US-20260128481-A1 - Electrode Stack Assembly for a Metal Hydrogen Battery

US20260128481A1US 20260128481 A1US20260128481 A1US 20260128481A1US-20260128481-A1

Abstract

An electrode stack can include a plurality of anode assemblies, each anode assembly including at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly including at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge arranged to engage each anode tab of each of the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each of the plurality of cathode assemblies; an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies and the plurality of cathode assemblies are alternately arranged and separated by the plurality of separators to form an electrode stack. A battery is also presented.

Inventors

Nelson Dichter
Jingyi Zhu
Ge Zu
Majid Keshavarz

Assignees

EnerVenue Holdings, Ltd.

Dates

Publication Date: 20260507
Application Date: 20251229

Claims (6)

1 . A method of forming an electrode stack assembly for a metal hydrogen battery, comprising: preassembling components of the electrode stack assembly by assembling a plurality of cathode assemblies, each cathode assembly having cathode tabs attached to one or more cathode material layers, assembling a plurality of anode assemblies, each anode assembly having anode tabs coupled to one or more anode material layers, forming a plurality of separators from separator material, forming frame top portions and frame bottom portions, forming an anode feedthrough bridge assembly, and forming a cathode feedthrough bridge assembly; stacking the separators, anode assemblies, and cathode assemblies in alternate fashion between the frame top portion and the frame bottom portion to capture the electrodes between the frame top portion and the frame bottom portion; pressing the electrodes, the frame top portion, and the frame bottom portion; forming an electrode stack by attaching the frame top portion to the frame bottom portion to form a frame; attaching cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly; and attaching anode tabs of the plurality of anode assembles in the electrode stack to the anode feedthrough bridge assembly.
2 . The method of forming an electrolyte stack assembly of claim 1 , wherein assembling the plurality of cathode assemblies comprises, for each of the cathode assemblies, producing two cathode components, each of the cathode components include a cathode layer attached to a cathode tab structure; arranging the two cathode components such that the cathode tab structures form the cathode tab; forming a separator pouch; and inserting the cathode components into the separator pouch.
3 . The method of forming an electrolyte stack assembly of claim 1 , wherein assembling a plurality of anode assemblies includes stacking a plurality of layers of anode material; and attaching the anode tabs to the layers of anode materials.
4 . The method of forming an electrolyte stack assembly of claim 1 , wherein forming an anode feedthrough bridge assembly includes providing an anode feedthrough bridge that includes a plurality of slots for receiving tabs from the anode assemblies; and attaching an anode feedthrough terminal to the anode terminal bridge.
5 . The method of forming an electrolyte stack assembly of claim 1 , wherein forming a cathode feedthrough bridge assembly includes providing a cathode feedthrough bridge that includes a plurality of slots for receiving tabs from the cathode assemblies; and attaching a cathode feedthrough terminal to the cathode terminal bridge.
6 . A method of forming a hydrogen metal battery, comprising: forming an electrode stack assembly, wherein forming the electrode stack assembly includes: assembling a plurality of cathode assemblies, each cathode assembly having cathode tabs attached to one or more cathode material layers, assembling a plurality of anode assemblies, each anode assembly having anode tabs coupled to one or more anode material layers, forming a plurality of separators from separator material, forming frame top portions and frame bottom portions, forming an anode feedthrough bridge assembly that includes an anode feedthrough terminal, forming a cathode feedthrough bridge assembly that includes a cathode feedthrough terminal, stacking the separators, anode assemblies, and cathode assemblies in alternate fashion between the frame top portion and the frame bottom portion to capture the electrodes between the frame top portion and the frame bottom portion, pressing the electrodes, the frame top portion, and the frame bottom portion, forming an electrode stack by attaching the frame top portion to the frame bottom portion to form a frame, attaching cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly, and attaching anode tabs of the plurality of anode assembles in the electrode stack to the anode feedthrough bridge assembly; attaching an anode end cap to a vessel side wall; inserting the electrode stack assembly into the vessel side wall so that the anode feedthrough terminal engages with the anode end cap; attaching a cathode end cap to the vessel side wall such that the cathode feedthrough terminal passes through a feedthrough in the cathode end cap.

Description

RELATED APPLICATIONS The present application is a divisional of U.S. patent application Ser. No. 17/830,193, filed on Jun. 1, 2022, which is incorporated by reference in its entirety. TECHNICAL FIELD Embodiments of the present invention are related to metal-hydrogen batteries and, in particular, to configurations of metal-hydrogen batteries. DISCUSSION OF RELATED ART For renewable energy resources such as wind and solar to be competitive with traditional fossil fuels, large-scale energy storage systems are needed to mitigate their intrinsic intermittency. To build a large-scale energy storage, the cost and long-term lifetime are the utmost considerations. Currently, pumped-hydroelectric storage dominates the grid energy storage market because it is an inexpensive way to store large quantities of energy over a long period of time (about 50 years), but it is constrained by the lack of suitable sites and the environmental footprint. Other technologies such as compressed air and flywheel energy storage show some different advantages, but their relatively low efficiency and high cost should be significantly improved for grid storage. Rechargeable batteries offer great opportunities to target low-cost, high capacity and highly reliable systems for large-scale energy storage. Improving reliability of rechargeable batteries has become an important issue to realize a large-scale energy storage. Consequently, there is a need for better metal-hydrogen battery configurations. SUMMARY In accordance with embodiments of this disclosure an electrode stack and battery formed with the electrode stack is disclosed. An electrode stack assembly for a metal hydrogen battery according to some embodiments includes a plurality of anode assemblies, each anode assembly including at least one anode layer attached to an anode tab; a plurality of cathode assemblies, each cathode assembly including at least one cathode layer attached to a cathode tab; a plurality of separators; an anode feedthrough bridge arranged to engage each anode tab of each of the plurality of anode assemblies; a cathode feedthrough bridge arranged to engage each cathode tab of each of the plurality of cathode assemblies; an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies and the plurality of cathode assemblies are alternately arranged and separated by the plurality of separators to form an electrode stack. A metal hydrogen battery according to some embodiments includes an electrode stack assembly, the electrode stack assembly including: a plurality of anode assemblies, each anode assembly including at least one anode layer attached to an anode tab, a plurality of cathode assemblies, each cathode assembly including at least one cathode layer attached to a cathode tab, a plurality of separators, an anode feedthrough bridge arranged to engage each anode tab of each of the plurality of anode assemblies, a cathode feedthrough bridge arranged to engage each cathode tab of each of the plurality of cathode assemblies, an anode feedthrough terminal coupled to the anode feedthrough bridge; and a cathode feedthrough terminal coupled to the cathode feedthrough bridge, wherein the plurality of anode assemblies, the plurality of cathode assemblies, and the plurality of separators are alternately arranged to form an electrode stack; a pressure vessel surrounding the electrode stack assembly such that the cathode feedthrough terminal extends through the pressure vessel; and an electrolyte contained within the pressure vessel. A method of forming an electrode stack assembly for a metal hydrogen battery, according to some embodiments includes: preassembling components of the electrode stack assembly by assembling a plurality of cathode assemblies, each cathode assembly having cathode tabs attached to one or more cathode material layers, assembling a plurality of anode assemblies, each anode assembly having anode tabs coupled to one or more anode material layers, forming a plurality of separators from separator material, forming frame top portions and frame bottom portions, forming an anode feedthrough bridge assembly, and forming a cathode feedthrough bridge assembly; stacking the separators, anode assemblies, and cathode assemblies in alternate fashion between the frame top portion and the frame bottom portion to capture the electrodes between the frame top portion and the frame bottom portion; pressing the electrodes, the frame top portion, and the frame bottom portion; forming an electrode stack by attaching the frame top portion to the frame bottom portion to form a frame; attaching cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly; and attaching anode tabs of the plurality of anode assembles in the electrode stack to the anode feedthrough bridge assembly. A method of formi