Electrochemical energy storage devices and housings

The disclosure provides electrochemical batteries, electrochemical battery housings and methods for assembling electrochemical batteries. The battery housing can include a container, a container lid assembly and an electrical conductor. The container can include a cavity that extends into the container from a cavity aperture. The lid assembly can seal the cavity, and can include an electrically conductive container lid and an electrically conductive flange. The container lid can cover the cavity aperture and can include a conductor aperture that extends through the container lid. The flange can cover the conductor aperture and can be electrically isolated from the container lid. The conductor can be connected to the flange and can extend through the conductor aperture into the cavity. The conductor can be electrically isolated from the container lid.

BACKGROUND

A battery is a device capable of converting stored chemical energy into electrical energy. Batteries are used in many household and industrial applications. In some instances, batteries are rechargeable such that electrical energy (e.g., converted from non-electrical types of energy, such as mechanical energy) is capable of being stored in the battery as chemical energy (i.e., charging the battery).

SUMMARY

The disclosure provides energy storage devices (e.g., batteries) and housings that may be used within an electrical power grid or as part of a standalone system. The batteries may be charged from an electricity production source, for later discharge when there is a demand for electrical energy consumption.

Energy storage devices of the disclosure aid in alleviating at least some of the issues with renewable energy sources. Renewable energy may be intermittent, where energy supply and demand may not be matched time-wise (e.g., within instantaneous or near-instantaneous timeframes). For example, solar energy is only produced when the sun is shining and wind energy is only produced when the wind is blowing. Further, demand at any given time is a function of industrial, commercial, community and household activity. Using the batteries and battery housings described herein can offer a means for balancing intermittent electrical energy supply with demand.

The disclosure provides systems for directing electrical current through a metallic wall at elevated temperatures while minimizing the introduction of leaks or electrical contacts between the current flow path and the wall. In some cases this is achieved through the use of a mated flange connection with mica, vermiculite, glass, brazed ceramics, or other high-temperature dielectric sealing material, and may be secured with electrically-insulating fasteners (e.g., bolts, clamps) or through the mechanical and/or chemical adhesion of the seal with the metal flange surfaces. The feed-through assembly may be sealed onto an appropriate opening in the metallic wall (e.g., through secure weld). In some instances, the feed-through assembly distributes current evenly across the electrode.

Bolted flange assemblies provided herein can provide a compressive force that may be adequate to seal a cavity of a housing of an energy storage device. In some cases, use of a flange assembly can also provide a geometry that is amenable to the use of mica or vermiculite gaskets as the sealant and electrical isolation material. In some implementations, the geometry of the sealing surface is decoupled from the geometry of the housing (or vessel) being sealed. The size and shape of the housing, in some cases, may not dictate the size and shape of the seal.

In an aspect, an electrochemical cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture in the housing and is electrically isolated from the housing, wherein the electrochemical cell is capable of storing and/or taking in at least 25 Wh of energy. In some embodiments, the electrochemical cell comprises a liquid metal anode adjacent to said current collector. In some embodiments, the liquid metal comprises lithium.

In another aspect, a battery comprises a plurality of the electrochemical cells of claim1, wherein the battery is capable of storing at least 100 kWh of energy.

In another aspect, a battery housing comprises an electrically conductive container and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture in the container and is electrically isolated from the container, wherein the housing is capable of enclosing an electrochemical cell that is capable of storing and or taking in at least 25 Wh of energy. In some embodiments, the housing is capable of hermetically sealing the electrochemical cell.

In another aspect, an electrochemical cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture of the housing and is electrically isolated from the housing, wherein the ratio of the area of the aperture to the area of the housing is less than 0.1. In some embodiments, the cell comprises a liquid metal anode adjacent to said current collector. In some embodiments, the liquid metal comprises lithium. In some embodiments, the cell is capable of storing and or taking in at least 25 Wh of energy.

In another aspect, a battery housing comprises an electrically conductive container and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the container through an aperture in the container and is electrically isolated from the container, wherein the ratio of the area of the aperture to the area of the container is less than 0.1 and wherein the housing is capable of enclosing a battery that is capable of storing and or taking in at least 25 Wh of energy.

In another aspect, an electrochemical energy storage device comprises a housing, a liquid metal electrode, a current collector in contact with the liquid metal electrode, and a plurality of conductors that are in electrical communication with the current collector and protrude through the housing through apertures in the housing. In some embodiments, the current is distributed substantially evenly across the liquid metal electrode. In some embodiments, the liquid metal electrode is in contact with an electrolyte along a surface and the current flowing across the surface is uniform. In some embodiments, the maximum density of current flowing across an area of the surface is less than about 150% of the average density of current flowing across the surface. In some embodiments, the minimum density of current flowing across an area of the surface is greater than about 50% of the average density of current flowing across the surface.

In another aspect, a battery housing comprises an electrically conductive container, a plurality of container apertures and a plurality of conductors in electrical communication with a current collector, wherein the conductors pass through the container apertures and are electrically isolated from the electrically conductive container, wherein the housing is capable of enclosing an electrochemical cell comprising a liquid metal electrode in contact with the current collector. In some embodiments, the current is distributed substantially evenly across the liquid metal electrode. In some embodiments, the liquid metal electrode is in contact with an electrolyte along a surface and the current flowing across the surface is uniform. In some embodiments, the maximum density of current flowing across an area of the surface is less than about 150% of the average density of current flowing across the surface. In some embodiments, the minimum density of current flowing across an area of the surface is greater than about 50% of the average density of current flowing across the surface.

In another aspect, an electrochemical energy storage device comprises a liquid metal anode and a cathode, wherein the electrochemical energy storage device is capable of storing and or taking in at least 25 Wh of energy and is hermetically or non-hermetically sealed. In some embodiments, the device is capable of storing at least 100 kWh of energy. In some embodiments, the electrochemical energy storage device comprises a liquid anode comprising lithium. In some embodiments, the rate of oxygen transfer into the electrochemical energy storage device is less than 0.5 mL per hour when the electrochemical energy storage device is contacted with air at a pressure of 1 bar and temperature of 500° C. In some embodiments, the electrochemical energy storage device comprises less than 15 bolts or fasteners. In some embodiments, the electrochemical energy storage device comprises no bolts or fasteners.

In another aspect, a compilation of electrochemical cells, an individual cell of said compilation comprising a liquid lithium anode in a charged state, wherein the compilation is capable of storing and or taking in at least 25 Wh of energy and each of the cells are hermetically sealed. In some embodiments, the compilation is capable of storing at least 100 kWh of energy.

In another aspect, a battery housing comprises an electrically conductive container, a container aperture and a conductor in electrical communication with a current collector, wherein the conductor passes through the container aperture and is electrically isolated from the electrically conductive container, wherein the housing is capable of hermetically sealing a battery which is capable of storing and or taking in at least 25 Wh of energy. In some embodiments, the housing is capable of hermetically sealing a battery which is capable of storing at least 100 kWh of energy. In some embodiments, the battery comprises a liquid metal anode adjacent to said current collector.

In another aspect, an energy storage device, comprises: a first electrochemical cell adjacent to a second electrochemical cell, each of said first and second cells comprising an electrically conductive housing and a conductor in electrical communication with a current collector, wherein the conductor is electrically isolated from the housing and protrudes through the housing through an aperture in the housing such that the conductor contacts the housing of an adjacent electrochemical cell of the energy storage device. In some embodiments, the first and/or second electrochemical cells comprise a liquid metal anode adjacent to said current collector. In some embodiments, the conductor contacts the housing of an adjacent electrochemical cell of the energy storage device when the first and second cells are in a stacked configuration. In some embodiments, the first and second cells are capable of storing and or taking in at least 25 Wh of energy. In some embodiments, the energy storage device comprises a stack of 1 to 10 electrochemical cells. In some embodiments, the energy storage device comprises a stack of 11 to 50 electrochemical cells. In some embodiments, the energy storage device comprises a stack of 51 to 100 electrochemical cells, or more.

In another aspect, a battery housing comprises an electrically conductive container and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture in the container and is electrically isolated from the container, wherein the conductor of a first housing contacts the container of a second housing when the first and second housings are in a stacked configuration. In some embodiments, the housing is capable of hermetically sealing an electrochemical cell comprises a liquid metal electrode. In some embodiments, the housing is capable of hermetically sealing an electrochemical cell capable of storing and or taking in at least 25 Wh of energy.

In another aspect, an electrochemical energy storage device comprises an anode, a cathode, an electrolyte, a positive current collector and a negative current collector, wherein the negative current collector is in contact with the anode and the positive current collector is in contact with the cathode, wherein the electrolyte is disposed in-between said anode and cathode, and wherein the electrochemical energy storage device is capable of storing and or taking in at least 25 Wh of energy and comprises less than 15 bolts or fasteners. In some embodiments, the device is capable of storing at least 100 kWh of energy. In some embodiments, the electrochemical energy storage device comprises less than 5 bolts or fasteners. In some embodiments, the electrochemical energy storage device comprises no bolts or fasteners. In some embodiments, the electrochemical energy storage device comprises a liquid metal anode adjacent to said current collector.

In another aspect, a compilation of electrochemical cells, an individual cell of said compilation comprising a liquid lithium anode in a charged state, wherein the compilation is capable of storing and or taking in at least 25 Wh of energy and each of the batteries comprise less than 10 bolts or fasteners. In some embodiments, the compilation is capable of storing at least 100 kWh of energy.

In another aspect, a battery housing that hermetically seals an electrochemical energy storage device having a liquid metal anode, which electrochemical energy storage device is capable of storing and or taking in at least 25 Wh of energy, wherein the battery housing comprises less than 10 bolts or fasteners. In some embodiments, the housing is capable of hermetically sealing an electrochemical energy storage device capable of storing at least 100 kWh of energy.

In another aspect, an electrochemical cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture in the housing and is electrically isolated from the housing with a gasket, wherein the force on the gasket is at least 5,000 psi when the housing is sealed. In some embodiments, the force on the gasket is at least 10,000 psi when the housing is sealed. In some embodiments, the gasket is affixed with a flange and no more than 10 bolts or fasteners. In some embodiments, the gasket is adhesive and the cell comprises no bolts or fasteners.

In another aspect, a battery housing comprises an electrically conductive container and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the container through an aperture in the container and is electrically isolated from the container with a gasket, wherein the force on the gasket is at least 5,000 psi when the battery housing is sealed. In some embodiments, the force on the gasket is at least 10,000 psi when the battery housing is sealed. In some embodiments, the gasket is affixed with a flange and no more than 10 bolts or fasteners. In some embodiments, the housing is capable of enclosing an electrochemical cell that is capable of storing and or taking in at least 25 Wh of energy. In some embodiments, the housing is capable of hermetically or non-hermetically sealing the battery.

In another aspect, an electrochemical battery housing, comprises: (a) a container including a cavity that extends into the container from a cavity aperture; (b) a container lid assembly sealing the cavity, the lid assembly including an electrically conductive container lid and an electrically conductive flange, wherein the container lid covers the cavity aperture and includes a conductor aperture that extends through the container lid, and wherein the flange covers the conductor aperture and is electrically isolated from the container lid; and (c) an electrical conductor connected to the flange and extending through the conductor aperture into the cavity, wherein the conductor is electrically isolated from the container lid.

In some embodiments, (a) the conductor aperture is one of a plurality of conductor apertures extending through the container lid; (b) the flange is one of a plurality of electrically conductive flanges respectively covering the conductor apertures and electrically isolated from the container lid; and/or (c) the conductor is one of a plurality of electrical conductors respectively connected to the flanges, respectively extending through the conductor apertures, and electrically isolated from the container lid. In some embodiments, the housing further comprises a current collector within the cavity and connected to the conductors. In some embodiments, the housing further comprises a gasket arranged between and electrically isolating the flange and the container lid. In some embodiments, the gasket comprises dielectric material. In some embodiments, the container lid is fixedly and/or securely connected to the container, and the flange is removably connected to the container lid. In some embodiments, the container lid includes a mounting ring connected to a base, and the conductor aperture extends through the mounting ring, and wherein the flange is removably connected to the mounting ring with a plurality of fasteners. In some embodiments, portions of the fasteners that engage the mounting ring are electrically isolated from the mounting ring. In some embodiments, the fasteners are electrically isolated from the flange by dielectric material. In some embodiments, the housing further comprises an insulating sheath attached to an interior sidewall surface of the container. In some embodiments, the container has one of a circular cross-sectional geometry and a rectangular cross-sectional geometry. In some embodiments, the cavity aperture has a cavity aperture diameter, and wherein the conductor aperture has a conductor aperture diameter that is about two (2) times less than that cavity aperture diameter. In some embodiments, the container lid assembly hermetically seals said cavity.

In another aspect, an electrochemical battery, comprises: (a) a container including a cavity that extends into the container from a cavity aperture; (b) an electrochemical battery cell arranged within the cavity; (c) a container lid assembly sealing the battery cell in the cavity, the lid assembly including an electrically conductive container lid and an electrically conductive flange, wherein the container lid covers the cavity aperture and includes a conductor aperture that extends through the container lid, and wherein the flange covers the conductor aperture and is electrically isolated from the container lid; and (d) an electrical conductor extending through the conductor aperture, and electrically coupled to the battery cell and the flange, wherein the conductor is electrically isolated from the container lid. In some embodiments, the battery cell comprises a liquid electrolyte arranged between a negative liquid metal electrode and a positive liquid metalloid electrode. In some embodiments, the battery further comprises a current collector electrically coupled to the negative liquid metal electrode, wherein the current collector is connected to the conductor which is connected to the top flange in the assembly, which is electrically isolated from the cell lid.

In some embodiments, (a) the conductor aperture is one of a plurality of conductor apertures extending through the container lid; (b) the flange is one of a plurality of electrically conductive flanges respectively covering the conductor apertures and electrically isolated from the container lid; and/or (c) the conductor is one of a plurality of electrical conductors respectively electrically coupled to the battery cell and the flanges, respectively extending through the conductor apertures, and electrically isolated from the container lid. In some embodiments, the battery further comprises a gasket arranged between and electrically isolating the flange and the container lid. In some embodiments, the gasket comprises dielectric material. In some embodiments, the container lid includes a mounting ring connected to a base that is fixedly and/or securely connected to the container, and the conductor aperture extends through the mounting ring, and wherein the flange is removably connected to the mounting ring with a plurality of bolts or fasteners. In some embodiments, the container lid assembly hermetically or non-hermetically seals said battery cell in said cavity.

In another aspect, an electrochemical cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture in the housing and is electrically isolated from the housing with a seal that hermetically seals the electrochemical cell. In some embodiments, the seal is formed by brazing ceramic onto a metal substrate. In some embodiments, the seal is formed by mechanically and/or chemically bonded glass or glass-ceramic composite. In some embodiments, the seal is formed between dissimilar materials. In some embodiments, the seal is under compression at the operating temperature of the electrochemical cell. In some embodiments, the seal is formed between two surfaces in at least two planes. In some embodiments, the seal is formed from at least two different materials, at least one of which is resistant to degradation from contact with materials contained in the electrochemical cell.

In another aspect, a method for sealing an electrochemical cell comprises: (a) applying a sealant material between a housing and an article recessed into the housing, wherein the sealant is applied at a temperature at which the sealant material is malleable, viscous, or flowable, and wherein the housing and the article have different coefficients of thermal expansion; and (b) lowering the temperature to a temperature at which the sealant material is not malleable, viscous, or flowable, thereby creating a seal between the housing and the article that is under a compressive force. In some embodiments, the sealant material is a borosilicate glass. In some embodiments, the housing has a greater coefficient of thermal expansion than the article. In some embodiments, the seal is resistant to reactive metal vapors such as sodium (Na), lithium (Li) or magnesium (Mg). In some embodiments, the sealant material is a chalcogenide based compound. In some embodiments, the chalcogenide has the chemical formula CaAl2S4.

In another aspect, an electrochemical cell comprises an electrically conductive housing as a first current collector and a conductor in electrical communication with a second current collector, wherein the conductor protrudes through the housing through an aperture in the housing and is electrically isolated from the housing. In some embodiments, the electrochemical cell comprises a liquid metal anode adjacent to the first current collector or the second current collector.

In some embodiments, the liquid metal comprises lithium.

In another aspect, a battery comprises one or more electrochemical cells as described herein, wherein the battery is capable of storing at least 25 Wh of energy. In some embodiments, the battery is capable of storing at least 100 kWh of energy.

INCORPORATION BY REFERENCE

DETAILED DESCRIPTION

This disclosure provides electrochemical energy storage devices (or batteries) and electrochemical battery housings. An electrochemical battery can include an electrochemical battery cell sealed (e.g., hermetically sealed) within an electrochemical battery housing.

Electrochemical Cells and Housings

The term “cell,” as used herein, generally refers to an electrochemical cell. A cell can include a negative electrode of material ‘A’ and a positive electrode of material ‘B’, denoted as A∥B. The positive and negative electrodes can be separated by an electrolyte.

The term “module,” as used herein, generally refers to cells that are attached together in parallel by, for example, mechanically connecting the cell housing of one cell with the cell housing of an adjacent cell (e.g., cells that are connected together in an approximately horizontal packing plane). A module can include a plurality of cells in parallel. A module can comprise any number of cells (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more). In some cases, a module comprises 9, 12, or 16 cells. In some cases, a module is capable of storing about 700 Watt-hours of energy and/or delivering about 175 Watts of power.

The term “pack,” as used herein, generally refers to modules that are attached through different electrical connections (e.g., vertically). A pack can comprise any number of modules (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more). In some cases, a pack comprises 3 modules. In some cases, a pack is capable of storing about 2 kilo-Watt-hours of energy and/or delivering about 0.5 kilo-Watts of power.

The term “core,” as used herein generally refers to a plurality of modules or packs that are attached through different electrical connections (e.g., in series and/or parallel). A core can comprise any number of modules or packs (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more). In some cases, the core also comprises mechanical, electrical, and thermal systems that allow the core to efficiently store and return electrical energy in a controlled manner. In some cases, a core comprises 12 packs. In some cases, a core is capable of storing about 25 kilo-Watt-hours of energy and/or delivering about 6.25 kilo-Watts of power.

The term “pod,” as used herein, generally refers to a plurality of cores that are attached through different electrical connections (e.g., in series and/or parallel). A pod can comprise any number of cores (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more). In some cases, the pod contains cores that are connected in parallel with appropriate by-pass electronic circuitry, thus enabling a core to be disconnected while continuing to allow the other cores to store and return energy. In some cases, a pod comprises 4 cores. In some cases, a pod is capable of storing about 100 kilo-Watt-hours of energy and/or delivering about 25 kilo-Watts of power.

The term “system,” as used herein, generally refers to a plurality of cores or pods that are attached through different electrical connections (e.g., in series and/or parallel). A system can comprise any number of cores or pods (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more). In some cases, a system comprises 20 pods. In some cases, a system is capable of storing about 2 megawatt-hours of energy and/or delivering about 500 kilowatts of power.

The term “battery,” as used herein, generally refers to one or more electrochemical cells connected in series and/or parallel. A battery can comprise any number of electrochemical cells, modules, packs, cores, pods or systems.

Electrochemical cells of the disclosure may include an anode, an electrolyte adjacent to the anode, and a cathode adjacent to the electrolyte. In some examples, an electrochemical cell is a liquid metal battery cell. A liquid metal battery cell may include a liquid electrolyte separator arranged between a negative liquid (e.g., molten) metal electrode and a positive liquid metalloid electrode. In some embodiments, a liquid metal battery cell has a molten alkali metal (e.g., lithium) anode, an electrolyte, and a molten metal (e.g. lead, lead-antimony alloy) cathode.

To maintain the electrodes in the liquid states, the battery cell may be heated to any suitable temperature. In some embodiments, the battery cell is heated to a temperature of about 200° C., about 250° C., about 300° C., about 350° C., about 400° C., about 450° C., about 500° C., about 550° C., about 600° C., about 650° C., or about 700° C. The battery cell may be heated to a temperature of at least about 200° C., at least about 250° C., at least about 300° C., at least about 350° C., at least about 400° C., at least about 450° C., at least about 500° C., at least about 550° C., at least about 600° C., at least about 650° C., or at least about 700° C. In some situations, the battery cell is heated to between 200° C. and about 500° C., between 200° C. and about 700° C. or between about 300° C. and 450° C.

Electrochemical cells of the disclosure may be adapted to cycle between charged (or energy storage) modes and discharged (or energy depleted) modes. In some examples, an electrochemical cell can be fully charged, partially discharged, or fully discharged.

In some implementations, during a charging mode, electrical current received from an external power source (e.g., a generator or an electrical grid) may cause metal atoms in the metalloid cathode to shed one or more electrons, dissolving into the electrolyte as a positively charged ion (i.e., cation). Simultaneously, cations of the same species can migrate through the electrolyte, and may accept electrons at the anode, causing them to transition to a neutral metal species, adding to the mass of the electrode. The removal of the active metal species from the cathode and the addition of the active metal to the anode stores electrical potential energy. During an energy discharge mode, an electrical load is coupled to the electrodes. The previously added metal species in the anode are released from the metal electrode (e.g. through melting), and pass through the electrolyte as ions. These ions in the electrolyte alloy with the cathode, with the flow of ions accompanied by the external and matching flow of electrons through the external circuit/load. This electrochemically facilitated metal alloying reaction discharges the previously stored electrical potential energy to the electrical load.

In a charged state, the anode can include anode material and the cathode can include cathode material. During discharging (e.g., when the battery is coupled to a load), the anode material yields one or more electrons and cations of the anode material. The cations migrate through the electrolyte to the cathode material and react with the cathode material to form an metal or metal alloy. During charging, the alloy disassociates to yield cations of the anode material, which migrates to the anode.

Electrochemical cells of the disclosure can include housings that may be suited for various uses and operations. A battery housing can be configured to electrically couple the electrodes to a switch, which is connected to the external power source and the electrical load. The battery cell housing may include, for example, an electrically conductive container that is electrically coupled to a first pole of the switch and/or another cell housing, and an electrically conductive container lid that is electrically coupled to a second pole of the switch and/or another cell housing. The container can be an electrode of the battery cell. The battery cell can be arranged within a cavity of the battery container. One of the electrodes contacts and/or is in electrical communication with an endwall of the battery container. A ceramic sheath may electrically insulate remaining portions of the battery cell from other portions of the battery container. A conductor electrically couples a second one of the electrodes to the container lid, which can seal (e.g., hermetically or non-hermetically) the battery cell within the cavity.

Batteries and Housings

A battery, as used herein can comprise a plurality of electrochemical cells. With reference toFIG. 1, an electrochemical cell (A) is a unit comprising an anode and a cathode. The cell may comprise an electrolyte and be sealed in a housing as described herein. In some cases, the electrochemical cells can be stacked (B) to form a battery (i.e., a compilation of electrochemical cells). The cells can be arranged in parallel, in series, or in both parallel and series (C). The cells can be made into different shapes and geometries that may differ from what is depicted.

Electrochemical cells of the disclosure may be capable of storing (and/or taking in) a suitably large amount of energy. In some instances, a cell is capable of storing (and/or taking in) about 1 Wh, about 5 Wh, 25 Wh, about 50 Wh, about 100 Wh, about 500 Wh, about 1 kWh, about 1.5 kWh, about 2 kWh, about 3 kWh, or about 5 kWh. In some instances, the battery is capable of storing (and/or taking in) at least about 1 Wh, at least about 5 Wh, at least about 25 Wh, at least about 50 Wh, at least about 100 Wh, at least about 500 Wh, at least about 1 kWh, at least about 1.5 kWh, at least about 2 kWh, at least about 3 kWh, or at least about 5 kWh. It is recognized that the amount of energy stored in an electrochemical cell and/or battery may be less than the amount of energy taken into the electrochemical cell and/or battery (e.g., due to inefficiencies and losses).

Batteries of the disclosure may be capable of storing a suitably large amount of energy for use with a power grid (i.e., a grid-scale battery) or other loads or uses. In some instances, a battery is capable of storing (and/or taking in) about 5 kWh, 25 kWh, about 50 kWh, about 100 kWh, about 500 kWh, about 1 MWh, about 1.5 MWh, about 2 MWh, about 3 MWh, or about 5 MWh. In some instances, the battery is capable of storing (and/or taking in) at least about 5 kWh, at least about 25 kWh, at least about 50 kWh, at least about 100 kWh, at least about 500 kWh, at least about 1 MWh, at least about 1.5 MWh, at least about 2 MWh, at least about 3 MWh, or at least about 5 MWh.

In some instances, the cells and cell housings are stackable. Any suitable number of cells can be stacked. Cells can be stacked side-by-side, on top of each other, or both. In some instances, at least about 10, 50, 100, or 500 cells are stacked. In some cases, a stack of 100 cells is capable of storing at least 50 kWh of energy. A first stack of cells (e.g., 10 cells) can be electrically connected to a second stack of cells (e.g., another 10 cells) to increase the number of cells in electrical communication (e.g., 20 in this instance). In some instances, the energy storage device comprises a stack of 1 to 10, 11 to 50, 51 to 100, or more electrochemical cells.

Cell Lid Assemblies

An electrochemical cell can be housed in a container, which can include a container lid. In some cases, the container is an electrode of the electrochemical cell. The container lid may utilize, for example, a seal or gasket (e.g., annular dielectric gasket) to electrically isolate the battery container from the container lid. Such a gasket may be constructed from a relatively hard electrically insulating material, such as, for example, glass, silicon oxide, aluminum oxide, boron nitride, aluminum nitride, or other oxides comprising of lithium oxide, calcium oxide, barium oxide, yttrium oxide, silicon oxide, aluminum oxide, lithium nitride, or other ceramics. The gasket may be subject to relatively high compressive forces (e.g., greater than 10,000 psi) between the container lid and the battery container in order to provide the seal in addition to the electrical isolation. In order to subject the dielectric gasket to such high compressive forces, the fasteners may have relatively large diameters and may be closely spaced together. Such large diameter fasteners may be expensive and, thus, may significantly increase the cost to build a relatively large diameter battery container. In addition, as the diameter of the dielectric gasket is increased to accommodate a large diameter battery container, the gasket may become more and more fragile and difficult to maneuver.

With reference toFIG. 2, a battery comprises an electrically conductive housing201and a conductor202in electrical communication with a current collector203. The conductor may be electrically isolated from the housing and may protrude through the housing through an aperture in the housing such that the conductor of a first cell contacts the housing of a second cell when the first and second cells are stacked.

In an aspect, a cell housing comprises an electrically conductive container and a conductor in electrical communication with a current collector. The conductor may protrude through the housing through an aperture in the container and is electrically isolated from the container. The conductor of a first housing may contact the container of a second housing when the first and second housings are stacked.

In some instances, the area of the aperture through which the conductor protrudes from the housing and/or container is small relative to the area of the housing and/or container. In some cases, the ratio of the area of the aperture to the area of the housing is about 0.001, about 0.005, about 0.01, about 0.05, about 0.1, about 0.15, about 0.2, about 0.3, about 0.4, or about 0.5. In some cases, the ratio of the area of the aperture to the area of the housing is less than 0.001, less than 0.005, less than 0.01, less than 0.05, less than 0.1, less than 0.15, less than 0.2, less than 0.3, less than 0.4, or less than 0.5.

In an aspect, a cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector. The conductor protrudes through the housing through an aperture in the housing and may be electrically isolated from the housing. The ratio of the area of the aperture to the area of the housing may be less than about 0.1.

In an aspect, a cell housing comprises an electrically conductive container and a conductor in electrical communication with a current collector. The conductor protrudes through the container through an aperture in the container and is electrically isolated from the container. The ratio of the area of the aperture to the area of the container may be less than 0.1. The housing can be capable of enclosing a cell that is capable of storing and or taking in at least 25 Wh of energy.

In some instances, the conductor is electrically isolated from the housing with a gasket or seal.FIG. 3shows a cell lid assembly301that can be welded onto a container305. At least one conductive feed-through (i.e., conductor) passes through the lid assembly and is in electrical communication with a liquid anode302. In some embodiments, the current collector is an electrically conductive foam, wherein the anode comprises a liquid metal (e.g. lithium, magnesium, sodium). The anode is in contact with a molten salt electrolyte304, which is in contact with a liquid metal cathode303. In some embodiments the liquid metal cathode comprises lead and antimony.

FIG. 4shows a conductor401, housing aperture and associated structures for electrically isolating the conductor from the housing402and sealing the electrochemical cell. In some embodiments, at least one bolt403holds the assembly in place. The bolt can be in electrical communication with the housing and electrically insulated from the conductive feed-through. In some embodiments, the bolt compresses a top flange404with a bottom flange405. The bottom flange is welded to the cell lid in some instances. An electrically insulating washer or washer assembly406can insulate the bolt from the top flange. In some cases, a dielectric gasket407insulates the top flange from the bottom flange. A dielectric sheath (not shown) can be used to prevent the bolt from contacting the top flange in some cases. In some cases, the feed-through conductor has negative polarity (e.g., is in electrical communication with the anode) and the bolts and housing have positive polarity (e.g., is in electrical communication with the cathode).

When sealed, the force applied to the gasket can be about 1,000 psi, about 2,000 psi, about 5,000 psi, about 10,000 psi, about 15,000 psi, or about 30,000 psi. In some instances, the force applied to the gasket is at least 1,000 psi, at least 2,000 psi, at least 5,000 psi, at least 10,000 psi, at least 15,000 psi, or at least 30,000 psi.

In some cases, a cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector. The conductor can protrude through the housing through an aperture in the housing and is electrically isolated from the housing with a gasket. The force on the gasket may be at least 1,000 psi, at least 5,000 psi, at least 10,000 psi, and the like.

A cell housing can comprise an electrically conductive container and a conductor in electrical communication with a current collector. The conductor may protrude through the container through an aperture in the container and may be electrically isolated from the container with a gasket. The force on the gasket can be at least 1,000 psi, at least 5,000 psi, at least 10,000 psi, and the like.

Few Bolts and Fasteners

Bolts and fasteners can add to the cost of the battery and/or housing substantially. In some instances, the battery or battery housing comprises few bolts or fasteners. In some embodiments, the battery or housing comprises about 50, about 40, about 30, about 20, about 10, about 5, or about 2 bolts or fasteners. The battery or battery housing may comprise no bolts or fasteners. In some embodiments, the battery or housing comprises less than 50, less than 40, less than 30, less than 20, less than 10, less than 5, or less than 2 bolts or fasteners. In other embodiments, the dielectric sealing material may be mechanically and/or chemically adhered to the surfaces of the cell lid and the feed through leads, allowing the system to achieve a hermetic gas-tight seal without the need for any bolts or fasteners on the cell. Pressure may also be applied to the top of the feed-through, such as through cell stacking or adding a weight to the top of the cell, improving the performance and durability of the seal.

A battery can comprise an anode, a cathode, an electrolyte, a positive current collector, and a negative current collector. The negative current collector can be in contact with the anode and the positive current collector is in contact with the cathode. The battery can be capable of storing and or taking in at least 25 Wh of energy and comprises less than 10 bolts or fasteners.

A cell housing can be capable of hermetically sealing a cell which is capable of storing and or taking in at least 25 Wh of energy. The housing comprises less than 20, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 bolt(s) or fastener(s).

Cell lid assemblies can use adhesive seals instead of flanges and gaskets. In some cases, adhesive seals eliminate bolts from the electrochemical cell housing. As seen inFIG. 5, the conductive feed-through501is electrically isolated from the housing and the housing is sealed by an adhesive sealing material502disposed between the feed-through and the housing.

In some cases, for cells that are sealed with adhesive dielectric seals that do not use bolts, a pressure of less than 1 psi may be all that is required to maintain a gas tight seal. In some cases, at least part of the pressure can be supplied by the weight of one or more electrochemical cells stacked upon each other in a battery. The adhesive seal material can comprise a glass seal or a brased ceramic, such as Alumina with Cu—Ag braze alloy, or other ceramic-braze combination.

Sealing the electrochemical cell with an adhesive material rather than bolts and flanges can reduce the height at which the lid assembly can extend above the housing (“head space”). In a stacked battery configuration, it may be desirable to reduce the head space so that relatively more of the volume of the battery can comprise anode and cathode material (i.e., a higher energy storage capacity). In some instances, the width of the head space (as measured from the top of the feed-through to the top surface of the anode) is a small fraction of the width of the battery (as measured from the top of the feed-through to the bottom surface of the housing). In some embodiments, the head space is about 5%, about 10%, about 15%, about 20%, or about 25% of the height of the battery. In some embodiments, the head space is at most about 5%, at most about 10%, at most about 15%, at most about 20%, or at most about 25% of the height of the battery.

In some embodiments, the combined volume of anode and cathode material is about 50%, about 60%, about 70%, about 80%, about 90%, or about 95% of the volume of the battery (e.g., as defined by the outer-most housing of the battery, such as a shipping container). In some embodiments, the combined volume of anode and cathode material is at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% of the volume of the battery.

In some situations, the use of a few or only a single conductive feed-through can result in uneven current distribution in the electrode. As described herein, a plurality of conductive feed-throughs can more evenly distribute the current in the electrode.

In an aspect, an electrochemical energy storage device comprises a housing, a liquid metal electrode, a current collector in contact with the liquid metal electrode, and a plurality of conductors that are in electrical communication with the current collector and protrude through the housing through apertures in the housing. In some embodiments, current is distributed substantially evenly across the liquid metal electrode.

In some embodiments, the liquid metal electrode is in contact with an electrolyte along a surface (and/or interface) and the current flowing across the surface (and/or interface) is uniform. The current flowing through any portion of the surface (and/or interface) does not deviate far from the average current. In some embodiments, the maximum density of current flowing across an area of the surface (and/or interface) is less than about 105%, less than about 115%, less than about 125%, less than about 150%, less than about 175%, less than about 200%, less than about 250%, or less than about 300% of the average density of current flowing across the surface (and/or interface). In some embodiments, the minimum density of current flowing across an area of the surface (and/or interface) is greater than about 50%, greater than about 60%, greater than about 70%, greater than about 80%, greater than about 90%, or greater than about 95% of the average density of current flowing across the surface (and/or interface).

Hermetic Sealing of Cells

A hermetically sealed battery or battery housing may prevent an unsuitable amount of air, oxygen and/or water into the battery (e.g., an amount such that the battery maintains at least 80% of its energy storage capacity for at least one year, at least 2 years, at least 5 years, at least 10 or at least 20 years).

In some instances, the rate of oxygen, nitrogen, and water vapor transfer into the battery is less than about 0.25 mL per hour when the battery is contacted with air at a pressure of 1 bar and temperature of 400 to 700° C. In some embodiments, the number of moles of oxygen, nitrogen, or water vapor that leaks into the cell over a 10 year period is less than 10% of the number of moles of active metal material in the cell.

In an aspect, a battery comprises an anode and a cathode. The battery is capable of storing at least 10 Wh of energy and is hermetically or non-hermetically sealed. At least one of the anode and the cathode can be a liquid metal. In some cases, the anode is a liquid metal (e.g. lithium, magnesium, sodium).

In an aspect, a group of batteries is capable of storing at least 10 Wh of energy and each of the batteries are hermetically or non-hermetically sealed.

In an aspect, a battery housing comprises an electrically conductive container, a container aperture and a conductor in electrical communication with a current collector. The conductor may pass through the container aperture and is electrically isolated from the electrically conductive container. The housing may be capable of hermetically sealing a battery which is capable of storing at least 100 kWh of energy.

Embodiments of Electrochemical Cells, Batteries and Battery Housings

FIG. 7illustrates an electrochemical cell20, in accordance with an embodiment of the invention. The cell20includes at least one electrochemical cell22sealed (e.g., hermetically sealed) within an electrochemical cell housing24. The cell housing24includes a cell container26, a container lid assembly28and one or more electrical conductors30(e.g., conductor rods). The cell housing24can also include a thermally and/or electrically insulating sheath32, a first (e.g., negative) current collector34and a second (e.g., positive) current collector36.

The battery cell22may be configured as a liquid metal battery cell. The battery cell22may include, for example, a liquid separator38arranged axially between a liquid first (e.g., negative) electrode40and a liquid second (e.g., positive) electrode42.

In some instances, the electrochemical battery departs from that inFIG. 7. For example, the top electrode40can be contained within the top current collector (e.g., foam)34. In this embodiment, the salt layer comes up in contact with the bottom and sides of the foam34, and the top metal in the foam is held away from the sidewalls32or26, thus allowing the cell to run without the insulating sheath32. In some cases, a graphite sheath is used to prevent ‘creeping’ of the cathode up the sidewall, which can prevent shorting of the cell.

The separator38may be an ionically conducting liquid electrolyte. An example of a liquid electrolyte is a liquid solution of one or more ionically conductive molten salts such as, for example, fluoride salt, chloride salt, bromide salt, iodide salt, or a combination thereof. The first electrode40may be a liquid (e.g., molten) metal. Examples of materials that may be used as the first electrode40include, without limitation, sodium (Na), potassium (K), lithium (Li), calcium (Ca), barium (Ba), magnesium (Mg), or combinations thereof. The liquid metal of the first electrode40may contain one or more of the listed examples. The second electrode42may be a liquid metal or metalloid. Examples of materials that may be used as the second electrode42include, without limitation, antimony (Sb), lead (Pb), tin (Sn), bismuth (Bi), tellurium (Te), selenium (Se), or combinations thereof. The second electrode42may contain one or more of metals or metalloid metals listed above. Other examples of separator, first electrode and second electrode materials and/or configurations are disclosed in U.S. Patent Application Publication Nos. 2008/0044725, 2011/0014503, 2011/0014505 and 2012/0104990, each of which is entirely incorporated by reference herein. The present invention, however, is not limited to any particular battery cell configurations and/or materials.

The battery container26can be constructed from an electrically conductive material such as, for example, steel, iron, stainless steel, graphite, nickel, nickel based alloys, titanium, aluminum, molybdenum, tungsten, or conductive glass. The cell container may also comprise of a structure component, and thinner lining component of a separate metal or electrically insulating coating, such as, for example, a steel container with a graphite lining, or a steel container with a boron nitride coating. The battery container26can have a cross-sectional geometry that can extend axially between a first container end (e.g., edge)44and a second container end (e.g., edge)46. The cross-sectional geometry can be, for example, circular as illustrated inFIG. 13, rectangular (e.g., square) as illustrated inFIG. 16, or any other shape that may be selected based on design requirements for the battery20. The battery container26includes a cell cavity48defined by a container (bottom) endwall50and a container sidewall52. The cavity48can extend axially into the battery container26from a cavity aperture54that is located at the first container end44to the container endwall50that is located at the second container end46. The cavity48can also extend laterally between opposing sides of the container sidewall52.

The container lid assembly28can include an electrically conductive container lid56, one or more electrically conductive flanges58, and one or more electrically insulating gaskets60(e.g., annular dielectric gaskets).

Referring toFIGS. 8 and 9, the container lid56can be constructed from an electrically conductive material such as, for example, steel, iron, copper, stainless steel, graphite, nickel, nickel based alloys, titanium, aluminum, molybdenum, tungsten, or conductive glass. The container lid56can extend axially between a first lid end62and a second lid end64. The container lid56can include an electrically conductive base66and one or more electrically conductive mounting rings68(also referred to as “feed through flanges”). The base can extend axially between the first lid end62and a base end70, which is located axially between the first lid end62and the second lid end64. The base66can include one or more mounting ring apertures72that can extend axially through the base66between the first lid end62and the base end70. The mounting rings68are respectively mated with the mounting ring apertures72, and connected (e.g., welded, adhered or otherwise fastened) to the base66. The mounting rings68can extend axially between the first lid end62and the second lid end64. Each of the mounting rings68includes a first conductor aperture74that can extend axially therethrough between the first lid end62and the second lid end64. The first conductor aperture74has a diameter that is, for example, at least 2 (e.g., between about 2 and 6) times less than a diameter of the cavity aperture54(seeFIG. 7). Each of the mounting rings68may also include one or more threaded fastener apertures76arranged circumferentially around the respective first conductor aperture74. The fastener apertures76extend axially into the respective mounting ring68from the first lid end62.

Referring toFIGS. 10 and 11, each of the flanges58is constructed from an electrically conductive material such as, for example, steel, iron, stainless steel, graphite, nickel, nickel based alloys, titanium, aluminum, molybdenum, tungsten, or conductive glass. Each of the flanges58can extend axially from a first flange end78to a second flange end80. Each of the flanges58may include an electrically conductive base82and an electrically conductive flange ring84. The base82can extend axially between the first flange end78and the second flange end80. The base82includes a threaded conductor aperture86that can extend axially into the base82from the second flange end80to a base endwall88. The flange ring84can extend circumferentially around the base82. The flange ring84can also extend axially between a first flange ring end90and a second flange ring end92. The first flange ring end90may be offset from the first flange end78by a first axial distance, and/or the second flange ring end92may be offset from the second flange end80by a second axial distance. The flange ring84may include a plurality of fastener apertures94arranged circumferentially around the base82. The fastener apertures94extend axially through the flange ring84between the first flange ring end90and the second flange ring end92.

Referring toFIGS. 7 and 12, the gaskets60are constructed from a dielectric material such as, for example, glass, brazed ceramic, thermiculite, aluminum nitride, mica and/or vermiculite. Each of the gaskets60includes a second conductor aperture96that can extend axially therethrough between a first gasket end98and a second gasket end100. The second conductor aperture96has a diameter that is substantially equal to or less than the diameter of a respective one of the first conductor apertures74.

Referring toFIG. 7, the conductors30can be constructed from an electrically conductive material such as, for example, steel, iron, stainless steel, graphite, nickel, nickel based alloys, titanium, aluminum, molybdenum, or tungsten. The conductors30extend axially between a first conductor end102and a second conductor end104. Each of the conductors30may include a threaded end region106adjacent the first conductor end102.

Referring toFIG. 7, the sheath32can be constructed from a thermally insulating and/or electrically insulating material such as, for example, alumina, titania, silica, magnesia, boron nitride, or a mixed oxide including calcium oxide, aluminum oxide, silicon oxide, lithium oxide, magnesium oxide, etc. The sheath32has an annular cross-sectional geometry that can extend axially between a first sheath end (top)108and a second sheath end (bottom)110.

As an alternative, the sheath can be used to prevent corrosion of the container and/or prevent wetting of the cathode material up the side wall, and may be constructed out of an electronically conductive material, such as steel, stainless steel, tungsten, molybdenum, nickel, nickel based alloys, graphite, or titanium. The sheath may be very thin and could be a coating. The coating can cover just the inside of the walls, and/or, can also cover the bottom of the inside of the container.

Referring toFIG. 7andFIG. 12, the first current collector34is constructed from an electrically conductive material such as, for example, nickel-iron (Ni—Fe) foam, perforated steel disk, sheets of corrugated steel, sheets of expanded metal mesh, etc. The first current collector34may be configured as a plate that can extend axially between a first collector end112and a second collector end114. The first current collector34has a collector diameter that is less than the diameter of the cavity aperture54, and greater than the diameter of the first conductor aperture74. Examples of other current collector configurations are disclosed in U.S. Patent Publication Nos. 2011/0014503, 2011/0014505, and 2012/0104990, which are entirely incorporated herein by reference. The present invention is not limited to any particular first current collector configurations.

The second current collector36may be configured as a part of the cell container26. In the embodiment illustrated inFIG. 7, for example, the container endwall50is configured as the second current collector36. As an alternative, the current collector may be discrete from and, for example, electrically connected to, the battery container. Examples of such a current collector arrangement are disclosed in the aforementioned U.S. Patent Publication Nos. 2011/0014503, 2011/0014505, and 2012/0104990, which are entirely incorporated herein by reference. The present invention is not limited to any particular second current collector configurations.

FIGS. 13 and 14illustrate an alternative embodiment electrochemical battery housing120. A sheath in such a case can in some cases be precluded. In contrast to the battery housing24ofFIGS. 7 and 12, each of the flanges58of the battery housing120includes a flange ring122that is directly connected (e.g., welded, glued, fused, adhered and/or otherwise fastened) to a respective one of the conductors30. Each of the gaskets60of the battery housing120may additionally include a plurality of fastener apertures124, which receive the fasteners116. Each of the fasteners116may be electrically isolated from the flange ring122via an electrically insulating sleeve126and an electrically insulating washer128. The sleeve126and the washer128are each constructed from a dielectric such as, for example, mica or vermiculite. The battery housing120may also include one or more fluid ports130(e.g., quick connect gas fittings) that direct fluid (e.g., inert gas) into and/or out of the sealed cavity48.

FIGS. 15 and 16illustrate another alternative embodiment electrochemical battery housing132. In contrast to the battery housing24ofFIGS. 7 and 12, each of the flanges58of the battery housing132includes a base134that can extend axially between the first flange ring end90and the second flange end80. Each of the flanges58can also include a protrusion136(e.g., a boss) that is connected to the base134and/or the flange ring84, and can extend axially to the first flange end78. Such a protrusion136may be utilized for vertically stacking and/or electrically interconnecting a plurality of the battery housing132as illustrated inFIG. 15.

FIG. 17illustrates an embodiment that reduces the number of pieces of the electrochemical cells and/or batteries described herein (e.g., allows the assembly of a plurality of electrochemical cells using a single pre-assembled piece). In some cases, the conductors of a first electrochemical cell1701are connected to, and/or are formed from the same piece of metal as, the housing (e.g., positive current collector) of a second electrochemical cell1702. In some cases, the top of a first electrochemical cell is directly connected to (e.g., welded or bolted) or formed from the same piece of metal as the bottom of a second electrochemical cell that is located on top of the first electrochemical cell. The cells can be assembled as shown in panel A inFIG. 17. As seen here, a plurality of pieces1703comprising a housing portion and a container lid assembly portion1704are put together (e.g., welded) one on top of another to form a plurality of electrochemical cells. The negative current collector1705, positive electrode1706and electrolyte1707can be inserted and/or filled into the electrochemical cells as the cells are assembled from the pieces. The negative current collector1705can include (e.g., house, contain) the negative electrode. For example, the negative current collector1705can be a porous material that includes material of the negative electrode (e.g., lithium) in the pores of the negative current collector1705.

The electrochemical cell can be hermetically and/or electrically sealed by placing a sealant material between two surfaces.

In an aspect, an electrochemical cell comprises an electrically conductive housing and a conductor in electrical communication with a current collector, wherein the conductor protrudes through the housing through an aperture in the housing and is electrically isolated from the housing with a seal that hermetically seals the electrochemical cell.

With reference toFIG. 18, the sealant1800can be disposed and/or placed between the housing of the electrochemical cell1801and another article1802(e.g., a conductive feed through).FIG. 19shows that the two surfaces1900can be metal. In some cases, the seal and/or sealant1901is a ceramic, glass, or glass-ceramic composite.FIG. 20shows a top view for each layer of the assembly with the electrochemical cell housing on the left2000, the seal in the center2001and the article2002(e.g., conductive feed through) on the right.

In some cases, the surfaces are made of dissimilar materials (i.e., materials that are not the same, such as two different metal surfaces). The materials can have different coefficients of thermal expansion. The dissimilar materials can be inlaid and/or recessed into one another (e.g., one material surrounds the other on at least two planes, such as a flat surface and an edge).FIG. 21shows an embodiment where a conductive feed-through2100is inlaid in the housing of the electrochemical cell2101. In some cases, the feed-through is sealed from the housing along two planes including along a horizontal plane2102and along the edges2103(i.e., a vertical plane).

In some instances, the feed-through is recessed in the housing and electrically insulated from the housing on all sides, but only sealed along one plane. For example, a horizontal shim (e.g., made of ceramic material) can be put between the feed through and the housing in the horizontal direction and the sealant can be disposed along the vertical direction. In some embodiments, a vertical ring (e.g., made of ceramic material) is placed between the feed through and the housing in the vertical direction (e.g., along the edges) and the sealant can be disposed along the horizontal direction.FIG. 22shows a 3-dimensional exploded view of the feed-through, housing and seal, horizontal shim2201and/or vertical ring2200along two planes (e.g., vertical and horizontal).

FIG. 23shows a top view of each layer of the assembly including from left to right; the electrochemical cell housing2300, the horizontal shim2301, the conductive feed through2302, and the vertical ring2303on the far right. In an embodiment, the layers of the assembly have relative dimensions as shown. In particular, the housing2300may have a hole with an inner diameter of one arbitrary unit (denoted by the symbol ϕ) 1.00 with a second diameter of 1.5 and an outer diameter of 4.00 (e.g., 4 inches). The base of the housing2300can be made of metal and be about 0.5 thick. In some cases, the horizontal shim2301has an inner diameter of 0.6 and an outer diameter of 1.5 with a thickness of 0.05. In some embodiments, the conductive feed through2302has a diameter of 1.38 and a thickness of 0.2. In some instances, the vertical ring2303has an inner diameter of 1.38, an outer diameter of 1.5 and a thickness of 0.2.

A compressive force can be established on the seal if the housing and feed-through are made of dissimilar materials that have a different coefficient of thermal expansion. In some embodiments, the housing has a greater coefficient of thermal expansion than the feed-through. The seal can be put between the materials when expanded at a high temperature. Upon cooling, the materials can shrink in volume (e.g., with the outer housing shrinking more than the inner feed-through) to establish a compressive force upon the seal. The force can be any suitable force (e.g., suitable for hermetically sealing the electrochemical cell). In some cases, the force is about 1,000 psi, about 2,000 psi, about 5,000 psi, about 10,000 psi, or about 20,000 psi. In some cases, the force is at least 1,000 psi, at least 2,000 psi, at least 5,000 psi, at least 10,000 psi, or at least 20,000 psi.

In an aspect, a method for sealing an electrochemical cell comprises (a) applying a sealant material between a housing and an article recessed into the housing, wherein the sealant is applied at a temperature at which the sealant material is malleable, viscous, and/or flowable, and wherein the housing and the article have different coefficients of thermal expansion; and (b) lowering the temperature to a temperature at which the sealant material is not malleable, viscous, and/or flowable, i.e. solidifies or hardens, thereby creating a seal between the housing and the article that is under a compressive force. In some embodiments, the seal is under compression at the operating temperature of the electrochemical cell.

The sealant can be any suitable material. In some instances, the seal is formed by brazing ceramic onto a metal substrate. In some embodiments, the seal is formed by solidifying ceramic and/or glass. In some embodiments, the seal is formed by mechanically and/or chemically bonded glass or glass-ceramic composite.

In some cases, the sealant material is a re-flowable material such as borosilicate glass (or other seal-specific glass). In such an embodiment, a hermetic seal can be established by sliding a borosilicate glass tube around the cell top as a horizontal spacer. After insertion of the re-flowable material into the inlaid space, heating to a temperature of about, for example, 700 to 800° C. can allow flow of the borosilicate glass to form a glass seal. The seal can be stable at the temperatures of battery operation. In some instances, the glass seal is suitably thick to hermetically seal the cell and be resilient to shear stress. In some embodiments, the cell is slowly and evenly cooled following melting such that the seal forms evenly without cracks, delamination, and the like.

In some cases, more than one sealant material can be used. In some embodiments, the seal is formed from at least two different materials, at least one of which is resistant to degradation from contact with materials contained in the electrochemical cell. In some embodiments, the seal is resistant to reactive metal vapors such as sodium (Na), lithium (Li) or magnesium (Mg). In some instances, the seal is a chalcogenide seal (e.g., comprises a chalgen such as CaAl2S4). In some embodiments, the sealant material is a chalcogenide based compound. In some cases, the chalcogenide has the chemical formula CaAl2S4.

Systems, apparatuses and methods of the disclosure may be combined with or modified by other systems, apparatuses and/or methods, such as batteries and battery components described in U.S. Patent Publication No. 2012/0104990 (“Alkali Metal Ion Battery with Bimetallic Electrode”), which is entirely incorporated herein by reference.

Energy storage devices of the disclosure may be used in grid-scale settings or stand-alone settings. Energy storage device of the disclosure can, in some cases, be used to power vehicles, such as scooters, motorcycles, cars, trucks, trains, helicopters, airplanes, and other mechanical devices, such as robots.

A person of skill in the art will recognize that the battery housing components may be constructed from materials other than the examples provided above. One or more of the electrically conductive battery housing components, for example, may be constructed from metals other than steel and/or from one or more electrically conductive composites. In another example, one or more of the electrically insulating components may be constructed from dielectrics other than the aforementioned glass, mica and vermiculite. The present invention therefore is not limited to any particular battery housing materials.

It is to be understood that the terminology used herein is used for the purpose of describing specific embodiments, and is not intended to limit the scope of the present invention. It should be noted that as used herein, the singular forms of “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. In addition, unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.