Electrochemical cells and electrochemical cell stacks with series connections and methods for creating, operating and monitoring them - Patents.com

Abstract

Embodiments described herein relate to electrochemical cells and multi-cells. A multi-cell can include cell packaging containing two or more electrochemical cells connected in series within the cell packaging. In some aspects, an apparatus includes a plurality of electrochemical cell stacks, each including a plurality of electrochemical cells connected in series, a first conductive plate including a first section and a second section, and a second conductive plate. The first section of the first conductive plate contacts a first terminal end of a first electrochemical cell stack from the plurality of electrochemical cell stacks. The second section of the first conductive plate contacts a first terminal end of a second electrochemical cell stack from the plurality of electrochemical cell stacks.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 394,341, filed August 2, 2022, entitled "Electrochemical Cells and Electrochemical Cell Stacks with Series Connections and Methods of Producing, Operating, and Monitoring the Same," the disclosure of which is incorporated herein by reference in its entirety.

[0002] SUMMARY OF THE INVENTION The embodiments described herein relate to electrochemical cells and multi-cells arranged in stacks as part of modular constructions, and methods for producing and operating them. [Background technology]

[0003] An electrochemical cell stack can be formed by arranging a plurality of such electrochemical cells in a stack. Existing methods of arranging electrochemical cells in a stack and connecting them in series are utilized in low-power battery applications such as portable consumer electronics (e.g., lithium coin cells in laser pointers, alkaline batteries in flashlights, etc.). In such systems, individual electrochemical cell casings can serve as electrical connection points between the electrochemical cells in the stack. However, it may be desirable to produce electrochemical cell stacks that can achieve high total voltages for use in high-power applications such as electric vehicle batteries or solar energy systems. Existing electrochemical cell systems are not suitable for producing electrochemical cell stacks that can achieve high total voltages while maintaining a compact size, being relatively easy to transport, and being convenient and low-cost to manufacture. Summary of the Invention

[0004] Embodiments described herein relate to electrochemical cells and multi-cells. A multi-cell can include cell packaging containing two or more electrochemical cells connected in series within the cell packaging. In some aspects, a device includes a plurality of electrochemical cell stacks, each including a plurality of electrochemical cells connected in series, a first conductive plate including a first section and a second section, and a second conductive plate. The first section of the first conductive plate contacts a first terminal end of a first electrochemical cell stack from the plurality of electrochemical cell stacks. The second section of the first conductive plate contacts a first terminal end of a second electrochemical cell stack from the plurality of electrochemical cell stacks. The second conductive plate contacts a second terminal end of the first electrochemical stack. In some embodiments, the first section of the second conductive plate contacts a second terminal end of the first stack, and the second conductive plate includes a second section contacting a second terminal end of the second electrochemical cell stack.

[0005] In some aspects, the device includes a plurality of electrochemical cell stacks, each electrochemical cell stack from the plurality of electrochemical cell stacks including a plurality of electrochemical cells connected in series, a first conductive plate configured to electrically connect a first pair of electrochemical cell stacks from the plurality of electrochemical cell stacks in series, and a second conductive plate configured to electrically connect a second pair of electrochemical cell stacks from the plurality of electrochemical cell stacks in series. In some embodiments, the first pair of electrochemical cell stacks have one electrochemical cell stack in common with the second pair of electrochemical cell stacks.

[0006] In some embodiments, an apparatus includes a first stack of electrochemical cells connected in series, a second stack of electrochemical cells connected in series, and a conductive plate contacting the first electrochemical cell at a terminal end of the first stack of electrochemical cells and contacting the second electrochemical cell at a terminal end of the second stack of electrochemical cells. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a block diagram of an assembly of electrochemical cell stacks, according to one embodiment. [Figure 2] FIG. 1 is a block diagram of an electrochemical cell stack, according to one embodiment. [Figure 3A] FIG. 1 is a diagram of an electrochemical cell stack, according to one embodiment. [Figure 3B] FIG. 1 is a diagram of an electrochemical cell stack, according to one embodiment. [Figure 3C] FIG. 1 is a diagram of an electrochemical cell stack, according to one embodiment. [Figure 3D] FIG. 1 is a diagram of an electrochemical cell stack, according to one embodiment. [Figure 4A] FIG. 1 is a diagram of an electrochemical cell stack, according to one embodiment. [Figure 4B] FIG. 1 is a diagram of an electrochemical cell stack, according to one embodiment. [Figure 5A] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5B] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5C] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5D] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5E] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5F] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5G] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5H] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 5I] 1 is a diagram of an electrochemical cell stack and a method of producing the same, according to one embodiment. [Figure 6A] 1 illustrates an assembly of electrochemical cell stacks, according to one embodiment. [Figure 6B] 1 illustrates an assembly of electrochemical cell stacks, according to one embodiment. [Figure 7] 1 is a schematic flow chart of a method for producing an assembly of electrochemical cell stacks, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] The embodiments described herein describe the production of electrochemical cells as part of a modular construction. High-voltage cells, modules, and packs can be constructed, and the cells can then be formed into high-voltage system blocks, thereby reducing the manufacturing process steps and components required for the overall system. To achieve higher total voltages (e.g., 500 V), modules can be assembled, sent to a forming area, and connected in series in the forming area. However, any intermediate voltage may be selected based on the needs of the building, safety, process, grid, or battery forming tester. Limits on voltage can also be based on available DC / DC or AC / DC conversion technology based on cost or conversion efficiency. Control systems for bypassing energy (both charging and discharging) around modules, cells, or packs can ensure safe operation, preventing overcharging and allowing the complete formation of each cell. Safety systems can monitor temperature, current, and / or voltage to prevent cell damage and thermal runaway due to overheating, overcharging, or over-discharging. A method for producing electrochemical cells connected in series in a single pouch is described in U.S. Patent Publication No. 2022 / 0278427 (the "'427 Publication"), entitled "Electrochemical Cells Connected in Series in a Single Pouch and Method of Making the Same," filed May 13, 2022, the entire disclosure of which is incorporated herein by reference.

[0009] Existing methods for arranging electrochemical cells in a stack and connecting the electrochemical cells contained within the stack in series are utilized in low-power battery applications such as portable consumer electronics (e.g., lithium coin cells in laser pointers, alkaline batteries in flashlights, etc.). Existing methods include either (1) disposing the electrochemical cells in a casing and stacking such casings on top of each other, with the casing serving as an electrical connection point between the electrochemical cells in the stack, or (2) arranging multiple electrochemical cells in a stack, connecting the multiple electrochemical cells in series, and disposing the multiple electrochemical cells within a single pouch. However, existing electrochemical cell systems often do not achieve high total voltages while maintaining a compact size, being relatively easy to transport, and being convenient and low-cost to manufacture.

[0010]

[0003] Embodiments described herein relate to electrochemical cells and multi-cell systems arranged in stacks as part of a modular construction, and methods for producing and operating the same. The embodiments described herein may provide one or more benefits, including, for example, (1) the ability to achieve higher overall voltages (e.g., 500V), (2) reduced component count at the system level (e.g., elimination of bus bars), (3) reduced manufacturing steps and components required for the system, (4) elimination of the requirement for welding equipment (e.g., laser or ultrasonic welders), (5) the ability to assemble the system on-site, (6) easy replacement of cells and / or strings upon cell and / or string failure without permanent welded connections, (7) ease of transportability of the system, (8) simple design that reduces manufacturing time and cost, and (9) the ability to implement flexible voltage levels.

[0011] High voltage cells, modules, and packs are useful for high power applications such as electric vehicle batteries and solar energy systems. High voltage cells offer benefits such as (1) higher charge and discharge efficiency than lower voltage batteries, thereby enabling support of higher load demands, (2) higher energy density, and (3) improved performance of the device, system, appliance, or machine being powered.

[0012] In some embodiments, the electrodes described herein can comprise conventional solid electrodes. In some embodiments, the solid electrodes can comprise a binder. In some embodiments, the electrodes described herein can comprise semi-solid electrodes. The semi-solid electrodes described herein (i) can be made thicker (e.g., greater than 100 μm, up to 2,000 μm, or even greater) than conventional electrodes due to the reduced tortuosity and increased conductivity of the semi-solid electrodes, (ii) can involve higher loading of active material, and (iii) can be made by simplified manufacturing processes utilizing less equipment. These relatively thick semi-solid electrodes reduce the volume, mass, and cost contribution of inactive components relative to the active components, thereby enhancing the commercial attractiveness of batteries made with semi-solid electrodes. In some embodiments, the semi-solid electrodes described herein are binderless and / or do not use binders used in conventional battery manufacturing. Instead, the volume of the electrode typically occupied by a binder in conventional electrodes is now occupied by: 1) an electrolyte. 1) an active material, which reduces tortuosity and increases the total salt available for ion diffusion, thereby countering the salt depletion effect inherent in thick, conventional electrodes when used at high rates; 2) an active material, which increases the charge capacity of the battery; or 3) a conductive additive, which increases the electronic conductivity of the electrode, thereby countering the high internal impedance of thick, conventional electrodes. The reduced tortuosity and increased electronic conductivity of the semi-solid electrodes described herein result in superior rate capabilities and charge capacities for electrochemical cells formed from the semi-solid electrodes. Because the semi-solid electrodes described herein can be made substantially thicker than conventional electrodes, the ratio of active material (i.e., semi-solid cathode and / or anode) to inactive material (i.e., current collector and separator) can be much higher in batteries formed from electrochemical cell stacks containing semi-solid electrodes compared to similar batteries formed from electrochemical cell stacks containing conventional electrodes. This results in a substantial increase in the overall charge capacity and energy density of batteries containing the semi-solid electrodes described herein.

[0013] In some embodiments, the electrode materials described herein can be flowable semi-solid or condensed liquid compositions. In some embodiments, the electrode materials described herein can be binderless or substantially binder-free. A flowable semi-solid electrode can include a suspension of electrochemically active material (anode or cathode particles or particulates) and, optionally, an electronically conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. Stated another way, active electrode particles and conductive particles are co-suspended in the electrolyte to produce a semi-solid electrode. Examples of battery architectures utilizing semi-solid suspensions are described in International Patent Publication No. 2012 / 024499, entitled "Stationary, Fluid Redox Electrode," and International Patent Publication No. 2012 / 088442, entitled "Semi-Solid Filled Battery and Method of Manufacture," the entire disclosures of which are incorporated herein by reference.

[0014] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, the term "element" is intended to mean a single element or a combination of elements, and "material" is intended to mean one or more materials, or a combination thereof.

[0015] The term "substantially," when used in connection with "cylindrical," "linear," and / or other geometric relationships, is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As an example, a portion of a support member described as "substantially linear" is intended to convey that while linearity of the portion is desirable, some non-linearity may occur in the "substantially linear" portion. Such non-linearity may result from manufacturing tolerances or other practical considerations (e.g., pressure or force applied to the support member). Thus, a geometric structure modified by the term "substantially" includes such geometric characteristics within a tolerance of plus or minus 5% of the described geometric structure. For example, a "substantially linear" portion is one that defines an axis or centerline that is within plus or minus 5% of being linear.

[0016] As used herein, the terms "set" and "plurality" can refer to multiple features or a singular feature with multiple portions. For example, when referring to a set of electrodes, the set of electrodes can be considered one electrode with multiple portions, or the set of electrodes can be considered multiple separate electrodes. Additionally, for example, when referring to multiple electrochemical cells, the multiple electrochemical cells can be considered multiple separate electrochemical cells, or one electrochemical cell with multiple portions. Thus, a set of portions or multiple portions may include multiple portions that are contiguous or discontinuous with one another. Multiple particles or multiple materials can also be made from multiple articles that are produced separately and then joined together (e.g., by mixing, adhesive, or any suitable method).

[0017] As used herein, the term "semi-solid" refers to a material that is a mixture of liquid and solid phases, such as, for example, a particle suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle.

[0018] As used herein, the terms "energy density" and "volumetric energy density" refer to the amount of energy (e.g., MJ) stored in an electrochemical cell per unit volume (e.g., L) of materials included to operate the electrochemical cell, such as electrodes, separators, electrolytes, and current collectors. Specifically, materials used to package the electrochemical cell are excluded from the calculation of volumetric energy density.

[0019] As used herein, the terms "high capacity material" or "high capacity anode material" refer to a material having an irreversible capacity greater than 300 mAh / g that can be incorporated into an electrode to promote the uptake of electroactive species. Examples include tin, tin alloys such as Sn-Fe, tin monoxide, silicon, silicon alloys such as Si-Co, silicon monoxide, aluminum, aluminum alloys, metal monoxides (such as CoO and FeO), or titanium oxide.

[0020] As used herein, the term "composite high capacity electrode layer" refers to an electrode layer having both a high capacity material and a conventional anode material, for example, a silicon graphite layer.

[0021] As used herein, the term "solid high capacitance electrode layer" refers to an electrode layer having a single solid-phase high capacitance material, for example, sputtered silicon, tin, tin alloys such as Sn-Fe, tin monoxide, silicon, silicon alloys such as Si-Co, silicon monoxide, aluminum, aluminum alloys, metal monoxides (such as CoO, FeO), or titanium oxide.

[0022] FIG. 1 is a block diagram of an apparatus 100000 including a plurality of multi-cells 10000a-10000n (collectively referred to as multi-cells 10000), according to one embodiment. In some embodiments, multi-cells 10000a-10000n may include a plurality of electrochemical cells stacked together to form an electrochemical cell stack 1000a-1000n (hereinafter, "stack"). In some embodiments, the plurality of electrochemical cells included in a stack 1000a-1000n may be connected in parallel. In some embodiments, the plurality of electrochemical cells included in a stack 1000a-1000n may be connected in series. Any number of electrochemical cells may be included in a stack. In some embodiments, the number of electrochemical cells in each stack 1000a-1000n may range from about 2 to about 100, inclusive (e.g., about 3, about 4, about 5, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, about 95, or about 100 electrochemical cells, including all ranges and values therebetween). In some embodiments, an odd number of electrochemical cells may be included in each stack 1000a-n. In some embodiments, an even number of electrochemical cells may be included in each stack 1000a-1000n. A device may include multiple stacks (collectively referred to as stacks 1000).

[0023] Multi-cells 10000a-10000n may include an upper pallet 150 that includes biasing members 151. In some embodiments, biasing members 151 are a plurality of springs (e.g., helical springs, Belleville springs, reed springs, etc.) integrated into upper pallet 150. In some embodiments, 48 springs are integrated into upper pallet 150. In some embodiments, the top pallet 150 can include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, at least about 800, or at least about 900 biasing members 151. In some embodiments, the top pallet 150 can include about 1,000 or less, about 900 or less, about 800 or less, about 700 or less, about 600 or less, about 500 or less, about 400 or less, about 300 or less, about 200 or less, about 100 or less, about 90 or less, about 80 or less, about 70 or less, about 60 or less, about 50 or less, about 40 or less, about 30 or less, about 20 or less, about 10 or less, about 9 or less, about 8 or less, about 7 or less, about 6 or less, about 5 or less, about 4 or less, about 3 or less, or about 2 or less biasing members 151. Combinations of the above numbers of biasing members 151 are also possible (e.g., at least about 2 or more and less than about 1,000, or at least about 30 or more and less than about 100), including all values and ranges therebetween. In some embodiments, the upper pallet 150 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 100, about 200, about 300, about 400, about 500, about 600, about 700, about 800, about 900, or about 1,000 biasing members 151.

[0024] The biasing member(s) 151 may contact one or more conductive plates 152 (hereinafter "conductive plates") and press onto the stack 1000 to provide pressure. The conductive plates 152 may electrically connect the stack 1000 in series or parallel. In some embodiments, the conductive plates 152 may include an integrated spring mechanism instead of a standalone spring (e.g., stamped dimples or spring fingers). In some embodiments, the conductive plates 152 may be plated for reduced contact resistance and enhanced corrosion resistance. Raised geometries (e.g., dimples) may be used to reduce contact resistance. The contact pads and springs may be pre-assembled or otherwise captured in a pallet to comprise a single assembly for ease of system construction.

[0025] In some embodiments, the top pallet 150 contacts two conductive plates 152. In some embodiments, the multicell 10000 can include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, or at least about 45 conductive plates 152. In some embodiments, the multicell 10000 can include no more than about 50, no more than about 45, no more than about 40, no more than about 35, no more than about 30, no more than about 25, no more than about 20, no more than about 15, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, no more than about 4, no more than about 3, or no more than about 2 conductive plates 152. Combinations of the above numbers of conductive plates 152 are also possible (e.g., at least about 1 and up to about 50, or at least about 2 and up to about 30), including all values and ranges therebetween. In some embodiments, the multicell 10,000 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, or about 50 conductive plates 152. In some embodiments, all of the conductive plates 152 can contact the top pallet 150 and / or the biasing member 151.

[0026] Apparatus 100000 may also include a lower pallet 155. Upper pallet 152 and lower pallet 155 may be used to align the electrochemical cells in each stack 1000a-1000n and provide a means to apply pressure to the large electrochemical cell surfaces. In some embodiments, lower pallet 155 may include biasing member(s) 151. In some embodiments, both upper pallet 152 and lower pallet 155 may include biasing member(s) 151. In some embodiments, biasing member(s) 151 may contact one or more conductive plates 154 and press onto stack 1000 to provide pressure. Conductive plates 154 may electrically connect cell stack 1000 in series or parallel. In some embodiments, conductive plates 154 may include an integrated spring mechanism instead of a standalone spring (e.g., stamped dimples or spring fingers). In some embodiments, conductive plates 154 may be plated to reduce contact resistance and enhance corrosion resistance. Raised geometries (e.g., dimples) may be used to reduce contact resistance. The contact pads and springs can be pre-assembled or otherwise captured in a pallet to provide a single assembly for ease of system construction.

[0027] The lower pallet 155 may be coupled to the conductive plates 154 via a system connector (not shown). The system connector may protrude outside the lower pallet 155 via positive and negative terminals and may electrically connect the multi-cells 10000a-n to one or more other multi-cells 10000a-n. In some embodiments, the multi-cell 10000 may include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, or at least about 45 conductive plates 154. In some embodiments, the multicell 10,000 can include about 50 or less, about 45 or less, about 40 or less, about 35 or less, about 30 or less, about 25 or less, about 20 or less, about 15 or less, about 10 or less, about 9 or less, about 8 or less, about 7 or less, about 6 or less, about 5 or less, about 4 or less, about 3 or less, or about 2 or less conductive plates 154. Combinations of the above numbers of conductive plates 154 are also possible (e.g., at least about 1 or more and about 50 or less, or at least about 2 or more and about 30 or less), including all values and ranges therebetween. In some embodiments, the multicell 10,000 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, or about 50 conductive plates 154. In some embodiments, all of the conductive plates 154 may contact the top pallet 155 and / or the biasing member(s) 151 .

[0028] The connections between the stack 1000 and the conductive plates 152, 154 allow current to flow through the stack 1000. In some embodiments, current flows from the negative terminal through the first stack 1000a to the first conductive plate 152 that contacts the top pallet 150. The current then passes through the second stack 1000b to the conductive plate 154 that contacts the bottom pallet 155. The current may then pass through the third stack to the second conductive plate 152 and then through the fourth stack to the positive terminal.

[0029] In some embodiments, multicell 10000a may be electrically connected to one or more other multicells 10000. In some embodiments, multicell 10000a may be electrically connected to multicell 10000b via a string connection, multicell 10000b may be electrically connected to a multicell via a string connection, etc. In some embodiments, device 100000 may include four multicells 10000. Including multiple multicells in device 100000 allows device 100000 to achieve a high total voltage for use in high power applications.

[0030] In some embodiments, the device 100,000 can include at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, at least about 800, or at least about 900 multicells 10,000. In some embodiments, the device 100,000 can include about 1,000 or less, about 900 or less, about 800 or less, about 700 or less, about 600 or less, about 500 or less, about 400 or less, about 300 or less, about 200 or less, about 100 or less, about 90 or less, about 80 or less, about 70 or less, about 60 or less, about 50 or less, about 40 or less, about 30 or less, about 20 or less, about 10 or less, about 9 or less, about 8 or less, about 7 or less, about 6 or less, about 5 or less, about 4 or less, or about 3 or less multicells 10,000. Combinations of the above numbers of multicells 10,000 are also possible (e.g., at least about 2 or more and less than about 1,000, or at least about 4 or more and less than about 50), including all values and ranges therebetween. In some embodiments, the device 100000 can include about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 100, about 200, about 300, about 400, about 500, about 600, about 700, about 800, about 900, or about 1,000 multicells 10000. The string connections can be constructed of a conductive material. The device 10000 includes a collective negative terminal and a collective positive terminal for connection to a voltage source.

[0031] 2 is a block diagram of an electrochemical cell stack (or multi-cell) 1000, according to one embodiment. As shown, the electrochemical cell stack 1000 includes electrochemical cells 100a, 100b, ..., 100n (collectively referred to as electrochemical cells 100). As shown, the electrochemical cells 100 are connected in series. Electrochemical cell 100 includes anodes 110a, 110b, ..., 100n (collectively referred to as anodes 110) disposed on anode current collectors 120a, 120b, ..., 120n (collectively referred to as anode current collectors 120), cathodes 130a, 130b, ..., 130n (collectively referred to as cathodes 130) disposed on cathode current collectors 140a, 140b, ..., 140n (collectively referred to as cathode current collectors 140), and separators 150a, 150b, ..., 150n (collectively referred to as separators 150) disposed between anodes 110 and cathodes 130. Anode current collector 120 includes anode tabs 122a, 122b, ..., 122n, each of which is coupled to a collective anode tab 122. The cathode current collector 140 includes cathode tabs 142a, 142b, ..., 142n, each coupled to the collective cathode tab 142. As shown, the cathode tabs 142a, 142b, ..., 142n are each connected to the collective cathode tab 142 in a parallel connection. As shown, the electrochemical cells 100 are disposed within a casing 160. In some embodiments, each of the electrochemical cells 100 can be installed within an individual casing.

[0032] In some embodiments, each stack 1000 may include electrochemical cells 100 arranged in the stack, a collective anode tab 142, a collective cathode tab 122, a casing 160 including a base and cover assembly, optional conformal layers, and insulating layers. In some embodiments, multiple electrochemical cells 100 may be arranged in multiple stacks, each stack disposed within a casing 160 that is stacked on top of one another to form multiple stacks. In some embodiments, the collective anode tab 122 and collective cathode tab 142 may be configured such that multiple electrochemical cells 100 (e.g., each anode current collector or cathode current collector of an electrochemical cell) are in contact with one tab, thereby allowing electrical energy to be transferred to and / or removed from one or more electrochemical cells via a single tab of the respective tab(s) coupled to the electrochemical cells.

[0033] 3A-3D illustrate a stack (or multi-cell) 3000, according to one embodiment. As shown, the stack 3000 includes electrochemical cells 300 arranged in the stack, a collective anode tab 322, a collective cathode tab 342, a casing 360 including a base 362 and a cover assembly 364, an optional conformal layer 366, and an insulating layer 368. Rivets 365 are fitted into rivet holes 367. In some embodiments, the electrochemical cells 300 and casing 360 can be the same as or substantially similar to the electrochemical cells 100 and casing 160, as described above with reference to FIGS. 1-2. Accordingly, certain aspects of the electrochemical cells 300 and casing 360 will not be described in further detail herein.

[0034] The base 362 and the cover assembly 364 form the casing 360. In some embodiments, the base 362 can be polarized. In some embodiments, the base 362 can be positively polarized or negatively polarized. In some embodiments, the cover assembly 364 can be polarized. In some embodiments, the cover assembly 364 can be positively polarized or negatively polarized. In some embodiments, the depth of the base 362 can correspond to the number of electrochemical cells 300 disposed on the base 362. For example, in some embodiments, if the base 362 accommodates a small number of electrochemical cells 300, the base 362 can be shallow. In some embodiments, the depth of the base 362 can be increased to accommodate a larger number of electrochemical cells 300. In some embodiments, the conforming layer 366 can provide insulation and / or space filling between the electrochemical cells 300 and the base 362. In some embodiments, the conforming layer 366 can be a soft layer that applies pressure to the electrochemical cells 300 when compressed. Insulation 368 may be disposed within the casing 360 to limit heat transfer within the electrochemical cell stack 3000 .

[0035] Rivets 365 are inserted through rivet holes 367 in the cover assembly 364, insulator 368, and base 362 to hold the casing 360 together. The rivets 365 can carry electrical current from the electrochemical cells 300 to the exterior of the casing 360. This can facilitate the transfer of electrical current from the stack 3000 to another stack. The rivet 365 feedthroughs can also maintain a hermetic seal within the casing 360. In some embodiments, the rivet 365 feedthroughs can be press-fit, insert-molded, epoxied, or secured via a threaded mechanism and backing nut. In some embodiments, the base 362 and / or cover assembly 364 can function as electrically active terminals, serving as electrical contact surfaces. In some embodiments, the base 362 and / or cover assembly 364 can be plated with a low-resistivity metal to enhance electrical conductivity. In some embodiments, the surface of the cover assembly 364 and / or the surface of the base 362 can be internally or externally treated with one or more coatings or treatments, or one or more coatings may be disposed on one or more surfaces of the cover assembly to increase the conductivity of the surface, for example, to increase current flow across the surface when in contact with another stack. In some embodiments, the cover assembly 364 and / or the base 362 can include additional layers and / or surface treatments to improve the number of contact points between the stacks. In some embodiments, the additional layers and / or surface treatments may include, for example, a soft and / or deformable layer, an expanded metal mesh layer, a plated layer (e.g., an electroplated layer), a conductive epoxy roughening treatment, a surface flatness treatment, or any treatment, coating, or layer configured to improve the connection area or points (i.e., reduce the resistance of the compression connection), or any suitable combination thereof. In some embodiments, the additional layer can include a semi-solid slurry having high electronic conductivity and bonding ability. In some embodiments, the semi-solid slurry can include a silicone oil-based liquid to enhance the security of the connection (e.g., to prevent short circuits).In some embodiments, the stack can be bonded using fastening screws, conductive polymer with an adhesive coating, and / or UV-curve polymer bonding, any other suitable fastening mechanism, or any suitable combination thereof. In some embodiments, the base 362 and / or cover assembly 364 can include raised geometries or features (e.g., dimples, detents, pins, protrusions, etc.) to enhance contact resistance.

[0036] 4A-4B are diagrams of a stack (or multi-cell) 4000, according to one embodiment. As shown, stack 4000 includes electrochemical cell 400, casing 460, anode connector 461, cathode connector 463, and insulator 468. In some embodiments, electrochemical cell 400, casing 460, and insulator 468 can be the same as or substantially similar to electrochemical cell 300, casing 360, and insulator 368, as described above with reference to FIGS. 3A-3D . Accordingly, certain aspects of electrochemical cell 400, casing 460, and insulator 468 will not be described in further detail herein.

[0037] The anode connector 461 is electrically connected to each of the anodes in the electrochemical cell 400 via anode tabs and carries current to the exterior surface of the casing 460. The cathode connector 463 is electrically connected to each of the cathodes in the electrochemical cell 400 via cathode tabs and carries current to the exterior surface of the casing 460 opposite the anode connector 461. The inclusion of the anode and cathode connectors allows for stacking of polarized plates. In some embodiments, the casing 460 can be metal (e.g., stamped), film (metal foil or laminated metal / polymer composite), molded / formed plastic with a conductive layer (e.g., metallized, insert-molded plate), and any combination thereof. In some embodiments, the insulator 468 can extend around the perimeter of the electrochemical cell stack 4000.

[0038] 5A-5I illustrate a multi-cell 50000 having multiple electrochemical cells and its construction, according to one embodiment. The stackable connections shown in the multi-cell 50000 can reduce component count at the system level (e.g., no bus bars are required). Additionally, while the use of welded connections is contemplated within the scope of this patent, welding equipment can be eliminated from the manufacturing process (e.g., laser or ultrasonic welders). The multi-cell 50000 can be assembled in the field. Because the multi-cell 50000 includes few or no permanent welded connections, field assembly facilitates easy replacement in the event of a cell or string failure. FIG. 5A illustrates a top pallet 550 with springs 551 coupled to conductive plates 552. The springs 551 exert pressure on the conductive plates 552, creating stack pressure within the multi-cell 50000. As shown, the springs 551 provide a mechanical connection or interface to the top pallet 550. Spring 551 may apply a defined pressure profile to conductive plate 552 and / or other components, such as bus bars, included in and / or coupled to multicell 50000. Spring 551 may include, but is not limited to, a coil spring, a flat spring, a leaf spring, a helical spring, a Belleville spring, a cantilever spring, or other specific biasing or spring device(s). In some embodiments, spring 551 may be replaced by or used in combination with a compressible material, such as, for example, an elastomer, rubber, foam, and / or other compressible material, or combinations thereof, that can apply a biasing force to conductive plate 552 or any other portion of multicell 50000.

[0039] As shown, the top pallet 550 includes 48 springs 551. In some embodiments, the top pallet 550 can include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, at least about 800, or at least about 900 springs 551. In some embodiments, the top pallet 550 can include about 1,000 or less, about 900 or less, about 800 or less, about 700 or less, about 600 or less, about 500 or less, about 400 or less, about 300 or less, about 200 or less, about 100 or less, about 90 or less, about 80 or less, about 70 or less, about 60 or less, about 50 or less, about 40 or less, about 30 or less, about 20 or less, about 10 or less, about 9 or less, about 8 or less, about 7 or less, about 6 or less, about 5 or less, about 4 or less, about 3 or less, or about 2 or less springs 551. Combinations of the above numbers of springs 551 are also possible (e.g., at least about 2 or more and about 1,000 or less, or at least about 30 or more and about 100 or less), including all values and ranges therebetween. In some embodiments, the top pallet 550 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 100, about 200, about 300, about 400, about 500, about 600, about 700, about 800, about 900, or about 1,000 springs 551.

[0040] The spring 551 contacts the conductive plate 552 and presses onto the electrochemical cells to provide pressure. The conductive plate 552 can electrically connect the electrochemical cells in series or parallel. In some embodiments, the conductive plate 552 can have one or more sections. As shown, the conductive plate 552 can have a first section and a second section. Each section can be in contact with a terminal end of the stack. In some embodiments, the conductive plate 552 can include about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, about 95, or about 100 sections, including all values and ranges therebetween. In some embodiments, the conductive plate 552 can include an integrated spring mechanism instead of a stand-alone spring (e.g., stamped dimples or spring fingers). In some embodiments, the conductive plate 552 can be plated to reduce contact resistance and enhance corrosion resistance. Raised geometries (e.g., dimples) may be used to reduce contact resistance. The contact pads and springs can be pre-assembled or otherwise captured in a pallet to provide a single assembly for ease of system construction.

[0041] As shown, the top pallet 550 contacts two conductive plates 552. In some embodiments, the multicell 50000 can include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, or at least about 45 conductive plates 552. In some embodiments, the multicell 5000 can include no more than about 50, no more than about 45, no more than about 40, no more than about 35, no more than about 30, no more than about 25, no more than about 20, no more than about 15, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, no more than about 4, no more than about 3, or no more than about 2 conductive plates 552. Combinations of the above numbers of conductive plates 552 are also possible (e.g., at least about 1 to about 50, or at least about 2 to about 30), including all values and ranges therebetween. In some embodiments, the multicell 50000 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, or about 50 conductive plates 552.

[0042] 5B shows the bottom pallet 555 in contact with the conductive plate 554. The top pallet 550 and bottom pallet 555 are used to align the electrochemical cells and provide a means to apply pressure to the large cell surfaces. The conductive plate 554 is coupled to the bottom pallet 555 via a system connector 557. The system connector 557 protrudes outside the bottom pallet 555 via the positive terminal 542 and the negative terminal 522, allowing the multi-cell 50000 to be electrically connected to another multi-cell.

[0043] As shown, the bottom pallet 555 includes three conductive plates 554. In some embodiments, the conductive plates 554 can have one or more sections. As shown, two conductive plates 554 have a first section and one conductive plate 554 has a first section and a second section. Each section can be in contact with a terminal end of the stack. In some embodiments, the conductive plates 554 can have about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, about 95, or about 100 sections, including all values and ranges therebetween. In some embodiments, the multicell 50000 can include at least about 1, at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, or at least about 45 conductive plates 554. In some embodiments, the multicell 50000 can include no more than about 50, no more than about 45, no more than about 40, no more than about 35, no more than about 30, no more than about 25, no more than about 20, no more than about 15, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, no more than about 4, no more than about 3, or no more than about 2 conductive plates 554. Combinations of the above numbers of conductive plates 554 are also possible (e.g., at least about 1 to about 50, or at least about 2 to about 30), including all values and ranges therebetween. In some embodiments, the multicell 5000 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, or about 50 conductive plates 554.

[0044] 5C-5D show a plurality of casings 560 stacked on a lower pallet 555. Electrochemical cells are contained within the casings 560. In some embodiments, the casings 560 can include electrochemical cells individually housed within the casings 560. In some embodiments, the casings 560 can be the same as or substantially similar to the casings 360, as described above with reference to FIGS. 3A-3D. Accordingly, specific aspects of the casings 560 will not be described in further detail herein. In some embodiments, the plurality of electrochemical cells can be individually housed within the casings 560. In some embodiments, each of the casings 560 can include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 15, about 20, about 25, about 30, about 35, about 40, about 45, or about 50 electrochemical cells housed therein, including all values and ranges therebetween.

[0045] As shown, the casings 560 are arranged in four stacks with 25 casings 560 in each stack. In some embodiments, the casings 560 can be arranged in m stacks with n casings 560 in each stack, where m and n are positive integers. In some embodiments, m and / or n can be at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 15, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, at least about 45, at least about 50, at least about 55, at least about 60, at least about 65, at least about 70, at least about 75, at least about 80, at least about 85, at least about 90, or at least about 95. In some embodiments, m and / or n can be about 100 or less, about 95 or less, about 90 or less, about 85 or less, about 80 or less, about 75 or less, about 70 or less, about 65 or less, about 60 or less, about 55 or less, about 50 or less, about 45 or less, about 40 or less, about 35 or less, about 30 or less, about 25 or less, about 20 or less, about 15 or less, about 10 or less, about 9 or less, about 8 or less, about 7 or less, about 6 or less, about 5 or less, about 4 or less, or about 3 or less. Positive terminal 542 and negative terminal 522 act as leads for electrical connection to another multi-cell.

[0046] 5E-5G show tie rods 559 and hard stops 558 incorporated into the multi-cell 5000. The tie rods 559 connect the upper pallet 550 and the lower pallet 555. The tie rods 559 can help apply pressure to the stack of casings 560 and the electrochemical cells therein. The hard stops 558 control the distance between the upper pallet 550 and the lower pallet 555. In some embodiments, the hard stops 558 insulate the tie rods 559, preventing corrosion or disassembly of the tie rods 559. The tie rods 559 may secure the stack between the upper pallet 550 and the lower pallet 555 to form the multi-cell 50000 without welding components, thereby eliminating the need for welding equipment (e.g., laser or ultrasonic welders). Utilizing tie rods 559 to secure the multi-cell 50000 also allows for easy replacement of any number of electrochemical cells in the stack in the event of a failure of an electrochemical cell or string of electrochemical cells, since there are no permanent welded connections.

[0047] 51 illustrates the movement of electrical current through the multiple stacks of electrochemical cells in multicell 50000. Current flows from negative terminal 522, through casing 560 and the first stack of electrochemical cells, to a first conductive plate 552 that contacts top pallet 550. The current then passes through casing 560 and the second stack of electrochemical cells to a conductive plate 554 that contacts bottom pallet 555. The current then passes through casing 560 and the third stack of electrochemical cells to second conductive plate 552, and then through casing 560 and the fourth stack of electrochemical cells to positive terminal 542.

[0048] 6A-6B illustrate a device 600000 having multiple multicells 60000a, 60000b, 60000c, and 60000d (collectively referred to as multicells 60000), according to one embodiment. In some embodiments, multicell 60000 can be the same as or substantially similar to multicell 10000, as described above with reference to FIG. 1. Accordingly, certain aspects of multicell 60000 will not be described in further detail herein. As shown, multicell 60000a is electrically connected to multicell 60000b via string connection 601a, multicell 60000b is electrically connected to multicell 60000c via string connection 601b, and multicell 60000c is electrically connected to multicell 60000d via string connection 601c. String connections 601a, 601b, 601c (collectively referred to as string connections 601) can be constructed of a conductive material. The device includes a collective negative terminal 622 and a collective positive terminal 642 for connection to a voltage source. In some embodiments, string connections 601 can be constructed of a metal (e.g., copper, aluminum, gold, silver, nickel, iron, stainless steel, iron, titanium, steel, or any combination thereof). In some embodiments, string connections 601 can be constructed of one or more conductive polymers.

[0049] As shown, device 600000 includes four multicells 60000. In some embodiments, device 600000 can include at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, at least about 800, or at least about 900 multicells 60000. In some embodiments, the device 600000 can include about 1,000 or less, about 900 or less, about 800 or less, about 700 or less, about 600 or less, about 500 or less, about 400 or less, about 300 or less, about 200 or less, about 100 or less, about 90 or less, about 80 or less, about 70 or less, about 60 or less, about 50 or less, about 40 or less, about 30 or less, about 20 or less, about 10 or less, about 9 or less, about 8 or less, about 7 or less, about 6 or less, about 5 or less, about 4 or less, or about 3 or less multicells 60000. Combinations of the above numbers of multicells 60000 are also possible (e.g., at least about 2 or more and less than about 1,000, or at least about 4 or more and less than about 50), including all values and ranges therebetween. In some embodiments, the device 600000 can include about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 100, about 200, about 300, about 400, about 500, about 600, about 700, about 800, about 900, or about 1,000 multicells 60000.

[0050] 7 is a schematic flow chart of a method 700 for stacking electrochemical cells and multi-cells as part of a modular construction. Although described with respect to electrochemical cells 100, stacks 1000, multi-cells 10000, and devices 100000, method 700 is equally applicable to any of the electrochemical cells, stacks, multi-cells, and devices described herein. All such variations should be considered within the scope of this disclosure.

[0051] The method 700 includes, at step 702, arranging a plurality of electrochemical cells 100 into a plurality of stacks 1000. At step 704, a first conductive plate 154 including a first section and a second section is disposed on a lower pallet 155. At step 706, the plurality of stacks 1000 can be disposed on the first conductive plate 154 such that the first section contacts a first terminal end of the first stack 1000 a, 1000 b, ..., 1000 n and the second section contacts a first terminal end of the second stack 1000 a, 1000 b, ..., 1000 n. In some embodiments, the plurality of stacks 1000 can be disposed on one or more conductive plates 154, each conductive plate 154 having one or more sections. In such embodiments, each section of each conductive plate 154 can contact a terminal end of a stack 1000 a, 1000 b, ..., 1000 n. In step 708, a biasing member, such as a plurality of springs 151, can be integrated into the top pallet 150, with the plurality of springs 151 contacting the second conductive plates 152. In step 710, the top pallet 150 is disposed above the stacks 1000 such that the second conductive plates 152 are in contact with second terminal ends of the first stacks 1000a, 1000b, ..., 1000n. In some embodiments, the plurality of springs 151 can be in contact with one or more conductive plates 152, with each conductive plate 152 having one or more sections. In such embodiments, each section of each conductive plate 152 can be in contact with a terminal end of a stack 1000a, 1000b, ..., 1000n. In step 712, the top pallet 150 and the bottom pallet 155 are connected using a plurality of tie rods to form multi-cell assemblies 10000a, 10000b, ..., 10000n. In step 714, the multi-cell assemblies 10000a, 10000b, ..., 10000n may optionally be electrically connected to one or more external multi-cell assemblies 10000. Electrically connecting multiple multi-cell assemblies 10000 allows for the formation of a high voltage device that may be used in high power applications.

[0052] Various concepts may be embodied as one or more methods, at least one example of which is provided. Acts performed as part of a method may be ordered in any suitable manner. Thus, although shown as sequential acts in an exemplary embodiment, embodiments may be constructed in which acts are performed in an order different from that illustrated, which may include performing some acts simultaneously. In other words, it should be understood that such features may not necessarily be limited to a particular order of execution, but rather, any number of threads, processes, services, servers, etc. may be executed sequentially, asynchronously, concurrently, in parallel, simultaneously, and / or synchronously in a manner consistent with this disclosure. Thus, some of these features may be mutually inconsistent, in that they cannot exist simultaneously in a single embodiment. Similarly, some features may be applicable to certain aspects of the invention and inapplicable to other aspects.

[0053] Additionally, the present disclosure may include other innovations not currently described. The applicants retain all rights in such inventions, including any rights to practice such inventions and to any additional applications, continuations, continuations-in-part, divisions, and / or the like. As such, it should be understood that the advantages, embodiments, examples, functions, features, logical, operational, organizational, structural, topological, and / or other aspects of the present disclosure should not be construed as limitations of the present disclosure defined by the embodiments or limitations of equivalents of the embodiments. Depending on the particular desires and / or characteristics of individual and / or business users, database organization and / or relational models, data types, data transmission and / or network frameworks, syntactic structures, etc., various embodiments of the technology disclosed herein may be implemented in a manner that allows for great flexibility and customization, as described herein.

[0054] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0055] As used herein, in certain embodiments, the term "about" or "approximately," when preceding a numerical value, indicates a range of plus or minus 10% of the value. When a range of values is provided, it is understood that, to the tenth of the unit of the lower limit, each intervening value between the upper and lower limit of that range, and any other stated or intervening value within that stated range, is encompassed within the disclosure, unless the context clearly dictates otherwise. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are subject to any specifically excluded limit in the stated range, also encompassed within the disclosure. Where a stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included within the disclosure.

[0056] As used herein in the specification and embodiments, the term "and / or" should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are present conjunctively in some cases and disjunctively in other cases. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements other than the elements specifically identified by the "and / or" clause may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," can refer in one embodiment to A only (optionally including elements other than B), in another embodiment to B only (optionally including elements other than A), or in yet another embodiment to both A and B (optionally including other elements), etc.

[0057] As used herein in the specification and embodiments, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as inclusive, i.e., including at least one of a number or list of elements, but including more than one, and optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as "only one of" or "exactly one of," or, when used in embodiments, "consisting of," will refer to the inclusion of exactly one element of a number or list of elements. Generally, as used herein, the term "or" should be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") only when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in embodiments, shall have its ordinary meaning as used in the field of patent law.

[0058] As used herein in the specification and embodiments, the phrase "at least one," in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of every element specifically listed in the list of elements and excluding any combination of elements in the list of elements. This definition also allows for elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, whether related to the specifically identified elements or not, may optionally be present. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently, "at least one of A and / or B") can refer to, in one embodiment, at least one, optionally, two or more A, and no B (and, optionally, including elements other than B); in another embodiment, at least one, optionally, two or more B, and no A (and, optionally, including elements other than A); in yet another embodiment, at least one, optionally, two or more A, and at least one, optionally, two or more B (and, optionally, including other elements); etc.

[0059] In embodiments, as well as in the above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "consisting of," and the like, are to be understood to be open-ended, i.e., to mean "including, but not limited to." As set forth in Section 2111.03 of the United States Patent Office Manual of Patent Examining Procedures, only the transitional phrases "consisting of" and "consisting essentially of" must be closed or semi-closed transitional phrases, respectively.

[0060] While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments, as described herein, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure. While the methods and steps described above indicate certain events occurring in a certain order, those skilled in the art, having the benefit of this disclosure, will recognize that the order of certain steps may be changed, and that such changes are in accordance with variations of the present invention. Additionally, some steps may be performed simultaneously in parallel processing, where possible, rather than simply sequentially as described above. While embodiments have been shown and described in detail, it will be understood that various changes in form and detail may be made.

Claims

1. 1. An apparatus comprising: a plurality of electrochemical cell stacks each including a plurality of electrochemical cells connected in series; a first conductive plate including a first section and a second section, the first section of the first conductive plate contacting a first terminal end of a first electrochemical cell stack from the plurality of electrochemical cell stacks and the second section of the first conductive plate contacting a first terminal end of a second electrochemical cell stack from the plurality of electrochemical cell stacks; a second conductive plate in contact with a second terminal end of the first electrochemical cell stack.

2. 10. The apparatus of claim 1, wherein a first section of the second conductive plate contacts the second terminal end of the first electrochemical cell stack, and wherein the second conductive plate includes a second section in contact with the second terminal end of the second electrochemical cell stack.

3. 10. The apparatus of claim 1, wherein a first section of the second conductive plate contacts the second terminal end of the first electrochemical cell stack, and wherein the second conductive plate includes a second section that contacts a first terminal end of a third electrochemical cell stack.

4. 4. The apparatus of claim 3, further comprising a third conductive plate including first and second sections, the first section of the third conductive plate contacting a second terminal end of the third electrochemical cell stack and the second section of the third conductive plate contacting a first terminal end of a fourth electrochemical cell stack.

5. The apparatus of claim 1 , further comprising an upper pallet disposed above the plurality of electrochemical cell stacks and a lower pallet disposed below the plurality of electrochemical cell stacks.

6. 6. The apparatus of claim 5, further comprising a plurality of springs integrated into the top pallet, the plurality of springs contacting the second conductive plate and configured to apply pressure to the plurality of electrochemical cell stacks.

7. The apparatus of claim 5 further comprising a plurality of tie rods connecting the upper and lower pallets.

8. 8. The apparatus of claim 7, wherein each of the plurality of tie rods is surrounded by a hard stop, the hard stop configured to control the distance between the upper pallet and the lower pallet, and to electrically insulate the tie rod and protect the tie rod from corrosion.

9. the plurality of electrochemical cell stacks is a first plurality of electrochemical cell stacks, and the apparatus comprises: a second plurality of electrochemical cell stacks; 10. The apparatus of claim 8, further comprising: a connector electrically coupling the first plurality of electrochemical cell stacks to the second plurality of electrochemical cell stacks.

10. 1. An apparatus comprising: a plurality of electrochemical cell stacks, each electrochemical cell stack from the plurality of electrochemical cell stacks including a plurality of electrochemical cells connected in series; a first conductive plate configured to electrically connect a first pair of electrochemical cell stacks from the plurality of electrochemical cell stacks in series; a second conductive plate configured to electrically connect a second pair of electrochemical cell stacks from the plurality of electrochemical cell stacks in series.

11. The apparatus of claim 10 , wherein the first pair of electrochemical cell stacks has one electrochemical cell stack in common with the second pair of electrochemical cell stacks.

12. the first conductive plate includes a first section in electrical contact with a first terminal end of a first electrochemical cell stack from the plurality of electrochemical cell stacks and a second section in electrical contact with a first terminal end of a second electrochemical cell stack; 12. The apparatus of claim 11, wherein the second conductive plate includes a first section in electrical contact with a second terminal end of the first electrochemical cell stack and a second section in electrical contact with a first terminal end of a third electrochemical cell.

13. 13. The apparatus of claim 12, further comprising a third conductive plate including a first section and a second section, the first section of the third conductive plate being in electrical contact with a second terminal end of the third electrochemical cell stack and the second section of the third conductive plate being in electrical contact with a first terminal end of a fourth electrochemical cell stack.

14. a top pallet disposed above the plurality of electrochemical cell stacks; The apparatus of claim 10 , further comprising: a lower pallet disposed below the plurality of electrochemical cell stacks.

15. 15. The apparatus of claim 14, further comprising a plurality of springs integrated into the top pallet, the plurality of springs contacting at least one of the first conductive plate or the second conductive plate, the plurality of springs configured to apply pressure to the plurality of electrochemical cell stacks.

16. 15. The apparatus of claim 14, further comprising a plurality of tie rods connecting the upper and lower pallets.

17. 17. The apparatus of claim 16, wherein each of the plurality of tie rods is surrounded by a hard stop, the hard stop configured to control the distance between the upper pallet and the lower pallet and to electrically insulate the tie rod and protect the tie rod from corrosion.

18. the plurality of electrochemical cell stacks is a first plurality of electrochemical cell stacks, and the apparatus comprises: a second plurality of electrochemical cell stacks; 11. The apparatus of claim 10, further comprising: a connector electrically coupling the first plurality of electrochemical cell stacks to the second plurality of electrochemical cell stacks.

19. 1. An apparatus comprising: a first stack of electrochemical cells connected in series; a second stack of electrochemical cells connected in series; a conductive plate contacting a first electrochemical cell at a terminal end of the first stack of electrochemical cells and contacting a second electrochemical cell at a terminal end of the second stack of electrochemical cells.

20. the conductive plate is a first conductive plate, the terminal end of the second electrochemical cell stack is a first terminal end, and the device comprises: a third stack of electrochemical cells; and 20. The apparatus of claim 19, further comprising: a second conductive plate contacting an electrochemical cell at a second terminal end of the second electrochemical cell stack and contacting an electrochemical cell at a terminal end of the third electrochemical cell stack.

21. the terminal end of the third electrochemical cell stack is a first terminal end, and the device comprises: a fourth stack of electrochemical cells; and 21. The apparatus of claim 20, further comprising: a third conductive plate contacting an electrochemical cell at a second terminal end of the third electrochemical cell stack and contacting an electrochemical cell at a terminal end of the fourth electrochemical cell stack.

22. an upper pallet disposed above the first electrochemical cell stack and the second electrochemical cell stack; 20. The apparatus of claim 19, further comprising: a lower pallet disposed below the first electrochemical cell stack and the second electrochemical cell stack.

23. 23. The apparatus of claim 22, further comprising a plurality of springs integrated into the top pallet, the plurality of springs contacting the conductive plates and configured to apply pressure to the first electrochemical cell stack and the second electrochemical cell stack.

24. 23. The apparatus of claim 22, further comprising a plurality of tie rods connecting the upper and lower pallets.

25. 25. The apparatus of claim 24, wherein each of the plurality of tie rods is surrounded by a hard stop, the hard stop configured to control the distance between the upper pallet and the lower pallet and to electrically insulate the tie rod and protect the tie rod from corrosion.

Images