SERIES FORMATION OF ELECTROCHEMICAL CELLS

In some aspects a method of monitoring an electrochemical cell stack can include measuring an anode voltage difference between a first anode tab from a plurality of anode tabs and a second anode tab from the plurality of anode tabs, measuring a cathode voltage difference between a first cathode tab from a plurality of cathode tabs and a second cathode tab from the plurality of cathode tabs, and calculating a difference between the cathode voltage and the anode voltage. In some embodiments, the first cathode tab and the first anode tab can be located at a proximal end of the electrochemical cell. In some embodiments, a distance between the first anode tab and the second anode tab is within about 5% of the distance between the first cathode tab and the second cathode tab.

TECHNICAL FIELD

Embodiments described herein relate to methods of formation of electrochemical cells and electrochemical cell stacks.

BACKGROUND

Existing lithium-ion manufacturing systems utilize individual cell formation systems where thousands or millions of cells are handled and processed via a formation process. Cells are then aged and degassed prior to installation. This processing is generally inefficient. Power systems for building electrochemical cells often operate at 0V-5V DC channels with very low power conversion efficiency. If the energy from discharge is not incorporated back into the grid, then 1 MWh of energy can be lost in the charging of each electrochemical cell. Additionally, conversion efficiency from a building grid to a production channel can be about 50-60%. Discharge system losses can also be about 5%. Conveyors and handling also add additional power load. Heating, ventilation, and air conditioning (HVAC) loading for removal of all the dissipated energy for discharge of the cells can add 1 MWh to the HVAC heat loading for the building, increasing tonnage for building systems. Total losses in a production system can be about 2.1 MWh for each 1 MWh produced, plus each additional 600 tons of refrigeration capacity may be necessary, assuming 1 MWh in Work in Progress (WIP). Capital cost is also a significant consideration. All of the equipment and machinery to move cells from one location to another during the formation process (e.g., conveyors, trays, baskets, fixtures, test channels, floorspace for formation aging and post-test) is an important aspect of the manufacture of each cell. Multiple locations and moves for each cell also increase the process complexity for the system and the cost of that system. The system size, complexity and cost are significant drivers for the inability to manufacture battery cells efficiently. Therefore, there is a need for more efficient systems and methods to store and transfer energy for manufacturing of electrochemical cells.

SUMMARY

Embodiments described herein relate to systems and methods for forming electrochemical cells and electrochemical cell modules connected in series. In some aspects, a method of forming an electrochemical cell, the electrochemical cell including an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, and a separator disposed between the anode material and the cathode material, includes transferring energy from an energy storage system to a battery formation system to charge the electrochemical cell, and transferring energy from the electrochemical cell to the energy storage system to prevent heat energy dissipation into the formation system, wherein the energy transferred is direct current (DC).

In some aspects, a system for forming an electrochemical cell module includes a first electrochemical cell module and a second electrochemical cell module connected in series, the first electrochemical cell module and the second electrochemical cell module configured to receive energy via an energy storage system; a first switch connected in series with the first electrochemical cell module and a second switch connected in parallel with the first electrochemical cell module. The first switch and the second switch have (1) a first configuration in which the first switch is closed and the second switch is open such that current moves through the first electrochemical cell module, and (2) a second configuration in which the first switch is open and the second switch is closed such that current moves directly to the second electrochemical cell module, bypassing the first electrochemical cell module. The system further includes a controller configured to transition the first switch and the second switch between the first configuration and the second configuration, thereby directing current flow to charge and discharge the first electrochemical cell module and second electrochemical cell module.

In some aspects, a system includes an energy storage system configured to receive energy from one or more power sources, and a formation system including a plurality of electrochemical cells connected in series and configured to control current flow through the plurality of electrochemical cells via a controller electrically coupled to a plurality of switches. The plurality of electrochemical cells connected to the energy storage system via a DC electrical connection such that energy is transferred between the plurality of electrochemical cells and the energy storage system without an AC transformer.

DETAILED DESCRIPTION

Embodiments described herein describe production of electrochemical cells as part of a module build. Module building can include a method of bypassing components of the battery formation system with current flow during formation of the electrochemical cell. High voltage cells, module and packs can be built and then the cells can be formed in higher voltage system blocks. Modules can be assembled and sent to formation area, where connected in series to achieve a higher total voltage (e.g., 500 V). However, any intermediate voltage may be selected based on building, safety, process, grid, or battery formation-test machine needs. Limitations on voltage can also be based on available DC/DC or AC/DC conversion technologies based on cost or conversion efficiencies. A control system for bypassing energy (charge, discharge both) around modules, cells, or packs can ensure safe operation, preventing overcharge and allowing for full formation of each cell. A safety system can monitor temperature, current, and/or voltage to prevent cell damage and thermal runaway due to over-temperature, over-charge or over-discharge.

Embodiments described herein can include algorithms to detect cell level failure, internal shorts, and other failure modes using sensors. Sensing can be used to sense or determine cell voltage, temperature, current, module level voltage, module level temperature, module level current, pack level voltage, pack level temperature, and/or pack level current. Algorithms can then be used to diagnose the functional status of each cell in the system. In some cases, sensing can be accomplished via a battery management system (BMS), test system sensing, secondary sensing systems, or any combination thereof. Safety systems can include area temperature (hot spot), fire detection, smoke detection, hydrogen detection, carbon monoxide (CO) detection, carbon dioxide (CO2) detection, volatile organic compound (VOC) detection, or other detection methods to ensure the systems are not damaged or to prevent damage to the system, batteries and facilities during formation. Safety systems can include fire suppression systems to prevent facility damage, active venting systems to prevent facility damage and personal injury, and protection systems to provide propagation protection between cells, modules, and/or battery packs under formation.

In some embodiments, an energy storage system can store and circulate power to and from formation systems. In some embodiments, the energy storage system can include a storage device. In some embodiments, the energy storage system can distribute DC power at a building or campus level. The energy storage system can also reduce parasitic losses due to transformers, power factor correction systems, and/or other AC components. A dual use of an energy storage system as a facility backup for critical systems is also applicable. In some embodiments, the energy storage system can function as a dry room backup to protect WIP from damage due to a loss of system power. In some embodiments, an energy system can include bi-directional power conversion between AC and DC in order to share power to and from a building grid, either in front of or behind an electrical meter. In some embodiments, an energy storage system can include bi-directional power conversion between AC and DC in order to share power to and from the building grid in a secondary or remote location to control the total power conversion at a campus or grid scale. In some embodiments, an energy storage system can include a bi-directional power conversion between AC and DC in order to share power to and from the building grid in a secondary or remote location to control total power conversion at a facility, multiple facilities, a campus, a micro grid, and/or a macro grid in order to create a secondary AC grid for power distribution.

In some embodiments, an energy storage system can include a bi-directional power conversion between DC and DC in order to share power to and from the formation system without additional AC conversion loss. In some embodiments, the energy storage system can include a bi-directional power conversion between DC and DC in order to share power to create a common DC power distribution within a single facility. In some embodiments, an energy storage system can include bi-directional power conversion between DC and DC in order to share power to create a common DC power distribution between two or more facilities. In some embodiments, an energy storage system can include bi-directional power conversion between DC and DC in order to share power to create a common DC distribution at a campus, a micro grid, or a macro grid level. In some embodiments, renewable power can provide energy to make up for conversion losses in the formation system, generating an off-grid formation system or a low power formation system.

In some embodiments, an energy storage system can include a grid or renewable connection for metering energy to the formation system and providing energy to account for efficiency losses. In some embodiments, an energy storage system with building controls can monitor power needs throughout the facility and campus to provide demand load, frequency regulation, peak shaving, load leveling, and/or other grid firming operations. In some embodiments, an energy storage system can serve a formation system and/or other secondary renewable uses, such as charging station power for plug-in-hybrid-electric vehicles (PHEV's), electric vehicles (EV's), or any other suitable implementations.

Monitoring voltage at various points throughout cells or electrodes can be an important aspect of building an energy storage system. Differences in voltage gradients or inflection points can help identify problematic cells or electrodes. Identifying these faulty elements during production or even during operation can significantly limit the downtime of the energy storage system during repair or replacement.

In some embodiments, electrodes described herein can include conventional solid electrodes. In some embodiments, the solid electrodes can include binders. In some embodiments, electrodes described herein can include semi-solid electrodes. Semi-solid electrodes described herein can be made: (i) thicker (e.g., greater than 100 μm-up to 2,000 μm or even greater) due to the reduced tortuosity and higher electronic conductivity of the semi-solid electrode, (ii) with higher loadings of active materials, and (iii) with a simplified manufacturing process utilizing less equipment. These relatively thick semi-solid electrodes decrease the volume, mass and cost contributions of inactive components with respect to active components, thereby enhancing the commercial appeal of batteries made with the semi-solid electrodes. In some embodiments, the semi-solid electrodes described herein are binderless and/or do not use binders that are used in conventional battery manufacturing. Instead, the volume of the electrode normally occupied by binders in conventional electrodes, is now occupied by: 1) electrolyte, which has the effect of decreasing tortuosity and increasing the total salt available for ion diffusion, thereby countering the salt depletion effects typical of thick conventional electrodes when used at high rate, 2) active material, which has the effect of increasing the charge capacity of the battery, or 3) conductive additive, which has the effect of increasing the electronic conductivity of the electrode, thereby countering the high internal impedance of thick conventional electrodes. The reduced tortuosity and a higher electronic conductivity of the semi-solid electrodes described herein, results in superior rate capability and charge capacity of electrochemical cells formed from the semi-solid electrodes. Since the semi-solid electrodes described herein, can be made substantially thicker than conventional electrodes, the ratio of active materials (i.e., the semi-solid cathode and/or anode) to inactive materials (i.e., the current collector and separator) can be much higher in a battery formed from electrochemical cell stacks that include semi-solid electrodes relative to a similar battery formed form electrochemical cell stacks that include conventional electrodes. This substantially increases the overall charge capacity and energy density of a battery that includes the semi-solid electrodes described herein.

In some embodiments, the electrode materials described herein can be a flowable semi-solid or condensed liquid composition. In some embodiments, the electrode materials described herein can be binderless or substantially free of binder. A flowable semi-solid electrode can include a suspension of an electrochemically active material (anodic or cathodic particles or particulates), and optionally an electronically conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. Said another way, the active electrode particles and conductive particles are co-suspended in an electrolyte to produce a semi-solid electrode. Examples of battery architectures utilizing semi-solid suspensions are described in U.S. Patent Publication No. 2022/0238923 (“the '923 publication”), filed Jan. 21, 2022 and titled “Production of Semi-Solid Electrodes Via Addition of Electrolyte to Mixture of Active Material, Conductive Material, and Electrolyte Solvent,” and U.S. patent application Ser. No. 18/212,414 (“the '414 application”), filed Jun. 21, 2023 and titled “Electrochemical Cells with High-Viscosity Semi-solid Electrodes, and Methods of Making the Same,” the entire disclosures of which are hereby incorporated by reference.

In some embodiments, power management systems described herein can include any of the aspects described in U.S. Pat. No. 10,153,651 (“the '651 patent”), filed Oct. 9, 2015, and titled, “Systems and Methods for Battery Charging,” the disclosure of which is hereby incorporated by reference in its entirety. In some embodiments, battery management systems described herein can include any of the aspects described in U.S. patent application Ser. No. 17/743,631 (“the '631 application”), filed Nov. 20, 2020, and titled, “Electrochemical Cells Connected in Series in a Single Pouch and Methods of Making the Same,” the disclosure of which is hereby incorporated by reference in its entirety.

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 or the like. As one example, a portion of a support member that is described as being “substantially linear” is intended to convey that, although linearity of the portion is desirable, some non-linearity can occur in a “substantially linear” portion. Such non-linearity can result from manufacturing tolerances, or other practical considerations (such as, for example, the pressure or force applied to the support member). Thus, a geometric construction modified by the term “substantially” includes such geometric properties within a tolerance of plus or minus 5% of the stated geometric construction. For example, a “substantially linear” portion is a portion that defines an axis or center line that is within plus or minus 5% of being linear.

As used herein, the term “set” and “plurality” can refer to multiple features or a singular feature with multiple parts. For example, when referring to a set of electrodes, the set of electrodes can be considered as one electrode with multiple portions, or the set of electrodes can be considered as multiple, distinct electrodes. Additionally, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered as multiple, distinct electrochemical cells or as one electrochemical cell with multiple portions. Thus, a set of portions or a plurality of portions may include multiple portions that are either continuous or discontinuous from each other. A plurality of particles or a plurality of materials can also be fabricated from multiple items that are produced separately and are later joined together (e.g., via mixing, an adhesive, or any suitable method).

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

As used herein, the terms “activated carbon network” and “networked carbon” relate to a general qualitative state of an electrode. For example, an electrode with an activated carbon network (or networked carbon) is such that the carbon particles within the electrode assume an individual particle morphology and arrangement with respect to each other that facilitates electrical contact and electrical conductivity between particles and through the thickness and length of the electrode. Conversely, the terms “unactivated carbon network” and “unnetworked carbon” relate to an electrode wherein the carbon particles either exist as individual particle islands or multi-particle agglomerate islands that may not be sufficiently connected to provide adequate electrical conduction through the electrode.

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 the materials included for the electrochemical cell to operate such as, the electrodes, the separator, the electrolyte, and the current collectors. Specifically, the materials used for packaging the electrochemical cell are excluded from the calculation of volumetric energy density.

As used herein, the terms “high-capacity materials” or “high-capacity anode materials” refer to materials with irreversible capacities greater than 300 mAh/g that can be incorporated into an electrode in order to facilitate uptake of electroactive species. Examples include tin, tin alloy such as Sn—Fe, tin mono oxide, silicon, silicon alloy such as Si—Co, silicon monoxide, aluminum, aluminum alloy, mono oxide metal (CoO, FeO, etc.) or titanium oxide.

As used herein, the term “composite high-capacity electrode layer” refers to an electrode layer with both a high-capacity material and a traditional anode material, e.g., a silicon-graphite layer.

As used herein, the term “solid high-capacity electrode layer” refers to an electrode layer with a single solid phase high-capacity material, e.g., sputtered silicon, tin, tin alloy such as Sn—Fe, tin mono oxide, silicon, silicon alloy such as Si—Co, silicon monoxide, aluminum, aluminum alloy, mono oxide metal (CoO, FeO, etc.) or titanium oxide.

FIG.1shows a block diagram of an electrochemical cell module110(hereinafter “battery module”), according to an embodiment. As shown, the battery module110includes electrochemical cells10a,10b,- . . .10nelectrically connected in series. Each electrochemical cell includes an anode material11a,11b,- . . .11ndisposed on an anode current collector12a,12b,- . . .12n, a cathode material13a,13b,- . . .13ndisposed on a cathode current collector14a,14b,- . . .14n, and a separator15a,15b,- . . .15ndisposed between the anode material11a-11nand the cathode material13a-13n. In some embodiments, the anode material11a-11nand/or the cathode material13a-13ncan include a semi-solid electrode material, as described above. In some embodiments, the battery module110can include individual electrochemical cells, modules (e.g., a plurality of individual electrochemical cells electrically connected, for example, in series or parallel), or a battery pack (e.g., a plurality of modules that are connected, for example, in series or parallel). In some embodiments, the battery module110can include a plurality of electrochemical cells for charging and discharging.

Electrochemical cells and electrochemical cell modules typically undergo formation, which involves an initial round of charging and discharging, as part of the manufacturing process. Battery formation systems (hereinafter “formation systems”) are systems or apparatuses for forming electrochemical cells. A formation system typically resides in a battery manufacturing facility, the battery manufacturing facility including a variety of other amenities for battery manufacturing such as, for example, electrochemical cell assembly lines, manufacturing rooms, dry rooms, heating, ventilation, and air conditioning (HVAC) systems for cooling, equipment for moving supplies, etc. On a higher level, a battery manufacturing campus (hereinafter “campus”) can include an aggregate of battery manufacturing facilities and other resources useful for battery manufacturing, but is not limited to battery manufacturing. Streamlined transfer of energy between elements at the formation system level, the manufacturing facility level, and the campus level is important for significantly reducing costs and materials and improving overall efficiency of manufacturing.

FIG.2shows a schematic block diagram of energy transfer within a campus2000, according to an embodiment. As shown inFIG.2, one or more power sources transfer energy to an energy storage system250. The energy storage system250may be configured to either (1) store the energy received for later use; (2) transfer the energy to a formation system220; or (3) transfer energy to additional loads240that may be associated with electrochemical cell manufacturing. The power sources205may transfer energy directly to the formation system220or directly to the additional loads240. Although not shown, the energy storage system250, the formation system220, and the additional loads240may reside in a facility. In some embodiments, the formation system220may be configured to transfer energy back to the energy storage system250for later use or for backup energy for the facility.

FIG.3shows schematic block diagram of energy transfer within a battery manufacturing campus, according to an embodiment. As shown inFIG.3, facilities300a,300b,300care configured to receive energy from power sources305. The power sources305, the formation system320, the additional loads340, and the energy storage system350may be substantially similar in function and/or structure to the power sources205, the formation system220, the additional loads240, and the energy storage system250and therefore certain aspects of the power sources305, the formation system320, the additional loads340, and the energy storage system350will not be described with respect toFIG.3. The power sources305may include solar energy306, wind energy307, and/or power grid energy308. In some embodiments, the facilities300a,300b,300cmay be configured to receive energy from other power sources. In some embodiments, facility300band facility300cmay include the same amenities and/or equipment as facility300. In some embodiments, facility300band300cmay include different amenities and/or equipment and may be used for a different purpose than facility300a. As shown, energy is transferred from the power sources305to one or more power converters330in facility300a. The power converters330may be DC/DC power converters to step incoming voltage to a desired level, such as for battery formation. In particular, the facilities300a-300cmay include DC/DC converters for converting solar energy into a desired voltage used to charge battery modules310. In some embodiments, AC/DC power converters are included to convert AC power coming from the wind energy source307and/or the power grid energy source308. After conversion, DC energy is either transferred to the energy storage system350where it is stored, or the DC energy is directly transferred to additional loads340including a dry room342, a manufacturing line346, HVAC344, and/or other loads348as needed. The energy storage system350and a formation system320are configured to transfer DC energy bidirectionally via a DC electrical connection depending on the needs of the facility300a. When the battery modules310are charging, the battery modules310act as a load to the energy storage system350, as power flows from the energy storage system350to the battery modules310. When the battery modules310are discharging, the energy flows into the energy storage system350, which is then charging relative to the battery modules310. During discharge of the battery modules310, the formation system320is configured to transfer DC energy back to the energy storage system350for storage via a DC connection to the DC load328rather than discharging excess charge through resistors, which results in loss of energy via heat. The formation system320includes battery management systems325and switches321-323electrically connected to the battery modules310to control flow of current through the battery modules310via a controller324, explained in further detail below with respect toFIG.4. In some embodiments, the DC load328and a DC charge327can be connected in parallel to the formation system320.

In some embodiments, the energy storage system350may provide energy for a facility, a campus, or a macro grid level DC supply with a low voltage (i.e., a voltage of about 0V to about 100 V). The energy storage system350may provide a voltage supply of no more than about 400 V, no more than about 350 V, no more than about 300 V, no more than about 250 V, no more than about 200 V, no more than about 150 V, no more than about 100 V, no more than about 95 V, no more than about 90 V, no more than about 85 V, no more than about 80 V, no more than about 75 V, no more than about 70V, no more than about 65 V, no more than about 60 V, no more than about 55 V, no more than about 50 V, no more than about 45 V, no more than about 40 V, no more than about 35 V, no more than about 30 V, no more than about 25 V, no more than about 20 V, no more than about 15 V, or no more than about 10 V.

In some embodiments, the energy storage system350may provide energy for a facility, a campus, or a macro grid level DC supply with a high voltage (a voltage of greater than about 250V). The energy storage system250may provide a voltage supply of at least about 200V, at least about 250 V, at least about 300 V, at least about 350 V, at least about 400 V, at least about 410 V, at least about 420 V, at least about 430 V, at least about 440 V, at least about 450 V, at least about 460 V, at least about 470 V, at least about 480 V, at least about 490 V, at least about 500 V, at least about 510 V, at least about 520 V, at least about 530 V, at least about 540 V, at least about 550 V, at least about 600 V, at least about 700 V, or at least about 800 V.

In some embodiments, the energy storage system350may allocate energy stored (such as excess energy generated by formation of the battery modules310) to power one or more of the additional loads340. With this energy storage system350, DC energy is stored, which reduces the number of transformers used in the facility300a, thereby reducing overall energy consumption. In other words, the energy storage system350may transfer DC energy to the formation system320without an AC transformer. The energy storage system may receive and store energy from renewable or sustainable power sources, reducing a total grid power requirement to enable lower cost renewable energy offset and to mitigate carbon footprint of the total grid. In addition, the facilities300a-cmay operate by pulling less energy at a given time from the power grid. Energy loss from AC/DC conversion increases when a larger starting voltage is converted; therefore, reducing the voltage transferred to the facilities300a-300cat a given time reduces energy lost due to AC/DC conversion, thereby reducing overall energy consumption of the facility and campus.

FIG.4shows a diagram of an electrochemical cell stack formation system, according to an embodiment. The energy storage system450and the formation system420may be substantially similar in function and/or structure to the energy storage system250,350and the formation system220,320, and therefore certain aspects of the energy storage system450and the formation system420will not be described with respect toFIG.4. As shown, the energy storage system450transfers DC energy to the formation system420via a DC electrical connection to the DC charge427. In some embodiments, the DC charge is configured to receive a signal (e.g., via an electrical connection) from the controller424to draw a desired amount of current into the formation system420. The DC charge427is electrically connected in series to a main switch422. The main switch422allows current flow through the battery modules410a,410b,- . . .410nwhen in a first configuration and blocks current from flowing through the battery modules410a-410nwhen in a second configuration. The main switch422may transition from the first configuration (Closed, or ON) to the second configuration (Open or OFF) in response to a signal from the controller424via relay control lines426.

The formation system420may also include switches421a,421b,- . . .421n,423a,423b,- . . .423n(e.g., contactors, relays, transistors, etc.), corresponding to each battery module410a-nand configured to control the current through each battery module410a,410b,- . . .410n. For example, a first switch421amay be connected in series with a first battery module410aand a second switch423amay be connected in parallel with the first battery module410asuch that when the first switch421ais closed and the second switch423ais open, current moves through the first battery module410atowards subsequent battery modules410b-nin series. In contrast, when the first switch421ais open and the second switch423ais closed, current is directed away from the first battery module410aand to different battery modules410b-nin the formation system that may need charging. In some embodiments, both the first switch421aand the second switch423amay be closed such that current is blocked from flowing through the first battery module410aand any subsequent battery modules410b-nin series. In some embodiments, both the first switch421aand the second switch423amay be open such that current may flow through the first battery module410aas well as subsequent battery modules410b-nin series. The switches421a-n,422a-nmay switch between an open configuration and a closed configuration in response to a signal from the controller424via relay control lines426. The battery modules410a-nare each connected to a battery management system429a,429b,- . . .429nfor monitoring voltage and battery health of the battery module. The battery management system429a-nis coupled to a current source425a,425b,- . . .425nto control the current through the respective battery module410a-n. While the switches421-423are shown in this configuration, the switches421-423may be arranged in any suitable arrangement such that current flow may be directed away from a battery module410if needed.

The arrangement of switches421a-n,423a-n, allows for the removal of faulty battery modules410a-nfrom the flow path of current such that formation of healthy battery modules may continue, thereby increasing formation efficiency. Additionally, fully charged battery modules may be removed from the flow path of current if needed. For example, the controller424may detect a faulty battery module410a-nfrom voltage measurements received from the battery management system429a-n. The controller424in turn may send a signal to open the first switch421a-nsuch that current is blocked from flowing through the faulty battery module, and instead moves directly to the second battery module410a-n. The controller424may also sense (via the battery management system429a-n) that one of the battery modules410a-nno longer needs to charge. The controller424may then send a signal to configure the switches421a-n,423a-nsuch that charge is drawn from the charged battery module and redirected toward a different battery module410a-nthat needs charge. In some embodiments, the formation system420blocks current flow through a faulty battery module410a-nautomatically. In some embodiments, the formation system420blocks current flow through a fully charged battery module410a-nautomatically. In some embodiments, the formation system420draws current from a fully charged battery module410a-nautomatically. Energy may be transferred out of the formation system420via a DC electrical to the DC load428back to the energy storage system450.

In some embodiments, the formation system420can include a range of about 1 to about 1000 battery modules410. In some embodiments, the formation system420can 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 battery modules410. In some embodiments, the formation system420can include no more than about 1,000, no more than about 900, no more than about 800, no more than about 700, no more than about 600, no more than about 500, no more than about 400, no more than about 300, no more than about 200, no more than about 100, no more than about 90, no more than about 80, no more than about 70, no more than about 60, no more than about 50, no more than about 40, no more than about 30, no more than about 20, 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 battery modules410. Combinations of the above-referenced numbers of battery modules410are also possible (e.g., at least about 2 and no more than about 1,000 or at least about 4 and no more than about 50), inclusive of all values and ranges therebetween. In some embodiments, the formation system420can 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 battery modules420.

In some embodiments, the formation system420can include a range of about 1 to about 1000 battery management systems429. In some embodiments, the formation system420may include a range of about 1 to about 1000 current sources425. In some embodiments, the formation system420has the same number of battery management systems429as battery modules410. In some embodiments, the formation system420has the same number of current sources425as battery modules410. In some embodiments, the formation system420may include a range of about 1 to about 3000 switches421,422,423. In some embodiments, the formation system420can include at least about 2, at least about 4, at least about 6, at least about 8, at least about 10, at least about 20, at least about 40, at least about 60, at least about 80, at least about 100, at least about 200, at least about 400, at least about 600, at least about 800, at least about 1000, at least about 2000, at least about 2200, at least about 2400 switches421,422,423. In some embodiments, the formation system620can include no more than about 3000, no more than about 2400, no more than about 2200, no more than about 2000, no more than about 1000, no more than about 800, no more than about 600, no more than about 400, no more than about 200, no more than about 100, no more than about 80, no more than about 60, no more than about 40, no more than about 20, no more than about 10, no more than about 8, no more than about 6, or no more than about 4 switches421,422,423. Combinations of the above-referenced numbers of battery switches421,422,423are also possible (e.g., at least about 2 and no more than about 1,000 or at least about 4 and no more than about 50), inclusive of all values and ranges therebetween.

FIGS.5A-5Bshow diagrams of battery manufacturing campus including an energy storage system, according to an embodiment. The facilities500a,500b,500c; the power sources506,507,508; the formation system520; the additional loads542,544,546,548; and the energy storage system(s)550may be substantially similar in function and/or structure to the power sources205,305; the formation system220,320,420; the additional loads240,340; and the energy storage system250,350,450, and therefore certain aspects of the facilities500a,500b,500c; the power sources506,507,508; the formation system520; the additional loads542,544,546,548; and the energy storage system550will not be described with respect toFIGS.5A-5B.

As shown, a solar power generator506delivers DC energy to the facilities500a,500b,500c. Facility500aincludes one or more energy storage systems550a,550b,- . . .550n(collectively referred to as energy storage systems550), which may transfer energy through a DC/DC power converter536to a DC charge527, which delivers current to a formation system520. As shown, the formation system520includes four battery modules510a,510b,510c,510dconnected in series and electrically coupled to respective battery management systems529a,529b,529c,529dand current sources525a,525b,525c, and525d. The formation system520includes main switches522aand522bas well as switches521a,521b,521c,521dand switches523a,523b,523c,523dcontrolled by a controller524and relay control lines526. The battery modules510a-d, the battery management system520a-d, the current sources525a-d, the main switches522a-b, the switches521a-dand523a-d, the controller524, and the relay control lines526may be substantially similar in function and/or structure to the battery modules410a-n, the battery management system420a-n, the current sources425a-n, the main switch422, the switches421a-dand423a-n, the controller424, and the relay control lines426, and therefore certain aspects of the battery modules510a-d, the battery management system520a-d, the current sources525a-d, the main switches522a-b, the switches521a-dand523a-d, the controller524, and the relay control lines526will not be described with respect toFIGS.5A-5B.

In some embodiments, the solar energy generator may transfer energy into the power distribution control station580. As shown, a wind power generator507transfers energy to a power distribution control station580. The energy from the wind power generator507may either be transferred (1) from the power distribution control center580through load transfer switches560to power additional loads of the facility500aincluding a dry room542, a manufacturing line544, an HVAC system546, or other loads548; or (2) through an AC/DC power converter535to the energy storage systems550for later use. A campus grid connection508may provide energy to facilities500a-c. In facility500a, the energy from the campus grid connection508is transferred through a facility meter590and then through load transfer switches560. The energy may then be either (1) used to power the additional loads; or (2) sent through the AC/DC power converter535and stored in the energy storage systems550for later use. If backup AC energy (i.e., resilient AC) is needed to power the additional loads, energy stored in the energy storage systems550may be transferred through a DC/AC converter535, to the load transfer switches560, and then to the additional loads. The resilient AC may also be transferred to the other facilities in the campus500b,500cif needed. The power distribution control center580, the facility meter590, the load transfer switches560, and the energy storage systems550may be configured to communicate to regulate energy flow throughout the campus5000.

The load transfer switches560include AC transformers. Because the formation system520is powered by DC energy stored in the energy storage systems550, the load transfer switches560may include less AC transformers. For instance, the facility500amay only include the AC transformers needed to support the dry room542, the manufacturing line544, the HVAC system546, and/or other loads548. Therefore, the facility500amay include a lower number of AC transformers, which lowers the overall energy consumption of the facility500a. In some embodiments, the facilities500band500cmay also include an energy storage system that allows for use of fewer AC transformers.

FIG.6shows a diagram of a station for a traditional formation of an electrochemical cell. As shown, energy losses are incident upon the cell via AC/DC conversion losses, cell efficiency losses, discharge energy, cell charging, and SEI layer formation. The cell manufacturing capacity represents the energy drawn for formation of the electrochemical cell and can be measured in gigawatt hours (GWh). Each GWh of the electrochemical cell's capacity should be charged with a GWh of energy. In the system shown, all energy needed for formation of the electrochemical cell is transferred through an AC/DC power converter and converted, which results in an energy usage of about 50% of the electrochemical cell's capacity. Energy loss also occurs due to cell efficiency losses. Energy loss due to cell efficiency is typically about 20% of the electrochemical cell's capacity. Some energy losses are specific to charging, including cell capacity (e.g., cell charge) and SEI layer formation. When charging the electrochemical cell in this system, the entirety of the energy comes from the power grid, meaning about 100% of the electrochemical cell's capacity is used. SEI layer formation causes loss of energy through ion consumption, which results in loss of about 10% of the electrochemical cell's capacity. During discharge of the electrochemical cell, about 100% of the electrochemical cell's capacity is expelled (during a complete discharge). Because of waste heat produced during discharge, energy is used to power an HVAC system to cool the facility to a suitable temperature. The additional energy loss incurred from running the HVAC system can be calculated by using the equation f(x)=0.3x, where x represents the total discharge energy. In some embodiments, energy loss incurred from running the HVAC system may vary depending on environmental factors such as ambient temperature. Overall, the traditional station for formation of the electrochemical cell results in a total power usage of at least about 200% of the electrochemical cell's capacity.

FIG.7shows a diagram of a series formation of electrochemical cells with an energy storage system and a formation system, according to an embodiment. In the system shown, charging and discharging of the electrochemical cells relies on energy stored in the energy storage system rather than from the power grid, meaning that energy loss due to charge/discharge reduces to about 0% of each electrochemical cell's capacity. Additionally, because DC energy is used directly, energy loss due to AC/DC conversion is reduced to about 8% of each electrochemical cell's capacity. Therefore, with this system only about 25% of each electrochemical cell's capacity is used during formation. In some embodiments, use of the energy storage system reduces energy loss due to running the HVAC system because energy from discharging the electrochemical cells is transferred back to the energy storage system for storage rather than dissipating as heat.

In some embodiments, energy losses from the formation of electrochemical cells are reduced by at least about 50%, at least about 75%, at least about 100%, at least about 125%, at least about 150%, at least about 175%, at least about 200%, at least about 225%, or at least about 250% of a full capacity of each electrochemical cell, as compared to the formation of an individual electrochemical cell.

FIG.8shows the interaction between a solar array607, an energy storage system650, and a formation power system627, according to an embodiment. As shown, the energy storage system650receives DC energy input from the solar array607through a DC/DC converter636. The formation power system627receives energy from the energy storage system650through the DC/DC converter636. The formation system can be electrically coupled to the energy storage system650. The energy storage system650includes an energy system controller655to regulate the transfer of energy between the energy storage system650and the formation power system627. The energy storage system controller655and the formation system controller624may communicate directly to control the transfer of energy therebetween. The formation system620may include a formation power system627electrically connected to a collection of electrochemical cell modules610a,610b,610c,610d,610e,610fconnected in series. The electrochemical cell modules610a-fmay be controlled via a formation system controller624. Each electrochemical cell module610a-fis coupled to a control and interface system625a,625b,625c,625d,625e,625fused to control current flow through the electrochemical cell modules610a-fduring charge and discharge. The control and interface systems625a-fmay be structurally and/or functionally similar to the battery management systems425a-n,525a-d; the switches421a-n,521a-d,422,522a-b,423a-n,523a-d, and/or the current sources429a-n,529a-d, as described above with respect toFIG.4andFIGS.5A-5B, and therefore the control and interface systems625a-fare not described further herein. Although the transfer voltage between the energy storage system650and the formation power system627is shown as 500V, the transfer voltage can be any suitable voltage for formation of the electrochemical cells625a-f. In some embodiments, the transfer voltage between the energy storage system650and the formation power system627can be at least about 200 V, at least about 250 V, at least about 300 V, at least about 350 V, at least about 400 V, at least about 450 V, or at least about 500 V, inclusive of all values and ranges therebetween.

In some embodiments, the energy storage system650can provide building power backup energy. As shown, the energy storage system650can transfer energy through a DC/AC converter635to provide AC backup energy. In some embodiments, the energy storage system650can provide DC backup energy as well.

FIG.9is a flowchart of a method800for forming an electrochemical cell or battery module via an energy storage system, according to an embodiment. At step802, an electrochemical cell is provided for formation. In some embodiments, a battery module including a plurality of electrochemical cells in series may be used. The electrochemical cell is charged using energy provided by an energy storage system, at step804. At step806, the electrochemical cell is discharged via the energy storage system to prevent heat dissipation into a formation system. In some embodiments, the charge leaving the electrochemical cell during discharge may be used to directly charge other electrochemical cells or battery modules connected in series.

In some embodiments, the electrochemical cell system, the battery module, the energy storage system, and the formation system can be substantially similar to and/or the same as any electrochemical cell, battery module, energy storage system, and formation system described above. Thus, the electrochemical cell, the battery module, the energy storage system, and the formation system are not described in further detail herein.

FIG.10is a flowchart of a method900for forming a battery module via a backup power from an energy storage system, according to an embodiment. In this method900, a power source is employed to transfer startup energy to an energy storage system, at step902, to initiate a battery formation procedure. At step904, the energy storage system charges a battery module or a plurality of battery modules, each of which can include a plurality of batteries. Charging states of the battery module can be monitored and controlled by a controller, therefore allowing the determination of whether the batteries are fully charged, as in step906. If the batteries are not fully charged, then the energy storage system can continue charging the battery module. If the batteries are fully charged, the controller then determines in step908whether battery discharge is needed due to, for example, requirements from battery formation or testing. If discharge is not needed, the fully charged batteries can be conveyed to next steps, such as battery grading or sorting at step912. If discharge is needed, the batteries can be discharged at step910, in which the discharged energy is transferred back to the energy storage system. After discharge, the controller can determine at step912whether recharge is necessary for battery formation or test, based on, for example, the state of health (SOH) of the batteries. If so, the batteries can be processed again via step904, in which the energy storage system charges the batteries using the energy from battery discharge in step910. If battery recharge is not needed, the batteries can be processed via step914for grading or sorting. In some embodiments, the controller can be substantially similar to and/or the same as any controller described above. Thus, the controller is not described in further detail herein.

In some embodiments, the power source can transfer energy to the energy storage system during battery charging or discharging. For example, the power source can provide makeup power to the energy storage system if the controller detects that the amount of energy in the energy storage system drops below a threshold. In another example, during discharge, the controller can estimate the amount of energy to be released from discharge and determine whether the amount of energy is sufficient for the next round of battery charging. If not, the controller can direct the power source to transfer supplemental energy to the energy storage system.

FIG.11is a flowchart of a method1000for forming a battery module via an energy storage system, according to an embodiment. A power source is employed to transfer energy to an energy storage system, at step1002, to initiate the charging procedure. The energy storage system can then charge a battery module at step1004. During charging, a controller can be employed to monitor charging states of the batteries, as well as any control signal from external utilities, at step1006. If backup power is needed due to, for example, unexpected power outage or low energy production rate of solar power plant (e.g., on cloudy days), the controller can direct the battery module to discharge the batteries and store the discharged energy in the energy storage system, as in step1008. The energy storage system can then supplement the power source to power external utilities by transferring the stored energy to the power source at step1010. In some embodiments, battery charging at step1004and energy transfer to the power source at step1010can occur concurrently, provided that the amount of energy stored in the energy storage system is sufficient. For example, the power source can be a solar plant, which can produce abundant energy during daytime while the demand is relatively low. The power source can store the excess energy into the energy storage system for both battery charging and power backup.

FIG.12is a flowchart of a method1100for forming a battery module via an energy storage system, according to an embodiment. In this method, a power source is first employed to transfer energy to an energy storage system to initiate the formation procedures at step1102, followed by the charging of a plurality of battery modules using the energy storage system at step1104. A controller is employed to monitor charging states of each battery module and determine whether any battery module is fully charged at step1106. A battery module can be regarded as fully charged when, for example, the voltage is above a preset value. If no fully charged module is found in step1106, the energy storage system can continue charging the battery modules. On the other hand, if one or more modules are fully charged, the controller then determines whether all modules are fully charged at step1108. If so, the controller can direct the battery modules to discharge the batteries and store the discharge energy in the energy storage system as in step1110. If some battery modules are fully charged but not the others, the controller can then direct the battery module to discharge those fully charged battery modules and store the discharge energy in the energy storage system, which can concurrently charge those battery modules that are not fully charged at step1112. In some embodiments, the controller can selectively discharge and/or charge certain fully charged battery modules at step1110and/or step1112. For example, the controller can monitor the capacity of batteries in each battery module and terminate the charging/discharging cycles for those battery modules that have a capacity greater than a preset value.

In addition, the disclosure may include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file additional applications, continuations, continuations-in-part, divisional s, and/or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments. Depending on the particular desires and/or characteristics of an individual and/or enterprise user, database configuration and/or relational model, data type, data transmission and/or network framework, syntax structure, and/or the like, various embodiments of the technology disclosed herein may be implemented in a manner that enables a great deal of flexibility and customization as described herein.

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 set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure. Where methods and steps described above indicate certain events occurring in a certain order, those of ordinary skill in the art having the benefit of this disclosure would recognize that the ordering of certain steps may be modified and such modification are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. The embodiments have been particularly shown and described, but it will be understood that various changes in form and details may be made.