]

[0130] 11A-11C illustrate an internal view of a portion of an electrochemical cell 950 including a direct (e.g., tab-less) top-to-bottom connection between the inner surface 960 of the lid 952 and the uncoated substrate of an electrode disposed within the housing 101. In the example of FIGS. 9A-9D, the current collector is the cathode layer 951, but a similar configuration applies to the anode layer.

[0116]

[0131] Each cathode layer 951 includes a coated portion 954 and an uncoated portion 956. The coated portion 954 of each cathode layer 951 is a metal substrate coated with an anode active material. The uncoated portion 956 of each cathode layer 951 is a metal substrate on which no cathode active material is substantially disposed, for example, the metal substrate is exposed. The uncoated portions 956 of the multiple cathode layers 951 are joined together to form a narrow cathode tip 958, which is directly connected to the inner surface 960 of the lid 952. Similarly, although not shown, each anode layer includes a coated portion including a metal substrate coated with an anode active material and an uncoated portion including a metal substrate on which no anode active material is substantially disposed. The uncoated portions of the anode layers are joined together to form a narrow anode tip, which is directly connected to the inner surface of the terminal of the corresponding lid.

[0117]

[0132] In the example of Figures 11A and 11B, the cathode tip 958 including the uncoated portion 956 of the cathode layer 951 fits into a corresponding groove 957 defined in the inner surface 960 of the lid 952. The groove 957 extends along the length of the lid 952, for example along the length of the electrochemical cell. For example, when the cathode layer and the anode layer are connected to opposing lids, the cathode tip 958 including the uncoated portion 956 of the cathode layer 951 fits into the groove 957 of one lid, while the anode tip including the uncoated portion of the anode layer fits into the groove of the opposing lid. The separator layer (see Figure 2) between the anode layer and the cathode layer does not contact the lid. The fitting of the uncoated portions of the cathode layer and the anode layer into the grooves can be by welding (e.g., laser welding, etc.), press fitting, or another suitable connection mechanism.

[0118]

[0133] 12A and 12B respectively illustrate top and perspective views of a cathode layer 151 in an example of an exemplary horizontal direct (e.g., no tab) arrangement for connection to the inner surface of the lid of an electrochemical cell. A similar configuration can be applied to the anode layer. Each cathode layer 151 includes a coated portion 154 and an uncoated portion 156 as described above. The uncoated portion 156 of the cathode layer 151 is angled with respect to the coated portion 154, e.g., the uncoated portion 156 is substantially perpendicular to the coated portion 154. These angled uncoated portions 156 form protrusions that extend in the direction of the thickness T of the electrochemical cell. In the illustrated example, each cathode layer 151 includes multiple protrusions that extend in alternating opposite directions along the length of the electrochemical cell. In some examples, all of the protrusions are oriented in the same direction. The plane of the protrusions is parallel to the terminal inner surface of the lid, and the outer surface 155 of the protrusions (e.g., uncoated metal foil) contacts the terminal inner surface of the lid. For example, the outer surface 155 of the projection is connected, eg, laser welded, to the inner surface of the terminal of the lid.

[0119]

[0134] 13A and 13B illustrate end and perspective views, respectively, of cathode layer 161 and anode layer 163 in an example of a horizontal, wing-based, direct (e.g., no tab) arrangement for connection to a lid. Each anode layer 161 includes a coated portion 164 and an uncoated portion 166, as described above. Similarly, each anode layer 163 includes a coated portion 174 and an uncoated portion 176.

[0120]

[0135] The non-coated portions 166 of the cathode layer 161 are angled relative to the coated portions 164, e.g., the non-coated portions 166 are substantially perpendicular to the coated portions 164. The angled non-coated portions 166 of the plurality of cathode layers 161 form a cathode protrusion extending in a first direction along the thickness T of the electrochemical cell. The non-coated portions 166 of the central-most cathode layer form an outer surface 165 of the cathode protrusion. The non-coated portions 176 of the anode layer 163 are angled relative to the coated portions 174, e.g., the non-coated portions 176 are substantially perpendicular to the coated portions 174. These angled non-coated portions 176 form an anode protrusion extending in a second direction opposite to the first direction of the cathode protrusion along the thickness T of the electrochemical cell. The non-coated portions 176 of the central-most anode layer form an outer surface 175 of the anode protrusion.

[0121]

[0136] The plane of the protrusion is parallel to the plane of the terminal inner surface of the lid, and the outer surfaces 165, 175 (e.g., uncoated metal foil) contact respective portions of the inner surface of the lid, e.g., the outer surfaces of the protrusions are connected, e.g., laser welded, to the inner surface of the lid.

[0122]

[0137] 13A-13B may be applied to the cathode layers only, e.g., some of the cathode layers are folded to form a first protrusion extending in a first direction and the remaining cathode layers are folded to form a second protrusion extending in a second direction opposite the first direction. A similar structure may also be applied to the anode layers for connection to the opposing lids.

[0123]

[0138] 14, in some examples, an elongated electrochemical cell 100 (or another electrochemical cell described herein) can be implemented as a replacement for an array 190 of cylindrical cells. An appropriately sized electrochemical cell 100 can be slotted, for example, to replace a one-dimensional array of cylindrical cells without requiring redesign of the slot. For example, an electrochemical cell having a length of 800 mm and a height of 18 mm can replace 44 18650 cylindrical cells.

[0124]

[0139] Although the specification contains many details, these embodiments should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular examples. Certain features described in the specification in relation to separate implementations may also be combined. Conversely, various features described in relation to a single implementation may also be realized in multiple embodiments separately or in any suitable subcombination.

Claims

1. 1. An electrochemical cell comprising: a housing defining an interior space of the electrochemical cell; a lid disposed on a first surface of the electrochemical cell defined by a length and a thickness of the housing, wherein a dimension of the housing extending perpendicular to the first surface of the electrochemical cell is a height of the housing, and the length of the housing is greater than the height of the housing; an anode and a cathode disposed in the interior space of the electrochemical cell, wherein at least one of the anode and the cathode is connected to the lid; An electrochemical cell comprising:

2. The lid is a first lid, and the electrochemical cell comprises: a second lid disposed on a second side of the electrochemical cell opposite the first side, the second lid being separated from the first lid by the height of the housing; 10. The electrochemical cell of claim 1, comprising: a first lid connected to the anode and a second lid connected to the cathode.

3. 10. The electrochemical cell of claim 1, wherein a ratio between the length of the housing and the height of the housing is greater than 1 and less than 40.

4. 10. The electrochemical cell of claim 1, wherein the height of the housing is less than 500 mm.

5. 5. The electrochemical cell of claim 4, wherein the height of the housing is less than 125 mm.

6. 10. The electrochemical cell of claim 1, wherein the length of the housing is at least 100 mm.

7. 7. The electrochemical cell of claim 6, wherein the length of the housing is greater than 500 mm.

8. 8. The electrochemical cell of claim 7, wherein the length of the housing is greater than 1 meter.

9. 10. The electrochemical cell of claim 1 configured such that current flow within the electrochemical cell is in a direction substantially parallel to the height of the electrochemical cell.

10. 10. The electrochemical cell of claim 1, wherein the lid includes a plurality of conductive sections, each first section being electrically isolated from each other section.

11. 11. The electrochemical cell of claim 10, wherein the anode comprises a plurality of anode elements, a corresponding subset of the anode elements being connected to each section of the lid.

12. 11. The electrochemical cell of claim 10, wherein the cathode includes a plurality of cathode elements, a corresponding subset of the cathode elements being connected to each section of the lid.

13. 12. The electrochemical cell of claim 11 , wherein a plurality of subcells are defined within the interior of the volume of the electrochemical cell, each subcell including a respective subset of the anode elements and a respective subset of the plurality of cathode elements of the cathode.

14. 14. The electrochemical cell of claim 13, wherein each subcell is fluidly isolated from each other of the subcells.

15. 14. The electrochemical cell of claim 13, wherein at least one subcell has performance characteristics that differ from the performance characteristics of one or more others of the subcells.

16. 14. The electrochemical cell of claim 13, wherein at least one subcell is controllable independently of one or more others of said subcells.

17. The electrochemical cell of claim 1 , wherein a fluid flow path is defined in an interior surface of the lid.

18. The anode is a metal substrate extending along the height of the electrochemical cell; an anode material coated on a portion of the surface of the metal substrate; 10. The electrochemical cell of claim 1, comprising: an uncoated portion of the metal substrate contacting an inner surface of the lid.

19. The cathode is a metal substrate extending along the height of the electrochemical cell; a cathode material coated on a portion of the surface of the metal substrate; 10. The electrochemical cell of claim 1, comprising: an uncoated portion of the metal substrate contacting an inner surface of the lid.

20. A battery pack comprising an array of electrochemical cells according to claim 1.

21. 21. The battery pack of claim 20, wherein the electrochemical cells in the array are arranged such that the largest surface of each electrochemical cell faces the largest surface of an adjacent electrochemical cell.

22. the lids include a first lid to which the anode is connected, and each electrochemical cell includes a second lid disposed on a second side of the electrochemical cell opposite the first side, and the cathode is connected to the second lid; 21. The battery pack of claim 20, wherein the electrochemical cells in the array are arranged such that the first lid of a first electrochemical cell in the array faces a first direction and the first lid of an adjacent electrochemical cell in the array faces a second direction opposite the first direction.

23. The battery pack of claim 20 , wherein the battery pack is disposed within a vehicle.

24. 24. The battery pack of claim 23, wherein the battery pack is positioned within the vehicle such that lengths of the electrochemical cells within the battery pack are oriented parallel to an axle of the vehicle.

25. 1. An electrochemical cell comprising: a housing defining an interior space of an electrochemical cell, the housing defining one or more side surfaces of the electrochemical cell, an inner surface of each of the one or more side surfaces facing the interior space of the electrochemical cell; an anode and a cathode disposed in the interior space of the electrochemical cell; a lid having an inner surface facing the interior space of the electrochemical cell, the anode, the cathode, or both being connected to the lid; and a thermal management module disposed on the inner surface of one or more of the sides of the electrochemical cell, the inner surface of the lid, or both; An electrochemical cell comprising:

26. The thermal management module includes: a fluid flow path; an inlet and an outlet fluidly connected to the fluid flow path; 26. The electrochemical cell of claim 25, comprising:

27. 27. The electrochemical cell of claim 26, wherein the fluid flow path has a serpentine configuration.

28. 27. The electrochemical cell of claim 26, wherein the fluid flow channels have a linear configuration.

29. 27. The electrochemical cell of claim 26, wherein the fluid flow paths extend in a direction perpendicular to the height of the electrochemical cell.

30. 27. The electrochemical cell of claim 26, wherein the fluid flow paths extend in a direction perpendicular to the length of the electrochemical cell.

31. 27. The electrochemical cell of claim 26, wherein the fluid flow path is configured to receive a thermal management fluid.

32. 27. The electrochemical cell of claim 26, wherein the fluid flow channels have a diameter of at least 100 μm.

33. 27. The electrochemical cell of claim 26, wherein the thermal management module comprises a metal tube that defines the fluid flow path.

34. 27. The electrochemical cell of claim 26, including a passive cooling element disposed external to the electrochemical cell, the fluid flow path extending through the passive cooling element.

35. 35. The electrochemical cell of claim 34, wherein the passive cooling element comprises a fin.

36. 27. The electrochemical cell of claim 26, wherein the fluid flow paths are defined in an interior wall of the electrochemical cell, the interior wall comprising the interior surface of one of the sides of the electrochemical cell or the interior surface of the lid of the electrochemical cell.

37. 37. The electrochemical cell of claim 36, wherein the thermal management module includes a second fluid flow path defined in a second interior wall of the electrochemical cell, the second interior wall including the interior surface of one of the sides of the electrochemical cell or the interior surface of the lid, the second interior wall being different from the first interior wall.

38. 37. The electrochemical cell of claim 36, wherein the inlet and the outlet are defined in the side of the electrochemical cell in which the fluid flow path is defined or in the lid of the electrochemical cell.

39. 39. The electrochemical cell of claim 38, wherein the inlet and the outlet are defined in the same end of the side or lid in which the fluid flow path is defined.

40. 39. The electrochemical cell of claim 38, wherein the inlet and the outlet are defined on opposite ends of the side or lid from which the fluid flow path is defined.

41. 37. The electrochemical cell of claim 36, wherein the thermal management module includes a plurality of fluid flow paths defined in the same interior wall.

42. 37. The electrochemical cell of claim 36, wherein the interior wall comprises a metal.

43. 37. The electrochemical cell of claim 36, wherein the area of ​​the interior wall occupied by the fluid flow paths is between 25% and 90% of the total surface area of ​​the interior wall.

44. 37. The electrochemical cell of claim 36, wherein the fluid flow path is defined in the inner surface of the lid, and the anode, the cathode, or both are directly connected to the inner surface of the lid.

45. 26. The electrochemical cell of claim 25, wherein the thermal management module includes a thermoelectric cooling system.

46. 26. The electrochemical cell of claim 25, wherein the lid includes a first lid and the electrochemical cell includes a second lid having an inner surface facing the interior space opposite the inner surface of the first lid, the anode being connected to the first lid and the cathode being connected to the second lid.

47. 1. A method of manufacturing an electrochemical cell, comprising: disposing an anode and a cathode in an interior space defined by a housing defining one or more side surfaces of the electrochemical cell, wherein an interior surface of each of the one or more side surfaces faces the interior space of the electrochemical cell; connecting a lid to the housing such that an inner surface of the lid defines a wall of the interior space, including connecting the anode, the cathode, or both to the lid. wherein a thermal management module is disposed on the inner surface of one or more of the sides of the electrochemical cell, the inner surface of the lid, or both.

48. 48. The method of claim 47, comprising forming fluid channels in the interior surface of one or more of the sides of the electrochemical cell, the interior surface of the lid, or both.

49. 49. The method of claim 48, wherein forming the fluid flow paths comprises fabricating the housing, the lid, or both using an additive manufacturing process.

50. 49. The method of claim 48, wherein forming the fluid flow path comprises using a mold to fabricate the housing, the lid, or both.

51. 1. A method of operating an electrochemical cell, comprising: generating an electric current from the electrochemical cell including an anode and a cathode disposed in an interior space of the electrochemical cell, the anode, the cathode, or both connected to a lid having an interior surface defining a wall of the interior space of the electrochemical cell; allowing a fluid to enter the inlet and exit the outlet through a fluid flow path defined in one or more interior surfaces of a side of the electrochemical cell, the interior surface of the lid, or both; A method comprising:

52. 52. The method of claim 51, wherein the flowing of a fluid comprises cooling the electrochemical cell.

53. 52. The method of claim 51, wherein the flowing of the fluid comprises heating the electrochemical cell.

54. 52. The method of claim 51, wherein flowing a fluid comprises flowing a liquid, a gas, or a mixture of a liquid and a gas.

55. 1. An electrochemical cell comprising: a housing defining an interior space of the electrochemical cell; a lid having an interior surface facing the interior space of the electrochemical cell, the lid extending along a length of the electrochemical cell; an electrode disposed in the interior space of the electrochemical cell and electrically connected to the lid, a metal substrate extending along the height of the electrochemical cell; an anode material or a cathode material coated on a portion of the surface of the metal substrate; an electrode comprising wherein an uncoated portion of the metal substrate contacts the inner surface of the lid.

56. 56. The electrochemical cell of claim 55, wherein the electrodes are welded to the inner surface of the lid.

57. 56. The electrochemical cell of claim 55, wherein a groove is defined in the interior surface of the lid, and the uncoated portion of the metal substrate is disposed within the groove.

58. 58. The electrochemical cell of claim 57, wherein the groove extends along the length of the electrochemical cell.

59. 58. The electrochemical cell of claim 57, comprising a plurality of electrodes, a plurality of grooves defined in the interior surface of the lid, the uncoated portion of the metal substrate of each electrode disposed within a corresponding one of the grooves.

60. 56. The electrochemical cell of claim 55, wherein the uncoated portion of the metal substrate includes a protrusion extending through a thickness of the electrochemical cell.

61. 61. The electrochemical cell of claim 60, wherein the protrusion defines a plane parallel to the plane of the inner surface of the lid.

62. 61. The electrochemical cell of claim 60, wherein the protrusion contacts the inner surface of the lid.

63. a plurality of anodes, each anode comprising an anode material coated on a portion of the surface of a respective anode substrate; a plurality of cathodes, each cathode including a cathode material coated on a portion of the surface of a respective cathode substrate; 56. The electrochemical cell of claim 55, comprising:

64. the plurality of anode substrates each include a protrusion that extends in a first direction along the thickness of the electrical cell such that the protrusion of a given anode substrate overlies the protrusion of an adjacent anode substrate; and 64. The electrochemical cell of claim 63, wherein the plurality of cathode substrates each include a protrusion that extends in a second direction along the thickness of the electrochemical cell such that the protrusion of a given cathode substrate overlies the protrusion of an adjacent cathode substrate.

65. 65. The electrochemical cell of claim 64, wherein an outermost protrusion of the plurality of anode substrates and an outermost protrusion of the plurality of cathode substrates contact the inner surface of the lid.

66. 56. The electrochemical cell of claim 55, wherein the lid comprises a first lid and the electrochemical cell comprises a second lid having an inner surface facing the interior space of the electrochemical cell opposite the inner surface of the first lid.

67. 67. The electrochemical cell of claim 66, wherein the electrode comprises an anode and the electrochemical cell comprises a second electrode comprising a cathode, the anode electrically connected to the first lid and the cathode electrically connected to the second lid.

68. 56. The electrochemical cell of claim 55, wherein a fluid flow path is defined in the interior surface of the lid.

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