WO2013106748A1 - Conception de batterie acide-plomb ayant un facteur de forme polyvalent - Google Patents

Conception de batterie acide-plomb ayant un facteur de forme polyvalent Download PDF

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Publication number
WO2013106748A1
WO2013106748A1 PCT/US2013/021287 US2013021287W WO2013106748A1 WO 2013106748 A1 WO2013106748 A1 WO 2013106748A1 US 2013021287 W US2013021287 W US 2013021287W WO 2013106748 A1 WO2013106748 A1 WO 2013106748A1
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WIPO (PCT)
Prior art keywords
electrochemical
electrode
cell
sector
storage device
Prior art date
Application number
PCT/US2013/021287
Other languages
English (en)
Inventor
Subhash Dhar
William Koetting
Kwok Tom
Franklin Martin
Jorge ESPINEL
Michael Nielson
Fabio Albano
Original Assignee
Energy Power Systems LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US13/350,505 external-priority patent/US20130183581A1/en
Priority claimed from US13/350,686 external-priority patent/US20130183572A1/en
Priority claimed from US13/626,426 external-priority patent/US9263721B2/en
Priority to BR112014017333A priority Critical patent/BR112014017333A8/pt
Priority to AU2013207761A priority patent/AU2013207761A1/en
Priority to IN6227DEN2014 priority patent/IN2014DN06227A/en
Priority to KR1020147022506A priority patent/KR20140121439A/ko
Application filed by Energy Power Systems LLC filed Critical Energy Power Systems LLC
Priority to EP13735954.3A priority patent/EP2803097A4/fr
Priority to JP2014552345A priority patent/JP2015507330A/ja
Priority to CN201380013469.2A priority patent/CN104160526A/zh
Priority to MX2014008544A priority patent/MX2014008544A/es
Priority to US13/766,991 priority patent/US8808914B2/en
Publication of WO2013106748A1 publication Critical patent/WO2013106748A1/fr
Priority to US14/145,692 priority patent/US20140113177A1/en
Priority to US14/326,784 priority patent/US20150010807A1/en
Priority to HK15104767.6A priority patent/HK1204391A1/xx
Priority to US14/753,478 priority patent/US20150303436A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/66—Selection of materials
    • H01M4/68—Selection of materials for use in lead-acid accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/06—Lead-acid accumulators
    • H01M10/12—Construction or manufacture
    • H01M10/125—Cells or batteries with wound or folded electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/06—Lead-acid accumulators
    • H01M10/12—Construction or manufacture
    • H01M10/123—Cells or batteries with cylindrical casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/72—Grids
    • H01M4/73—Grids for lead-acid accumulators, e.g. frame plates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • Embodiments of the present disclosure relate generally to electrochemical cells. More particularly, embodiments of the present disclosure relate to a design of a lead- acid electrochemical cell.
  • Ni-MH nickel-metal hydride
  • Li-ion lithium-ion
  • electrochemical cells that have been used in automotive applications, depicting their respective specific powers and specific energies compared to other technologies.
  • Lead-acid battery technology is low-cost, reliable, and relatively safe. Certain applications, such as complete or partial electrification of vehicles and back-up power applications, require higher specific energy than traditional SLI lead-acid batteries deliver, As shown in Table i, lead-acid batteries suffer from low specific energy due to the weight of the components. Thus, there remains a need tor low-cost, reliable, and relatively safe electrochemical cells for various applications that require high specific energy, including certain automotive and back-up power applications.
  • Lead-acid batteries have many advantages. First, they are a low-cost technology capable of being manufactured in any part of the world. Accordingly, production of lead-acid batteries can be readily scaled-up. Lead-acid batteries are available in large quantities in a variety of sizes and designs. In addition, they deliver good high-rate performance and moderately good low- and high-temperature performance. Lead-acid batteries are electrically efficient, with a turnaround efficiency of 75 to 80%, provide good "float" service (where the charge is maintained near the full-charge level by trickle charging), and exhibit good charge retention. Further, although lead is toxic, lead-acid battery components are easily recycled. An extremely high percentage of lead-acid battery components (in excess of 95%) are typically recycled.
  • Lead-acid batteries suffer from certain disadvantages as well. They offer relatively low cycle life, particularly in deep-discharge applications. Due to the weight of the lead components and other structural components needed to reinforce the plates, lead-acid batteries typically have limited energy density, if lead-acid batteries are stored for prolonged periods in a discharged condition, sulfation of the electrodes can occur, damaging the battery and impairing its performance. In addition, hydrogen can be evolved in some designs.
  • Ni-MH batteries In contrast to lead-acid batteries, Ni-MH batteries use a metal hydride as the active negative material along with a conventional positive electrode such as nickel hydroxide. Ni-MH batteries feature relatively long cycle life, especially at a relatively low depth of discharge. The specific energy and energy density of Ni-MH batteries are higher than for lead-acid batteries, in addition, Ni-MH batteries are manufactured in small prismatic and cylindrical ceils for a variety of applications and have been employed extensively in hybrid electric vehicles. Larger size Ni-MH cells have found limited use in electric vehicles.
  • Ni-MH electrochemical ceils share this disadvantage.
  • improvements in energy density and specific energy of Li-ion designs have outpaced advances in Ni-MH designs in recent years.
  • nickel metal hydride batteries currently deliver substantially more power than designs of a decade ago, the progress of Li-ion batteries, in addition to their inherently higher operating voltage, has made them technically more competitive for many hybrid applications that would otherwise have employed Ni-MH batteries.
  • Li-ion batteries have captured a substantial share not only of the secondary consumer battery market but a major share of OEM hybrid battery, vehicle, and electric vehicle applications as well.
  • Li-ion batteries provide high-energy density and high specific energy, as well as long cycle life, For example, Li-ion batteries can deliver greater than 1,000 cycles at 80% depth of discharge.
  • Li-ion batteries have certain advantages. They are available in a wide variety of shapes and sizes, and are much lighter than other secondary batteries that, have a comparable energy capacity (both specific energy and energy density). In addition, they have higher open circuit voltage (typically -3.5 V vs, 2 V for lead-acid cells), in contrast to i-Cd and, to a lesser extent, Ni-MH batteries, Li-ion batteries suffer no "memory effect," and have much lower rates of self discharge (approximately 5% per month) compared to NiMH batteries (up to 20% per month).
  • Li-ion batteries have certain disadvantages as well. They are expensive. Rates of charge and discharge above 1C at lower temperatures are challenging because lithium diffusion is slow and it does not allow for the ions to move fast enough. Further, Li-ion batteries use liquid electrolytes to allow for faster diffusion rates, which results in formation of dendritic deposits at the negative electrode, causing hard shorts and resulting in potentially dangerous conditions. Liquid electrolytes also form deposits (referred to as an SEI layer) at the electrolyte/electrode interface, that can inhibit electron transfer, indirectly causing the cell's rate capability and capacity to diminish over time. These problems can be exacerbated by high-charging levels and elevated temperatures.
  • SEI layer deposits
  • Li-ion cells may irreversibly lose capacity if operated in a float condition. Poor cooling and increased internal resistance cause temperatures to increase inside the cell, further degrading battery life. Most important, however, Li-ion batteries may suffer thermal runaway, if overheated, overcharged, or over-discharged. This can lead to cell rupture, exposing the active material to the atmosphere, in extreme cases, this can cause the battery to catch fire. Deep discharge may short-circuit the Li-ion cell, causing recharging to be unsafe.
  • Li-ion batteries are typically manufactured with expensive and complex power and thermal management systems, in a typical Li-ion application for a hybrid vehicle, two-thirds of the volume of the battery module may be given over to collateral equipment for thermal management and power electronics and battery management, dramatically increasing the overall size and weight of the battery system, as well as its cost.
  • Ni-MH and Li-ion batteries such as certain automotive and standby power applications.
  • Standby power application requirements have gradually been raised.
  • the standby batteries of today have to be truly maintenance free, have to be low-cost, have long cycle-life, have low self-discharge, be capable of operating at extreme temperatures, and, finally, should have high specific energy and high specific power.
  • Emerging smart grid applications to improve energy efficiency require high power, Song life, and lower cost for continued growth in the market place.
  • Table 2 compares the application of various battery electro-chemistries and the internal combustion engine (ICE) and their current roles in certain automotive applications.
  • SLI means starting, lighting, ignition
  • HEV means hybrid electric vehicle
  • PHEV means plug-in hybrid electric vehicle
  • EREV means extended range electric vehicle
  • EV means electric vehicle.
  • Micro- and mild-hybrid technologies are unable to displace as much of the power delivered by the internal combustion engine as a full hybrid or electric vehicle. Nonetheless, they may be able to substantially increase fuel efficiency in a cost-effective manner without the substantial capital expenditure associated with full hybrid or full electric vehicle applications.
  • the active material is usually formed as a paste that is applied to the grid in order to form the plates as a composite material.
  • the paste adheres well to itself, it does not adhere well to the grid materials because of paste shrinkage issues. This requires the use of grids that are more substantial and contain additional structural components to help support the active material, which, in turn, puts an extra weight burden on the cell.
  • the components are subjected to a number of mechanical stresses. Pasting active material onto the grid can stress the latticework of the grid, Expanded metal grids are lighter than cast grids, yet, the formation of the expanded grid itself introduces stress at each of the nodes of the expanded grid.
  • cast and expanded metal grids have non-uniform stress during the life of the battery due to the molar volume change of converting the lead metal to PbC>2.
  • This volume change of the corrosion product puts huge stress on the grids in a non-uniform manner because of the irregular cross-sectional shapes of the grid wires in cast and expanded metals.
  • rechargeable batteries should be able to be charged and discharged with less than 0.001% energy loss at each cycle. This is a function of the internal resistance of the design and the overvoltage necessary to overcome it.
  • the reaction should be energy-efficient and should involve minimal physical changes to the battery that might limit cycle life. Side chemical reactions that may deteriorate the cell components, cause loss of life, create gaseous byproducts, or loss of energy should be minimal or absent, in addition, a rechargeable battery should desirably have high specific energy, low resistance, and good performance over a wide range of temperatures and be able to mitigate the structural stresses caused by lattice expansion. When the design is optimized for minimum resistance, the charge and discharge efficiency will dramatically improve.
  • Lead-acid batteries have many of these characteristics. The charge-discharge process is essentially highly reversible. The lead-acid system has been extensively studied and the secondary chemical reactions have been identified. And their detrimental effects have been mitigated using catalyst materials or engineering approaches. Although its energy density and specific energy are relatively low, the lead-acid battery performs reliably over a wide range of temperatures, with good performance and good cycle life. A primary advantage of lead-acid batteries remains their low-cost.
  • a typical lead-acid electrochemical cell uses lead dioxide as an active material in the positive plate and metallic lead as the active material in the negative plate. These active materials are formed in situ.
  • a charged positive electrode contains Pb02.
  • the electrolyte is sulfuric acid solution, typically about 1 .2 specific gravity or 37% acid by weight.
  • the basic electrode process in the positive and negative electrodes in a typical cycle involves formation of Pb(3 ⁇ 4 Pb via a dissolution-precipitation mechanism, causing non-uniform stresses within the positive electrode structure.
  • the first stage in the discharge-charge mechanism is a double-suifate formation reaction. Sulfuric acid in the electrolyte is consumed by discharge, producing water as the product.
  • the electrolyte is itself an active materia! and can be capacity-limiting.
  • lead-acid batteries the major starting material is highly purified lead.
  • Lead is used for the production of lead oxides for conversion first into paste and ultimately into the lead dioxide positive active material and sponge lead negative active material. Pure lead is generally too soft to be used as a grid material because of processing issues, except in very thick plates or spiral-wound batteries.
  • Lead is typically hardened by the addition of alloying elements. Some of these alloying elements are grain refiners and corrosion inhibitors but others may be detrimental to grid production or battery performance generally.
  • One of the mitigating factors in the corrosion of lead/lead grids is the high hydrogen over-potential for hydrogen evolution on lead. Since most corrosion reactions are accompanied by hydrogen evolution as the cathode reaction, reduced hydrogen evolution may inhibit anodic corrosion as well.
  • the purpose of the grid is to form the support structure for the active materials and to collect and carry the current generated during discharge from the active material to the ceil terminals.
  • Mechanical support can also be provided by non-metallic elements such as polymers, ceramics, and other components. But these components are not electrically conductive. Thus, they add weight without contributing to the specific energy of the cell.
  • the typical curing process for SLI lead-acid plates is different for the positive and negative plates.
  • water is driven off the plate in a flash dryer until the amount of water remaining in the plate is between about 8 to 20% by weight.
  • the positive plate is hydro-set at low temperature ( ⁇ 55 C +/-5C) and high humidity for 24 to 72 hours.
  • the negative plate is hydro-set at about the same temperature and humidity for 5 to 12 hours.
  • the negative plate may be dried to the lower end of the 8 to 20% range and the positive plate to the upper end of the range. More recently, manufacturers use curing ovens where temperature and humidity are more precisely controlled.
  • the "hydro-set process” causes shrinkage of the "paste” active material that, in turn, causes it to break away from the grid in a non-uniform manner,
  • the grid metal that is exposed is corroded preferentially and, since it is not in contact locally with the active material, results in increased resistance as well as formation, and life issues.
  • a simple cell consists of one positive and one negative plate, with one separator positioned between them. Most practical lead-acid electrochemical cells contain between 3 and 30 plates with separators between them. Leaf separators are typically used, although envelope separators may be used as well. The separator electrically insulates each plate from its nearest counter-electrode but must be porous enough to allow acid transport in or out of the plates.
  • Formation i initiated after the battery has been completely assembled. Formation activates the active materials. Batteries are then tested, packaged, and shipped.
  • Blayner, et al. have disclosed further improvements in the composition of the substrate to reduce the weight of the electrodes and to increase the proportion of conductive material.
  • Blayner U.S. Patent Nos. 5,010,637 and 4,658,623.
  • Blayner discloses a method and apparatus for coating a fiber with an extruded, corrosion-resistant metal.
  • Blayner discloses a variety of core materials that can include high-tensile strength fibrous material, such as an optical glass fiber, or highly-conductive metal wire.
  • the extruded, corrosion-resistant metal can be any of a number of metals such as lead, zinc, or nickel.
  • Blayner discloses that a corrosion-resistant metal is extruded through die.
  • the core material is drawn through the die as the metal is extruded onto the core material.
  • Electrode Continuous lengths of metal wire or fiber are coated with a uniform layer of extruded, corrosion-resistant metal.
  • the wire is then used to weave a screen that acts as a substrate for the active material. There are no fusion points at the intersections of the woven wires.
  • the electrode may be constructed using such a screen as a grid with the active material being applied onto the grid.
  • Rechargeable lead-acid electrochemical cells are constructed using pairs of electrodes.
  • Biayner discloses further improvements regarding the grain structure of the metal coating on the core material.
  • Biayner discloses that the extruded corrosion-resistant metal has a longitudinally-oriented grain structure and uniform grain size, U.S. Patent No. 5,925,470 and 6,027,822.
  • Fang, et al. y disclose in their paper, Effect of Gap Size on Coating Extrusion ofPb-GF Composite Wire by Theoretical Calculation and Experimental Investigation, J. Mater, Sci. Techno!,, Vol. 21 , No, 5 (2005), optimizing the gap in extruding lead-coated glass fiber.
  • Biayner does not disclose the relationship between gap size and extrusion of the lead coated composite wire
  • Fang characterizes gap size as a key parameter for the continuous coating extrusion process.
  • Fang reports that a gap between 0, 12 mm and 0,24 mm is necessary, with a gap of 0.18 mm being optimal.
  • Fang further reports that continuous fiber composite wire can enhance load and improve energy utilization.
  • electrochemical ceils provide some of the power for either stop/start or certain acceleration applications, will be necessary in order to meet the CAFE standards.
  • Lead-acid battery systems may provide a reliable replacement for Li-ion or Ni-MH batteries in these applications, without the substantial safety concerns associated with Li-ion electrochemistry and the increased cost associated with both Li-ion and Ni-MH batteries.
  • the improved batteries of the present invention may be combined in hybrid systems with other types of electrochemical ceils to provide electric power that is tailored to the unique automotive application.
  • a lead-acid battery of the present invention which features high-power can be combined with a Lithium-ion (“Li-ion”) or Nickel metal hydride (“Ni-MH”) electrochemical cell offering high energy, to provide a composite battery system tailored to the needs of the particular automotive standby or stationary power application, while reducing the relative sizes of each component,
  • An aspect of the present disclosure includes an electrochemical cell having an electrode assembly, wherein the electrode assembly may include a plurality of electrode plates.
  • Each electrode plate may include a current collector having a first portion and a second portion, and wherein each first and second portion may have a first surface and a second surface opposing the first surface.
  • the first and second surfaces of the first portion may include a positively charged active material, and the first and second surfaces of the second portion may include a negatively charged active material.
  • the plurality of electrode plates may include at least three electrode plates, such that the electrochemical ceil may be arranged with a first portion of one plate of the at least three electrode plates
  • electrochemical!' connected to a second portion of a second plate of the at least three electrode plates, and a first, portion of the second plate of the at least three electrode plates electrochemieally may be connected to a second portion of a third plate of the at least three electrode plates.
  • the electrochemical cell may include the following features, either alone or i combination: each electrode plate may include a plurality of electrode connectors connecting the first portion to the second portion; each electrode plate may include shunt current mitigating means; the current collector may include a uniform current density; a first separator may be attached to the first surface of the first portion and a second separator may be attached to the first surface of the second portion; a plurality of electrode assemblies may be stacked in series for bu lding voltage; an insulator may be connected to the top electrode plate, and the insulator may include at least one slit therein with an electrode plate extending there through; the electrochemical ceil may be a lead-acid electrochemical ceil; the electrode assembly may be connected to tabs; at least two electrode assemblies may be stacked in parallel for building capacity; there may be at least one power bus assembly including at least one bolt for building capacity; at least two of the electrode plates may be electrochemical ly connected at a ninety degree angle relative to one another: and the
  • the second charged sector of the first plate is laid below the first charged sector of the second plate, the electrochemical device further comprising an insulator sector located, and preventing ionic or conductive charge exchange, between the second charged sector of the first plate and the first charged sector of the second plate.
  • each of the plurality of the layer electrodes in circular.
  • each sector has a semi-circle shape sized to about half of the corresponding layer electrode.
  • each plate of the plurality of layer electrodes further comprises a frame which houses the first charged sector and the second charged sector of the corresponding plate, in some embodiments, the electrochemical storage device further comprises a first cap and a second cap for encasing the plurality of layer electrodes, In some embodiments, the electrochemical storage device further comprises a conductive substrate for providing a conductive connection between the first charge sector and the second charged sector,
  • each of the plurality of the layer electrodes has a rectangular shape, in some embodiments, each sector has a half-rectangle shape sized to about half of the corresponding layer electrode.
  • an electrochemical storage device comprises a first electrochemical cell and a second electrochemical cell disposed in a common casing and each comprising an anode and a cathode, wherein the anode of the first electrochemical cell is disposed opposite the cathode of the second electrochemical cell; a separator disposed between the anode of the first electrochemical ceil and the cathode of the second
  • the device further comprises said current collector providing substantially uniform current collection granting uniform current density.
  • the device further comprises a hydrophobic coating disposed on the portion of the common current collector between said anode and said cathode,
  • the device further comprises a physical barrier to ionically insulate said first and second electrochemical cells, in some embodiments, the device further comprises one positive and one negative terminal connection.
  • the device further comprises an insulation frame for disposing anodes and cathodes of two or more electrochemical ceils in substantially the same plane.
  • a spiral wound electrochemical storage device comprises a cylindrical cell pack including a cell stack, wherein the ceil stack includes a ceil strip rolled from a flat configuration to form the cylindrical cell stack; and a cylindrical case for housing the cylindrical ceil pack,
  • the cell stack is a first ceil stack of a plurality of cell stacks included in the cylindrical cell pack, and wherein the plurality of cell stacks are connected in series.
  • the cell stack includes a plurality of strips including a positive half electrode strip, a negative half electrode strip, and a separator half part strip, and wherein the plurality of half strips are laid over each other to form the cell stack.
  • Some embodiments further comprise a center mandrel, wherein the ceil stack is rolled around the center mandrel.
  • an electrochemical storage device comprises an electrochemical cell pack, wherein the electrochemical cell pack terminates in a tab; and a power bus formed from a sheet of metal, wherein the power bus electrically connects the tab to a device terminal, and wherein the power bus is attached to the tab by welding the sheet of metal to the tab, in some embodiments, the sheet of metal is attached to the tab by ultrasonic welding, in some embodiments, the sheet of metal is folded to form a top surface, a front surface, and a back surface, and wherein the top surface is electrically connected to the device terminal and the front surface is welded around the tab,
  • the tab is one tab of a plurality of tabs and wherein the power bus is attached to each of the plurality of tabs by welding the sheet of metal to the corresponding tab.
  • the power bus has a varying resistivity at different points to provide balanced total resistances between each of the plurality of tabs and the device terminal, in some embodiments, the power bus has a varying resistivity at different points by having a varying thickness at different points. In some embodiments, the power bus has a varying resistivity at different points by forming holes at some locations of the power bus.
  • an electrochemical storage device comprises a plurality of layer electrodes, wherein each layer electrode includes a first charged sector and a second charged sector, wherein the second charged sector is charged' oppositely compared to the first charged sector, and wherein the plurality of layer electrodes are assembled with respect to each other such that the first charged sector of a first plate of the plurality of layer electrodes is laid below the second charged sector of a second plate of the plurality of layer electrodes located immediately above the first plate, wherein the charges of the first charged sectors of the first and second plates have a first sign and the charges of the second charged sectors of the first and second plates have a second sign that is opposite the first sign; a separator sector iocated, and enabling ionic charge exchange between the first charged sector of the first plate and the second charged sector of the second plate.
  • Some embodiments further comprise a first cap and a second cap for encasing the plurality of layer electrodes. Some embodiments further comprise a conductive substrate for providing a conductive connection between the first charge sector and the second charged sector, in some embodiments, each of the plurality of the layer electrodes has a rectangular shape. In some embodiments, each sector has a half-rectangle shape sized to about half of the corresponding layer electrode.
  • an electrochemical storage device comprises a first electrochemical cell and a second electrochemical cell disposed in a common casing and each comprising an anode and a cathode, wherein the anode of the first electrochemical cell is disposed opposite the cathode of the second electrochemical cell; a separator disposed between the anode of the first electrochemical cell and the cathode of the second electrochemical cell, wherein he anode of the first electroche ical cell and the cathode of the second electrochemical cell are electrically insulated and in communication through an iorticaily conductive medium adsorbed in the separator; a common current collector disposed on the anode of the first electrochemical cell and the cathode of the second electrochemical ceil, wherein the first and second electrochemical cells are electrically connected and insulated from ionic conduction and wherein the ionic separation of said first and second electrochemical cells mitigates shunt currents.
  • the current collector provides substantially uniform current collection granting uniform current density.
  • Some embodiments further comprise a hydrophobic coating disposed on the portion of the common current collector between the anode and the cathode.
  • Some embodiments further comprise a physical barrier configured to ionicallv insulate the first and second electrochemical cells.
  • Some embodiments further comprise one positive and one negative terminal connection.
  • Some embodiments further comprise an insulation frame for disposing anodes and cathodes of two or more
  • the conductive substrate is made of amorphous material.
  • the conductive substrate is a wire mesh that includes elongated straight wires extending in a direction pointing from the first sector to the second sector.
  • each of rectangular plurality of the layer electrodes has a width in a direction that points from the first sector to the second sector and a length that is perpendicular to, and larger than, the width.
  • Some embodiments further comprise an internal section, a base and an insert, wherein the internal section includes the plurality of layer electrodes and the separator, and wherein the base is configured to form an external surface of the electrochemical device, and wherein the insert is configured for insertion between the base and the internal section and is further configured to add to a rigidity of the base.
  • electrochemical cell showing a plurality of electrode assemblies connected in a spiral configuration accord ing to an embodiment of the present disclosure.
  • Fig. 2B is an exploded isometric view of a portion of the electrode assembly of Fig. 2A.
  • Figs. 3 A and 3B are side views of the electrode assembly of Fig. 2A.
  • Fig. 4B is an exploded isometric view of the electrode plate of Fig. 4A with accompanying separator and pasting papers.
  • Fig. 5 is a schematic top view of an alternative embodiment of an electrode plate of the electrode assembly of Fig. 2 A depicting the current collector.
  • Fig, 6 is an exploded isometric view of a lead-acid elecirochemical ceil module and package according to an embodiment of the present disclosure.
  • Fig. 7 is a schematic isometric view of a plurality of electrode assemblies connected in a spiral configuration according to another embodiment of the present disclosure.
  • Fig. 8 is an exploded isometric view of a portion of an electrode assembly of the lead-acid electrochemical cell of Fig. 7,
  • Fig. 9 is an exploded isometric view of a portion of a lead-acid
  • Fig. 10 is a schematic isometric view of two stacked lead-acid
  • Fig. 1 1 is a schematic isometric view of an electrode plate according to another embodiment of the present disclosure.
  • Fig. 12 is an exploded isometric view of a partial electrode assembly according to another embodiment of the present disclosure.
  • Fig, 13 is a schematic isometric view of a portion of a lead-acid
  • Fig. 14A is a schematic isometric view of the lead-acid electrochemical cell of Fig, 13 connected to a power bus.
  • Fig. 14B is an exploded isometric view of the power bus of FIG. 14A.
  • Figs, 15A-15D show electro-chemical cells including welded power buses according to some embodiments.
  • Figs. 15E-15H show depicts lid and base inserts according to some embodiments.
  • Fig. 16 is an exploded isometric view of a partial lead-acid electrochemical ceil module, power bus, and package according to another embodiment of the present disclosure.
  • Fig. 17 is a schematic isometric view of a lead-acid electrochemical cell with a plurality of electrode assemblies in a stacked configuration according to another embodiment of the present disclosure.
  • Fig, 1 8 shows a Ragone plot of various types of electrochemical cells.
  • Fig. 20 shows an electrode assembly of a battery module according to some embodiments
  • Fig. 21 shows two circular frames in accordance with some embodiments
  • Fig. 22 shows the structure of a circular frame in accordance with some other embodiments
  • Fig. 23 shows a circular module cover in accordance with one embodiment.
  • Fig. 24 shows the behavior of calculated capacity of circular plate modules as a function of the diameter of the circular plates, in accordance with some embodiments.
  • Figs. 26A-26H show a battery having a rectangular form factor in accordance with some embodiments.
  • Figs. 27A and 27B show a rectangular battery having a 192V voltage configuration according to one embodiment.
  • Figs. 28A-28D show a battery having a circular sector electrode design according to some embodiments.
  • Figs. 29A-29E show spiral wound modules according to various aspects
  • Fig. 30A shows a cross section of a spiral wound module according to some embodiments.
  • Embodiments of the present disclosure generally relate to a design of a lead- acid electrochemical cell.
  • Lead-acid electrochemical ceils typically are in the form of stacked plates with separators between the plates. Accordingly, embodiments of the present disclosure relate to improved stacking of electrode plates in a variety of form factors.
  • the improved stacking and variety of form factors of the lead-acid electrochemical cell design may enable lead-acid electrochemical cells to be used as part of lead-acid batteries, which, in turn, may be used in automobiles to aid in increasing fuel efficiency.
  • FIG. i depicts a lead-acid electrochemical cell 10 according to a first embodiment of the present disclosure.
  • the lead-acid electrochemical cell 10 may include a plurality of electrode assemblies 12.
  • Each electrode assembly 12 may include a plurality of electrode plates positioned in electrochemical contact with each other.
  • the electrode assemblies 12 may be connected in a spiral configuration to build voltage within the lead- acid electrochemical cell In particular, the spiral configuration may enable a lead-acid electrochemical cell to build voltage while maintaining constant capacity.
  • the number of electrode assemblies that make up the spiral configuration, as well as the configuration of each electrode assembly may vary depending on the desired shape and desired voltage of the lead-acid electrochemical cell.
  • the spiral configuration may have an opening 32 formed in the center of the stacked electrode assemblies, by virtue of the shapes of electrode assemblies 12.
  • the central opening 32 may extend through the entire spiral configuration, forming a central bore allows for the main positive and negative leads to run through each electrode assembly 12 and be connected to the top of the spiral configuration.
  • Each electrode assembly 12 in the lead-acid electrochemical eel! may be separated by an insulator 14 (FIG. 2B).
  • the insulator may be the cross-sectional shape of the electrode assembly and may include a radial slit 15.
  • the cross-sectional shape of each electrode assembly 12 may be semi-circular.
  • the insulator 14 may include a circular shape and a slit 15 along a radius. As shown in FIG, 2B S the insulator 14 may further include a bottom surface and a top surface. Further, each electrode assembly 12 may include multiple electrode plates 24 with a top plate 24D in contact with both the top and bottom surfaces of insulator 14. For example, as shown in FIG 2B, the top plate 24D of one electrode assembly may include a first portion in contact with the bottom surface of the insulator, and a second portion in contact with the top surface of the insulator. The spiral configuration of the !ead-acid electrochem cal cell may be achieved by connecting the second portion of the top electrode plate 24D in one electrode assembly 12 to th first portion of a bottom electrode plate 24A in another electrode assembly 32.
  • FIG, 2A and FIG. 2B of the present disclosure depict schematic views of an electrode assembly 12 of the lead-acid electrochemical cell of FIG. 1.
  • the electrode assembly may include four electrode plates 24A-D.
  • Each electrode plate may be in the shape of half of a semi-circular section, as shown in FIG. 4A and FIG. 4B.
  • each electrode plate 24 may include a first portion 28 and a second portion 30.
  • the fsrst and second portions 28 and 30 may be connected by a plurality of electrode connectors 26.
  • Each portion may include a substrate, which may be a current collector (not shown).
  • the electrode substrate may be of the type disclosed in U.S. Application No. 13/350,505 for Improved Substrate for Electrode of Electrochemical Cell, filed concurrently herewith by Subhash Dhar, et al, the entire disclosure of which is incorporated herein by reference.
  • the substrate may include a grid-like structure formed of conductive material, with spaces there between for supporting active material.
  • the substrate may include a sheet of material having aligned dimple-like spaces or a plurality of through-holes in linear patterns.
  • the substrate may include a plurality of pieces of material, such as wires, woven together to form a mesh.
  • the substrate may include an expanded sheet of material with holes there through.
  • the substrate may include material that may result in an increased adhesion between the substrate and the active material, as well as increased surface conductivity and reduced corrosion of the electrode plate.
  • the substrate may further be formed such that a relatively constant current density may be maintained throughout each electrode plate,
  • the electrode plate 24 may include a substantially semi-circular shape.
  • the substrate of the electrode plate 24 may include a substantially semi-circular shape as well. Constant current density throughout the substrate may be achieved by spacing the current collector elements of the substrate closer together in the radial direction at the outer radius of the electrode plate than at the inner diameters, and farther apart at the inner radial extent of the plate, as shown in FIG, 5,
  • the active material may be placed onto each portion of the substrate such that a pseudo bi-polar electrode plate may be formed.
  • the pseudo bi-polar design may be accomplished by disposing both positive and negative active materials in alternating fields on a common substrate.
  • the pseudo bipolar design may include placing positive active material onto the first portion 28 of the substrate; and placing negative active material onto the second portion 30 of the substrate.
  • This pseudo bi-polar design may offer lower resistance and higher power of the lead-acid electrochemical cell Further, it may enable the lead-acid electrochemical cell to operate at a lower temperature, which may reduce the need for collateral cooling equipment. As shown in FIG.
  • each electrode plate 24 may be positive 16, and the second portion 30 of each electrode plate 24 may be negative 20, with the electrode connectors 26 between the negative and positive regions of the electrode plate.
  • Each positive portion 16 and negative portion 20 of each electrode plate may further include a top surface and a bottom surface.
  • a thin layer of pasting paper 22 may he disposed on the top and bottom surfaces of each portion of the electrode plate.
  • a separator 1 8 may be disposed adjacent the pasting paper on the bottom surface of each portion.
  • each electrode assembly 12 may include four electrode plates 24A-D as shown in FIGS 2A and 2B.
  • the electrode assembly 12 may be formed by stacking each piate 24 at a ninety degree angle relative to one another such that a positive portion 1 of one plate may be connected to a negative portion 20 of another plate, in one embodiment, for exampie, a first electrode plate 24A having a positive portion 16 and a negative portion 20 may be the bottom plate of the electrode assembly, A second electrode piate 24B having a positive portion 16 and a negative portion 20 may then be stacked onto the first electrode plate 24A, This may be accomplished by turning the second electrode plate 24B ninety degrees relative to the first electrode plate and placing the positive portion 16 of the second plate 24B on top of the negative portion 20 of the first plate 24A (FIG.
  • a third electrode piate 24C having a positive portion 16 and a negative portion 20 may be stacked upon the second plate 24B in the same manner as previously discussed; and a fourth electrode plate 24D may then be stacked upon the third electrode plate 24C.
  • the fourth electrode plate 24D may he the top electrode plate of the electrode assembly 12 (FIG 2B).
  • insulator 14 may be placed on the electrode assembly.
  • the positive portion 16 of the fourth, i.e., top electrode plate 24D may be connected to the negative portion 20 of the third electrode plate 24C.
  • the insulator 14, including the slit 15, may be placed on the electrode assembly such that the top of positive portion 1 6 of the fourth plate 24D may be in contact with the bottom surface of the insulator 14, and the bottom of the negative portion 20 of the fourth plate 24D may be in contact with the top surface of the insulator 14.
  • the negative portion 20 of the fourth plate 24D may be stacked with a free, positive portion 16 of a first plate 24A of another electrode assembly 12, which may thereby form the spiral configuration of the lead-acid electrochemical cell shown in FIG. 1.
  • the electrode assembly may be formed such that the free portion of the fourth plate 24D is a positive portion and the free portion of the first piate 24A is a negative portion.
  • the free portion of the fourth plate 24D of the top electrode assembly in the spiral configuration may be connected to a single portion piate in order to complete the circuit.
  • the top plate 24D of the top electrode assembly may only be a single portion plate, thereby completing the circuit with the connection to the third plate 24D.
  • the separator material is a thin film membrane that allows for ionic diffusion and transfer of hydrogen, oxygen and sulfate ions, e.g. H+, OH-, S04- at rates that are comparable to liquid electrolyte diffusion
  • the separator membrane is a polymeric membrane e.g. Nafion material.
  • the substrate material of the plates is a suitable thin film electrically conductive medium in a form of a foil or a solid film, In some embodiments,
  • the thin film is a woven material selected from the group including metals, e.g. lead, conductive polymers, e.g. aniline based polymer, conductive ceramics, e.g. ebonex or conductive tin or titanium oxides.
  • the substrate material has a polished surface with a suitable attachment layer or a patterned surface to promote adhesion of the active material including holes, ridges, dimples interlocking features and stress mitigating features.
  • the positive and negative electrode assembly constitutes a fuel cell relying on separation principles of a ionically conductive membrane.
  • a suitabie fuel fluid is a gas, e.g. hydrogen or other suitabie fuel.
  • each electrode plate may allow for the spiral configuration to build voltage in the lead-acid electrochemical ceil to any desired value (e.g., 24V, 36V, 42V, or 48V) at a constant capacity, while maintaining a low weight of the lead- acid eiectrochemicai cell.
  • the low weight may be due to the sizes of the components of the electrode assembly, as well as the material-make up of each electrode plate.
  • the stacking of the electrode plates at a ninety degree angle relative to one another may allow for thinner components,
  • the electrode assembly 12 may include a diameter of about 8 inches and may be about 0.3 inches thick. More specifically, the positive portion 16 of the electrode may be about 0.082 inches thick; the negative portion 20 of the electrode may be about 0.06 inches thick; the separators 18 may be about 0.06 inches thick; and the pasting paper 22 may be about 0.004 inches thick.
  • the plates can be stacked so that the plates build, one upon the other, in a step-wise manner with each positive 16 and negative 20 portion and their accompanying connections 26, lying in the same plane, as shown in FIG 2,
  • connectors 26 may be angled so that they are offset by the thickness of a plate, pasting papers and separator, to facilitate the rise in the plates as they are stacked.
  • the electrode plates can be formed having a helical geometric shape, to facilitate stacking the plates in a helical pattern, mitigating step discontinuities and reducing stresses on the connector 26.
  • the lead-aeid eiectrochemicai cell may further include means for mitigating shunt currents due to leakage of electrolyte fluid from the electrodes and separators onto the electrode connectors, which may cause the electrodes to self-discharge.
  • the electrode connectors 26 and inner portion of a container proximate the electrode plates may be treated with a hydrophobic coating, which may prevent excess electrolyte fluid from wetting the electrodes, or electrode connectors 26, or casing.
  • the electrode connectors 26 may be blocked from leaking electrolyte fluid due to barriers formed on the edges of the positive and negative portions 16, 20 of each electrode plate.
  • the barrier may be a coating or other material, including frame material or even excess active materia! that may frame each positive and negative portion and contain the electrolyte.
  • the insulator may have a diameter that is larger than the diameter of both the electrode assembly the container in which the spiral configuration resides, such that the insulator may form a barrier with the container wall and soak up leaking electrolyte fluid.
  • FIG. 6 depicts a lead-acid electrochemical module 60 according to an embodiment
  • the module 60 may include a top portion 34, a bottom portion 38, and a casing 36. Top and bottom portions 34, 38 may enclose the lead-acid electrochemical cell 10 within the casing 36. Casing may include an inner opening 40. which may be substantially the same diameter and height of the lead-acid electrochemical cell 10, such that the lead-acid electrochemical cell may be fully disposed within the casing 36 and covered by the top and bottom portions 34, 38,
  • the module 60 may further include positive and negative terminals (not shown in FIG. 5) attached to the lead-acid electrochemical ceil, such thai the module may be used to provide energy and power,
  • the spiral configuration may connect electrode assemblies 12 in order to build voltage while maintaining a constant capacity of the lead- acid electrochemical cell.
  • the electrode assemblies 12 may be stacked such that the voltage of the lead-acid electrochemical cell remains constant while building capacity. Accordingly, in this second embodiment, instead of the top plate 24D of one electrode assembly 12 being connected to the bottom plate 24a of another electrode assembly 12, the top and bottom plates of a single eiectrode assembly may be connected to complete the circuit. Each electrode assembly 12 may be connected to a tab 50, which may further be connected to a power bus assembly 500 for capacity building.
  • FIG. 14B illustrates the components of one embodiment of the power bus assembly 500.
  • Power bus assembly 500 may include a power bus 502, a terminal 506, a connector piece 504 , and a nut 508.
  • a bolt 510 may be connected to the connector piece 504, extend through the power bus 502, and attach to the nut 508, Bolt 510, when connected to the connector portion 502 and nut 508, may complete the connection of the bus system 500, which may thereby building capacity.
  • connector 504 may include a first through-hole 504a and a second through-hole 504b formed therein.
  • First through-hole 504a may connect to the bolt 510, and second through-hole 504b allow top portion of terminal 506a to extend there through.
  • Terminal 506 ma additionally include a bottom portion 506b, that may sit atop a top surface of the lead-acid eiectrochemical cell 1000, Top portion of terminal 506b may be an elongate member having a cross section that is substantially the same shape as the second opening 504b. The bottom portion of terminal may be flat. Alternatively, as hown if FIG. 14A, the bottom portion of terminal 506b may have a concave inner surface.
  • Power bus 502 may include an elongate member having a length that is substantially the same as the height of the lead-acid electrochemical cell. Power bus 502 may further have slits disposed along its length, the slits being configured to receive connections from electrode plates, where the connections are solidified by compressing the power bus 502 in compression. Further, as shown in FIG, 14B, a top surface of the power bus 502 may be in contact with a bottom surface of the connector piece 504, such that the connector piece 504 may carry current from the power bus 502 to the terminal 506.
  • power bus 502 may be made of any materia! known to those skilled in the art that allows for the carrying of current and the building of capacity.
  • Figs. 15A- 15D show electro-chemical cells 1500 including welded power buses 1510 according to some embodiments.
  • Cell 1500 further includes a plurality of cell packs 1522, which terminate in a plurality of tabs 1524.
  • electro-chemical ceil 1500 is a battery or a battery module.
  • the power busses are welded to the cell's end tabs.
  • the welding is an ultrasonic welding.
  • Fig. 15A is an assembled view of one end of cell 1500 showing one power bus 1510 welded to tabs 1 24.
  • Fig. 15B is an exploded view of one end of cell 1500 showing one power bus 1510 separate from tabs 1524, which are welded together when assembled, in various embodiments, ultrasonic welding of the power bus to the tabs, as compared to other types of joining, reduces the creation of oxidized metals, Reduced oxidation, in turn, reduces vulnerability of the power bus to corrosion.
  • power bus 1510 includes a folded sheet of metal, in various embodiments, power bus 1510 is made from a sheet of lead, or a sheet of copper , In some embodiments, the power bus transfers current from the end-cell 'tabs' to the battery terminal, in some embodiments, such as the 'ribbon' style power bus the embodiment of Fig. 15A-15D, the power bus is designed to have low mass, low electrical resistance, and high environmental or sulfuric acid corrosion resistance.
  • power bus 1520 provides a balanced path for conducting electrons from each cell to the battery terminals.
  • each top surface 15104 is connected to a terminal 1512.
  • Front and back surfaces 1510-f and 1510-b provide electron paths from tabs 1524 to top surface 1 501 -t and terminal 1512.
  • power bus 1510 is designed with a non-uniform resistivity along its surface, to provide a balanced, or an approximately equal, total resistance between each tab 1524 and the corresponding terminal 1512.
  • the resistivity of the front or back surfaces are varied as functions of the distance from the top surface, in some embodiments, for example, the resistivity of front surface 1510-f decreases for points that are farther from top surface 15104, In some embodiments, the resistivity of back surface 1510-b, which provides a shorter path for lower tabs compared to the upper paths, is higher than front surface 1510-f. in various embodiments.
  • the resistivity of an area of the power bus is increased by removing some parts of the surface to create holes or by decreasing the thickness of the foil forming the bus.
  • a desired value of a resistivity as a function of the location on the power bus foil is determined by modeling various paths of electrons between the tabs and the terminals.
  • such bulging can occur due to the norma l cycling of the battery and the resulting increase of gas pressure inside the battery, which can deform the casing and cause the bulge.
  • the bulging co !d result in a loss of compression as well as non-uniform compression of the electrode stacks.
  • Fig. 15C shows that the bottom tray assembly 1554 is formed by assembling lower insert 1 53 in the external base 1552.
  • Fig, 15H shows that lid assembly 1559 is formed by assembling upper insert 1557 and external lid 1558,
  • inserts 1553 and 1557 are made of the same material as the casing 1556. Such material permits a high degree of flexibility in bonding the parts, In some embodiments, the inserts are made from polypropylene sheet.
  • the inserts are punched, cut, molded, formed b other suitable forming techniques, Alternatively, in some embodiments, the inserts are made from high impact poiystyrene (HIPS); acrylonitrile butadiene styrene (ABS); polyvinyl chloride (PVC), any suitable composite, or other thermoplastic material that is acid-resistant, high- strength, and easily formed. In various embodiments, the inserts provide shielding against electrolyte leakage,
  • the inserts prevent loss of compression of the electrodes and maintain even levels of compression across the electrode stacks. Further, the inserts help prevent shorting by providing gaps between the electrode stacks that prevent liquid pathways from forming between adjacent electrode stacks that may otherwise may cause shorting.
  • the electrode plates may be rectangular in shape.
  • the rectangular plates may be similar in area to the semi-circular electrode plates and may used to form similar-sized electrode assemblies and modules,
  • FIG, 7 shows a lead-acid electrochemical cell 100 according to a third embodiment of the present disclosure.
  • the embodiment of FIG. 7 depicts stacking of rectangular eiectrode plates at a ninety degree angle relative to one another to form electrode assemblies, and connecting the electrode assemblies in the spiral configuration.
  • rectangular electrode plates may be connected to form eiectrode assemblies, and thereby a spiral configuration having a square cross-sectional shape.
  • the lead-acid electrochemical cell 100 may further include a tab 50 connected to a positive end and a tab 50 connected to a negative end of the spiral configuration.
  • Tabs 50 may be securely connected to the positive and negative ends via any means known to those skilled in the art.
  • tabs 50 may be connected via soldering or ultrasonic welding.
  • Tabs 50 may each contain a through-hole 52, which may allow for passage of posts 148.
  • openings 141, 143, 147 in each of the casing 140, slotted tray 142. and drip tray 146, respectively, may also allow for posts 148 to pass there through.
  • posts 148 may extend out from respective openings 141 in the casing 140 so that they may act as positive and negative terminals for the lead-acid electrochemical cell module.
  • Posts 148 may further include an end portion 150 with an opening therein. The opening in the end portion 150 may allow for individual lead-acid electrochemical cell modules 200 to be stacked upon one another (FIG. 10).
  • a fourth embodiment may employ the square electrode assembly 1 12 geometry of the third embodiment to build capacity at a constant voltage, rather than building voltage as in the third embodiment. Similar to that disclosed in relation to the second embodiment, this fourth embodiment may include connecting the free portion of the top plate 124D with the free portion of the first plate 124A in order to complete the circuit and therefore form a 12V electrode assembly 1 12. The electrode assemblies may 1 12 then he stacked and connected to the power bus assembly 500 in order to build capacity while maintaining a constant 12V of the lead-acid electrochemical cell.
  • the fourth embodiment of the lead-acid electrochemical ceil may further include a module that may be similar to that of the third embodiment,
  • the electrode plates may further be used form electrode assemblies, and thereby lead-acid electrochemical cell configurations, having a variety of cross-sectional shapes, in addition to circular and square.
  • This variety of cross-sectional shapes may allow for stacked or spiral configurations of the lead-acid electrochemical ceil to be placed in a variety of locations (e.g., in a vehicle) with little or no modification of the design of the location (e.g., vehicle frame) to accommodate the lead-acid electrochemical cell system.
  • each electrode assembly may include more than four plates.
  • formation of these electrode assemblies may include stacking of the electrode plates linearly relative to one another, as well as at a ninety degree angle relative to one another.
  • rectangular plates may be used to form a spiral configuration with a rectangular cross-section. Accordingly, there may be more electrode plates along the length of each electrode assembly than along the width.
  • electrode plates may be oriented such that resulting electrochemical cells may provide volumetric efficiency in three orthogonal directions.
  • the orientation of the electrochemical cells may provide improved dimensions in an x-direetion, a y-direction, and/or a z-direction, where the xyz axes are not oriented in any particular way relative to an electrochemical ceil easing.
  • the orientation of the eiectrochemical cells may provide improved dimensions in an x-direction, a y-direction, and/or a z-direction, where the xyz axes are oriented relative to an electrochemical cell casing.
  • the electrochemical cells may be united through ionic connections and a common current collector in such as way as to build voltage or capacity in the direction of one of the orthogonal directions x, y, z.
  • a fifth embodiment of the present disclosure may include formation of electrode plates into an electrode assembly, where the electrode assembly may include an L- shaped cross-section.
  • Each electrode assembly may include electrode plates with positive and negative portions connected by electrode connectors, in addition, each electrode plate may include pasting paper and separators. Further, each electrode assembly may be separated by an L ⁇ shaped insulator having at least one slit to enable spiral connection of the L-shaped electrode assemblies.
  • each electrode plate may further include means for mitigating shunt currents (e.g., hydrophobic coating on electrode connectors, hydrophobic framing of the plates, or an oversized insulator for soaking up electrolyte fluid),
  • the L-shaped lead-acid electrochemical cell may further include an L-shaped module. Similar to the circular and square modules, the L-shaped module may include a easing, slotted tray, and drip tray for collecting leaking electrolyte fluid. There may further be a tab connected to positive and negative ends of the L-shaped spiral configuration, such that the tabs may be connected to shafts that form terminals of the L-shaped lead-acid electrochemical cell.
  • An alternative, sixth embodiment of the L-shaped electrode assemblies may further include a capacity building geometry, similar to the other capacity-building embodiments disclosed herein.
  • the L-shaped electrode assemblies in the sixth embodiment may each be connected in parallel, with each assembly terminating in a tab, with each of the respective tabs connected to the power bus assembly 500,
  • the capacity-building L-shaped electrochemical cell may be housed within a module that is similar to the L-shaped module for the spiral configuration.
  • a se venth embodiment of the present disclosure may an electrode assembly having a U-shaped cross-sectional shape.
  • the seventh embodiment may build voltage at a constant capacity, as disclosed herein.
  • an eighth embodiment may include a U-shaped electrode assembly disposed to build capacity.
  • FIG. 17 illustrates a lead-acid electrochemical ceil 2000 according to an eighth embodiment of the present disclosure.
  • the lead-acid electrochemical cell 2000 may include a plurality of electrode assemblies 2012 stacked, such that voltage may remain constant while capacity may be built.
  • Each electrode assembly 2012 includes the U-shaped configuration, such that the lead-acid electrochemical cell 2000 may fit within a module that may include an intermediate separator 2104.
  • the lead-acid electrochemical cell 2000 may further include a power bus 500 on each end to build capacity.
  • the electrochemical cell may be configured in an elongated rectangular shape.
  • FIG. 11 illustrates an electrode plate 1024 of a lead-acid electrochemical cell according to a ninth embodiment of the present disclosure, Similar to the electrode plates 24, 124 in FIG. 4A and FIG, 8, the electrode plate 1024 may include a first, positive portion 1028 and a second, negative portion 1030, with electrode connectors 1026 there between.
  • each electrode plate portion 1028 or 1030 has a width 1028-W in the direction of electron flow and a length 1028-L perpendicular to that direction,
  • each electrode plate has an aspect ratio, that is, a ratio of its length to its width (the length of 1028-L over the length of 1029-W) that is larger than one.
  • the ratio of length to width is about 1.5. In some other embodiments this ratio is about 2,0.
  • Such aspect ratios increase the efficiency of the batter cells as, for the same total surface of the electrode pates, the electron requires to travel a shorter path.
  • FIG, 13 illustrates a lead-acid electrochemical cell 1000, which may include the stacked electrode assemblies 1024 of FIG. 12.
  • the lead-acid electrochemical cell 1000 may include tabs 50. Similar to the tabs 50 in the lead-acid electrochemical cell 300 of FIG, 7, each tab may include a through-hole 52 and may be connected via soldering or ultrasonic welding to a positive end and a negative end of each electrode assembly.
  • FIG. 13 illustrates that tab 50 may be connected to two electrode assemblies, as opposed to only one
  • FIG. 14A further illustrates thai each end of the lead-acid electrochemical cell
  • a power bus assembly 500 which may allow for the individual electrode assemblies 1024 to be connected in parallel in order to build capacity of the lead- acid electrochemical cell 1000,
  • FIG. 16 illustrates a lead-acid electrochemical cell module 1200 including the lead-acid electrochemical cell 1000 of FIG. 14A.
  • the lead-acid electrochemical ceil module 1200 may include a casing 1202, a slotted tray 1204 with a plurality of slots 1205, and a drip tray 1206 for collecting electrolyte fluid that seeps through the slots 1205 of the slotted tray.
  • the casing 1202, slotted tray 1204, and drip tray 1206 may include a length, width, and height that are slightly larger than the dimensions of the lead-acid electrochemical cell 1000, such that the casing 1202 and drip tray 1206 may completely enclose the lead-acid electrochemical cell 1000.
  • the casing 1202 and the drip tray 1206 may be held together via any process known to those skilled in the art, including, but not limited to plastic ultrasonic welding.
  • Fig. I 9B shows a disassembled view of circular plate module 1900 and its various parts in accordance with some embodiments.
  • module 1900 includes one layer positive terminal 1920P, one layer negative terminal 1920N, five layer electrodes 1920E, six bolts 1930B, six nuts 1930N (of which four are visible), and four bushings 1932 (of which three are visible).
  • the disassembled parts shown in Fig. 19B combine into assembled module 1900 of Fig. 19 A.
  • the bolts 1930B pass through designated holes in layer positive terminal 1920P, either designated holes in layer electrodes 1920E or bushings 1932, and designated holes in layer negative terminal 3920N, and then engage nuts 1930N.
  • two of the holts marked by arrows, correspond to end-nuts-and-holts assemblies 1930a in Fig. 19A, and pass through the holes in layer electrodes 1920E.
  • the other four bolts correspond to side-nuts-and-bolts assemblies 1930b in Fig. 19A and pass through bushings 1932.
  • layer electrodes 1920E and layer negative or positive terminals are positioned on top of each other with a half turn for each layer compared to the previous, such that the positive haif layers of one plate is positioned right below the negative haif layer of the next plate, or vice versa,
  • module 1900 includes five layer electrodes 192GE placed between one layer positive terminal 1920P and one layer negative terminal 1920N.
  • such a combination of electrodes provides a twelve volt battery module.
  • Fig, 19C shows a detailed structure of layer electrode 1920E according to some embodiments.
  • layer electrode 1920E includes negative haif layer 1924, positive haif layer 1926, wire substrate 1920W, two thin separator haif layers 1927M and 1927t-2, thick, separator haif layer 1927T, circular frame 1920F, frame o-ring 1 921 , and insulator half layer 1925.
  • layer electrodes 1920E are assembled such that negative and positive haif layers of abutting layer electrodes come in contact.
  • a second layer electrode 1920E is positioned over a first !ayer electrode to form a module 1900, such as that seen in Fig.
  • the second one is rotated with respect to the first one by 180 degrees around its central axis, in this manner, the negative half layer of the second iayer electrode is positioned on top of the positive half layer of the first layer electrode and the positive half layer of the second Iayer electrode is positioned on top of the negative half layer of the first layer electrode, in each case with some separators or insulators coming between them,
  • the exploded view shown Fig, 19C represents the first layer electrode sandwiched between a second layer electrode on top and a third iayer electrode at the bottom.
  • the second and third layer electrodes, not shown, will he oriented similar to each other, but rotated by 180 degrees with respect to the first layer electrode.
  • negative half layer 1924 of the first layer is sandwiched between the positive half layers of the second and third layer electrodes, with a thick separator half layer coming before the positive half layer above it, and thin separator 1927t- l , insulator 1925, and thin separator 1927t-2 respectively coming before the positive half iayer beiow it.
  • positive half layer 1926 of the first layer electrode is sandwiched between negative half layers of the second and third iayer electrodes, with a thin separator half layer, an insulator half layer, and another thin separator half layer coming before the negative half layer above it, and the thick separator 1927T coming before the negative half layer below it,
  • the insulator half layer is an insulating layer that prevents the active half layers on its two sides from exchanging charges.
  • the insulator half layer of the second layer electrode prevents positive half layer 1926 of the first layer electrode from exchanging charges with the negative half layer of the second layer electrode iocated above it.
  • insulator half layer 1925 prevents negative half layer 1924 from exchanging charges with the positive half iayer of the third layer electrode located below it.
  • the separator half layer is an ionically conductive layer that is in contact with one or two active half layers, In some embodiments, the separator half layer preserves some of the electrolyte in the active half iayer to which it contacts. Further, in various embodiments, the separator half layer is in contact with two active, half layers on its two sides, enables ionic charge exchanges between those half layers, thus forming a unit cell.
  • thin separator half layer 1927t-l is in contact with negative active material 1924 above it and preserves and exchanges ions with that negative half iayer
  • thin separator half layer 19271-2 is in contact with a positive active material located beiow it.
  • Thick separator half layer 1927T enables ionic charge exchanges between positive half layer 1926 of the first layer electrode and the negative half layer of the third layer electrode below.
  • the thick separator half layer of the second layer electrode enables ionic charge exchanges between negative half layer 1924 and the positive half layer electrode of the second layer electrode,
  • This combination of positive half layer, separator half layer, and negative half layer creates a unit ceil inside module 1900.
  • negative half layer 1924 forms a unit cell with the positive half layer above it, while being insulated from the positive half layer below it.
  • positive half layer 3926 forms a second unit cell with the negative half layer below it, while being insulated from the negative half layer above it.
  • the wire substrate is a mesh created by a single- direction conductive wire, which enables conductive electron exchanges between the two active half layers that it connects.
  • the wire substrate thus connects within the same layer electrode the positive half layer of one unit ceil to the negative half layer of another unit cell.
  • the wire substrate has a composition and a design that increases the efficiency of the battery.
  • the wiring is a mesh of directional wires that extend from one electrode to the other electrode.
  • the wire substrate is made of a non-crystalline amorphous material that does not have a long range order. Such materials provide a better resistance against corrosion and thus are more suitable to be used in contact with the electrolytes,
  • wire substrate 1920W connects negative half layer 1024, belonging to the first unit cell, to positive ha!f layer 1926, belonging to the second unit cell.
  • circular plate module 1900 includes a set of unit cells connected in series.
  • each unit cell the middle is formed between two abutting layer electrodes, in the manner detailed above.
  • two end unit ceils are formed between a layer electrode and an abutting layer positive terminal or layer negative terminal.
  • the first layer electrode terminal 1920E-I includes a negative half layer 1924-1, which forms a unit cell with positive half layer 1926-P in layer positive terminal 3920P.
  • the fifth layer electrode 1920E-5 includes a positive half layer 1926-5, which forms a unit cell with negative half layer 1924-N in layer negative terminal 1920N.
  • Figs. 19D and 19E show the structure of the layer positive terminal and the layer negative terminal in more detail and in accordance with some embodiments.
  • Fig. 19D shows that layer positive terminal 1920P includes, in consecutive layers starting from top, cap 1910; thin separator half layer 1027t-l along with a lead sheet half layer 1954; positive half iayer 1926; wire substrate 1920W; thick separator half Iayer 1927T along with a gasket half layer 1952; and insulator 1925 and thin separator half layer 1027t ⁇ 2.
  • Layer positive terminal 1920P also includes circular frame 1920F, frame o-ring 1921 , a terminai 1956 and a terminal o-ring 1957.
  • layer negative terminal 1920N includes, in various layers starting from bottom, cap 1910; PVC half layer 1958 along with holed gasket half layer 1952h; another PVC half layer 1958 along with holed PVC half layer 1958h; insulator 1925 along with another holed PVC half layer 1958h; thin separator half layer 1927t along with lead sheet half layer 1954; wire substrate I 920W; and negative half iayer 1924 along with gasket half iayer 1952.
  • Layer negative terminal 1920N also includes circular frame 1920F, frame o-ring 1921 , a long terminal 1956L and terminal o-ring 1957.
  • Parts 1924 and 1926 are respectively the negative and positive active materials.
  • Thin and thick separators 1927t and 1927T are made of fiberglass mats of different thicknesses.
  • thick separator half iayer 1927T is thicker than thin separator half layer 1927t.
  • positive active material 1926 is thicker than negative active material 1924,
  • thin separator half layer 1927t is included on the side that also includes negative half layer 1924 to compensate for the smaller thickness of negative half iayer 1924 compared to positive half layer 1926.
  • separator half layers 1927 preserve the electrolyte of the active layer with which they contact,
  • the layer electrodes are assembled into a circular plate module in a manner that provide a continuous charge path among the plates.
  • Fig, 19F shows the charge path of an assembly of layer electrodes, including iayer electrodes 1920E- 1 to 1920E-4, in a circular module 1900 in accordance with some embodiments.
  • vertical and horizontal arrows indicate direction of charge transfer.
  • horizontal arrows 1942 indicate a conductive electron transfer from one unit cell to the next unit cell in the assembly, through a wire substrate.
  • Vertical arrows 1944 indicate ionic charge transfer within a unit ceil, an ionic charge transfer through a separator from the left hand side (positive) half layer of layer electrode 1920E-2 to the left hand side (negative) half layer of layer electrode 1920E-3.
  • the voltage produced by a unit cell is around two volts.
  • layer electrodes 1920E or layers for positive and negative terminals are manufactured by assembling its various parts in some specific order, in the embodiment shown in Fig. 19C, for example, when manufacturing layer electrode 1920E, wire substrate 1920W can be strung into the grooves etched on the upper face of circular frame 1 920F to create a wired-frame assembly. This wired-frame assembly can then be covered on the one side with negative active material to form negative half layer 1924 and on the other side with positive active material to form positive half layer 1926, Insulator and separator half layers 1925 and 1927 can then be attached on the appropriate faces of the negative and positive haif layers
  • Fig, 21 shows two circular frames 2120F-1 and 2120F-2 in accordance with two different embodiments.
  • Circular frame 2120F-1 has wire grooves 2152 etched on a section of its perimeter in a manner that a wire substrate strung into the grooves does not leave the perimeter of the frame and does not touch the perimeter of the wired-frame assembly
  • Circular frame 2120F-2 has wire grooves 2154 etched along the length of its perimeter in a manner that a wire substrate strung into the grooves forms part of the perimeter of the wired-frame assembly.
  • frame o-ring 1921 is used to seal the perimeter of the wired-frame assembly and prevent electrolyte from leaking out.
  • Fig, 22 shows the structure of a c ircular frame 2220F in accordance with some other embodiments.
  • Circular frame 2220F includes a perimeter section 2220Fp, a central diameter section 2220Fd, and an O-ring sealing 2258,
  • Perimeter section 2220Fp has grooves formed on it for the wire substrate in the form of vertical channels 2254.
  • Diameter section 2220Fd has grooves formed on it for the wire substrate in the form of horizontal channels 2256,
  • O-ring sealing 2258 provides a sealing mechanism to prevent leakage of the byproducts, such as acids, or gases generated by the battery, Moreover, in some embodiments, such leakage is aiso prevented in the center by cutting out along diameter section 2220Fd , a channel such as potting compound area 2257. After lead-wire substrate is strung on circular frame 2220F, an epoxy is poured into area 2257 to seal in the wire.
  • the epoxy can be wax or other suitable hydrophobic materials. The epoxy is used to prevent or reduce the leakage of the battery between half layers,
  • Fig. 23 shows a circular module cap 2300 in accordance with one embodiment.
  • Module cap 2300 includes six sectors 2302 and a terminal location 2304, Each of sectors 2302 includes a middle section, which has a reduced thickness and is a surrounded by a thicker rim. Because of the reduced thickness in the middle of sectors 2302, module cap 2300 is lighter than a cap that has a uniform thickness and is otherwise similar to module cap 2300.
  • each circular module cap 2300 for the top or bottom covers measures eight inches in the outside diameter, seven inches in the inside diameter, and 1 ⁇ 4 inches in thickness.
  • top and bottom covers are injection molded using PVC. In these
  • module cap 2300 weighs around 140 grams, while a similarly dimensioned cap with a uniform thickness weights around 270 grams. Lighter covers reduces the weight of the battery, and thus increases its specific energy or specific power.
  • Fig, 20 shows an electrode assembly 400 of a battery module according to some embodiments.
  • Assembly 400 includes semi-circular shaped full electrode plates 402, quarter-circular shaped positive and negative end plates 404 and 406, isolator layer 408, separator plates 410, positive terminal 432 and negative terminal 414.
  • Each full electrode plate 402 includes a positive half plate 402P and a negative half plate 402 .
  • Full electrode plates 402 are assembled in a manner that when a full plate is positioned above another full plate, it is rotated by 90 degrees about the axis of electrode assembly 400, such that positive half plate 402P of one plate is positioned against negative half plate 402N of the other plate.
  • a separator 410 is inserted between these two oppositely charge half plates to provide ionic connection between them.
  • This combination of negative half plate of one plate ionically connected to a positive half plate of another plate located over or under the first plate creates a unit cell.
  • the wire connection between the positive half plate 402P and negative half plate 402N in the same full plate 402 provides a series connects between two consecutive unit cells.
  • Positive end plate 404 forms a unit cell with the negative half plate 402N positioned against it (under it in Fig. 20).
  • negative end plate 406 forms another unit cell with the positive half plate 402P positioned against it (above it in Fig, 20).
  • Fig. 24 shows the behavior of calculated capacity of circular plate modules as a function of the diameter of the circular plates, in accordance with some embodiments.
  • Fig. 24 depicts graph 2400 in which abscissa 2410 lists the electrode diameter in inches and ordinate 2420 lists the corresponding calculated capacity in Ampere Hours (ah).
  • the curve 2430 shows the calculated values for the capacity as a function of the diameter, in particular, curve 2430 shows that increasing the diameter of the plates causes the calculated capacity to increase in a non-linear manner.
  • curve 2430 shows that, in one embodiment, the electrode diameter is set to seven inches and the capacity of the module is around 6.5ah.
  • a battery module is made of plates that have non- circular shapes.
  • Fig, 25 shows a battery 2500 shaped as a rectangular box (rectangular prism) in accordance with some embodiments.
  • Battery 2500 includes one or more rectangular plates 2510.
  • rectangular plate 2510 includes a rectangular active module 2520 and a rectangular nest module 2530.
  • two different frames thus comprise one layer of the battery module, in a manner similar to that shown in Fig. 25.
  • a first frame contains two active half layers including two different types of active materials.
  • the second frame has the same shape as the first frame and includes a separator or an isolator, or both.
  • these two types of frames are manufactured separately and are then put together to create one layer of a battery module. Multiple layers are then assembled to create the battery module.
  • each layer is rotated with respect to the layer below or above it, such that the negative and positive half layers of neighboring layers face each other.
  • a number of rectangular layers are assembled to form a rectangular module with a desired output voltage.
  • Figs. 26A and 26B show a 12 volt rectangular module 2600 in assembled and disassembled forms according to some embodiments.
  • rectangular module 2600 includes a top layer 2610, five current repeating frames 2630, and a bottom layer 2650.
  • Top layer 2610 includes a top cover 26 I OC and an upper half-electrode frame 2620.
  • Bottom layer 2650 includes a bottom cover 2650C and a lower half-electrode frame 2640, In the embodiment shown in Figs.
  • upper half electrode frame 2620 includes a negative half layer and lower half electrode frame 2640 includes a positive half layer, similar to positive and negative half layers discussed above,
  • module 2600 can be oriented and used differently such that, for example, the negative and positive half layers are respectively positioned at the bottom and at the top, or in any other orientation,
  • Figs. 26C and 26D respectively show assembled and disassembled views of center repeating frame 2630 of module 2600 according to some embodiments
  • current repeating frame 2630 includes a gasket, a negative acid reservoir half rectangle, positive and negative active material half rectangles, a wire substrate, a potting compound, an inner frame, a separator half rectangle, a positive acid reservoir half rectangle, and an outer frame thai includes an isolator half rectangle, These parts generally function in a manner similar to the parts of layer electrodes discussed above.
  • negative and positive acid reservoir half rectangles are made of thin separator material, in the embodiment shown in Fig.
  • negative and positive acid reservoirs respectively cover negative and positive active material half rectangles from above or below, and each function as a reservoir of acid for the corresponding active material half rectangle.
  • the gasket is made of EPDM rubber, other embodiments include Viton or similar elastomers, and acts as a washer between a center repeating frame and the one above it.
  • the inner frame is made of a suitable acid resistant plastic and functions as a general frame for the active material the wire substrate, the acid reservoirs, and other parts.
  • the potting compound is a curable epoxy compound and functions as a barrier for acid migration between positive and negative active material
  • Figs. 26E and 26F respectively show assembled and disassembled views of top layer 2610 of module 2600 according to some embodiments.
  • Top layer 2630 includes top cover 26 IOC and upper half-electrode frame 2.620.
  • Fig. 26F also shows, in accordance with some embodiments, different parts of upper half-electrode frame 2620 which include a gasket, a negative terminal, a current collector, a negative acid reservoir half rectangle, a potting compound, a wire substrate, an active material half rectangle that is negative, a separator half rectangle, a spacer half rectangle, and an outer frame that includes a separator half rectangle.
  • the current collector is made of a lead metal sheet and collects current from the active material and delivers it to the negative terminal.
  • Figs. 26G and 26H respectively show assembled and disassembled views of bottom layer 2650 of module 2600 according to some embodiments.
  • Bottom layer 2650 Includes bottom cover 2650C and lower half-electrode frame 2640. Fig.
  • 26H also shows, in accordance with some embodiments, different parts of lower half-electrode frame 2640 which include a gasket, an active material half rectangle that is positive, a spacer, a wire substrate, a potting compound, an inner frame, an acid reservoir for positive plate , an outer frame that includes an isolator half rectangle, a current collector, a positive terminal, and a second gasket,
  • FIGS. 27A and 27B show a 192 volt rectangular module 2700 according to one embodiment.
  • Rectangular module 2700 includes a lid 2710, positive bus 2722 and negative bus 2724, two electrode stacks 2730, center bus 2740, and case 2750. in this embodiment the center bus connects the lower terminal of stacks 2730 together in a series electrical connection,
  • Figs. 28A-D show a circular spiral module 2800 according to some embodiments.
  • Circular spiral module 2800 includes a plurality of partial modules 2810 assembled in a spiraling manner, as described below in more detail,
  • Figs. 28B and 28C show details of partial module 2810 according to some embodiments.
  • Partial module 2830 is shaped as a sector of a circle.
  • partial module 2810 is shaped as a 60 degree angle sector including two 30 degree half sectors with positive and negative active materials,
  • Figs. 28B and 28C show various parts of partial module 2810.
  • Partial module 2810 includes frame 2812, positive and negative active material half sectors 2814 and 2815, wire substrate 2816, isolator half sector 2817, and separator half sector 2818, The negative and positive active materials, the isolator, and the separator function in a manner similar to that explained above in circular plate module 1900 or other similar modules.
  • FIGs. 28A and 28D show the stacking of multiple partial modules 2810 to form circular spiral module 2800, according to some embodiments, in particular, as shown in Fig. 28D, circular spiral module 2800 includes five partial modules 2810-1 to 2810-5, The partial modules are stacked in a spiral manner so that the negative half sector of a partial module is located underneath and connected ionicallv to the positive half sector of the partial module above it.
  • the negative half sector of partial module 2810-1 is located underneath and connected ionicaliy via a separator to the positive half sector of partial module 2810-2.
  • the negative half sector of partial module 2810-2 is located underneath and connected ionicaliy via a separator to the positive half sector of partial module 2810-3, and so on,
  • a set of partial modules 2810 form a group of unit cells connected in series.
  • each unit ceil includes the negative half sector of partial module 2810-1, the positive half sector of the partial module 2810-1+ 1 located above the negative half sector, and the separator between these two half sectors.
  • Each unit cell, thus formed is connected in series with the cells before or after it by the trans-electrode substrates 2816.
  • one unit cell forms between the negative half sector of partial module 2810-1 and the positive half sector of partial module 2810-2 located above it. This unit cell is connected serially to the unit cell before and after it respectively by the trans- electrode substrate 2816 in partial modules 2810-1 and 2810-2.
  • each horizontal arrow shows the conductive transfer of charge from one unit cell to the next one, that is, from the positive half sector of each partial module 2S 10-1 to the negative half sector of the same partial module through the trans-electrode substrate of that partial module.
  • Each vertical arrow shows the ionic transfer of current within each unit cell, that is, from the negative half sector of a partial module 28 0-1 to the positive half sector of the next partial module 2810-!+ 1 positioned above the negative half sector through the separator inserted between them.
  • partial modules 2810-1 to 2810-5 form a serially connected set of four unit cells and two half sectors at the start and the end.
  • Some embodiments include a gasket which prevents internal shorting or electrolyte loss, in some embodiments a gasket prevents electrolyte loss in a manner similar to that explained above in circular plate module 1900 or other similar modules.
  • Fig. 28C for example, internal shorting is mitigated by the current isolator 2817.
  • an electro-chemical battery module is a cylindrical spiral wound module.
  • the cylindrical spiral wound module utilizes an alternative form factor and an alternative manufacturing method.
  • the module is built by winding long strip electrodes of mono- and bipole configurations around a center mandrel to create cylindrical cells for the module. Adjacent cells are connected in electrical series to one another through wire substrates. The cells are housed in a cylindrical, pressure tight case. Cylindrical spiral wound modules, thus built, have fewer parts, higher volumetric efficiency, and higher vibration and pressure resistance compared to their counterparts,
  • Figs. 29A-29C show spiral wound modules 2900 according to various embodiments.
  • Fig. 29A shows an external view.
  • Fig. 29B shows a view of the internal assembled parts, and
  • Fig. 29C shows an exploded view of the parts of spiral wound module 2900 according to various embodiments.
  • Spiral wound module 2900 includes a module case 2902, a case vent 2904, a top cover 2906, a positive terminal 2908, a negative terminal 2910, a positive current collector 2912, a positive half-electrode substrate termination strip 2914, a cylindrical ceil pack 2916, a negative haif-eieetrode substrate termination strip 2938, a negative current collector 2920, a center mandrel 2922, and a bottom cover 2924.
  • cylindrical cell pack 2916 includes six cylindrical cell stacks 2917, connected internally in series via wirings.
  • each ceil pack 2916 provides a two volt potential difference, and thus module 2900 is a twelve volt module.
  • positive half-electrode substrate termination strip 2914 electrically joins positive half-electrode end wiring in a common bus along outer edges and allows easy electrical joining of wiring to positive current collector 2912
  • positive current collector 2912 is a circular metal plate that electrically joins positive half-electrode termination strip to positive terminal 2908.
  • positive current collector 2912 is a low resistance, direct line path to the positive terminal,
  • positive terminal 2908 allows external electrical connection to the module.
  • negative half-electrode substrate termination strip 2918 electrically joins negative half-electrode end wiring in a common bus along outer edges and allows easy electrical joining of wiring to negative current collector 2920.
  • negative current collector 2920 is a circular metal plate that electrically joins negative half-electrode termination strip to negative terminal 2910.
  • negative current collector 2920 is a Sow resistance, direct line path to the negative terminal.
  • negative terminal 2910 allows external electrical connection to the module.
  • Figs. 29D and 29E depict an intermediate stage of manufacturing a cylindrical ceil pack similar to cylindrical cell pack 2916 according to some embodiments.
  • Figs. 29D and 29E each show two different views of a flat cell pack 2966 wh ile being roiled into a cylindrical cell pack.
  • Flat ceil pack 2966 includes six flat cell stacks 2970 and a center mandrel 2972.
  • each cell stack 2970 is a flat elongated strip.
  • each ceil stack 2970 includes four layers as described in more detail in relation to Fig, 3QA.
  • each cell stack 2970 includes alternating layers of electrodes and separators, The ends of those layers are staggered in Figs, 29D and 29E for illustration purposes. Some of neighboring layers of the cell stacks are connected via wirings, as detailed below.
  • Figs. 29D and 29E depict a starting stage of rolling flat cell stacks 2970 around center mandrel 2972 to build a cylindrical cell pack.
  • Figs, 29D and 29E also show- positive and negative half electrode termination strips 2974 and 2976 in their flat configuration, and while being rolled around center mandrel 2972. After the completion the rolling, these strips will take the spiral shape of parts 2914 and 2918 in Fig, 29C.
  • center mandrel 2972 is a cylindrical tube, made of a sulfuric acid-resistant plastic.
  • the material of center mandrel is similar to the material of the module case.
  • the electrodes are wound around the center mandrel.
  • center mandrel 2972 thus supports the electrode assembly.
  • Fig. 3 OA is a 2D sketch showing full- and half-electrode arrangement on the mandrel prior to winding.
  • Fig. 30A shows a cross section of a spiral wound module upon performing one roll of winding the cell stacks around the central mandrel.
  • a sequence of images 3001 - 3005 are used to show details of a cell pack 3000 according to some embodiments.
  • the full cell image 3005 shows a cross section of cell pack 3000 that includes layers resulting from winding a flat cell pack such as cell pack 2966 in Figs, 29D and 29E around a center mandrel 3020 after one full rolling.
  • cell pack 3000 After being wound for one roil, cell pack 3000 includes six cell stacks 3010.
  • Each rectangle in Fig. 30A represents a cross section of a layer of a ceil stack, rolled around center mandrel 3020,
  • Image 3001 shows a central mandrel 3020.
  • Image 3002 shows a layer of separator layer 3030 formed around central mandrel 3020 upon performing one roll of winding the cell stacks around the central mandrel
  • Separator layer 3030 includes six separator half parts 3032. Each separator half part 3032 corresponds to one of the six ceil stacks 3010.
  • separator layer 3030 is made of absorbent glass mat (AGM).
  • AGM absorbent glass mat
  • the separator layer holds electrolytes, such as sulfuric acid and promotes ionic transfer between the positive and negative electrodes of the cell.
  • Image 3003 shows an electrode layer 3040, formed around separator layer 3030 upon performing one roll of winding the cell stacks around the central mandrel.
  • Electrode layer 3040 includes three negative half electrodes 3042. and three positive half electrodes 3044, laid over the six separator half parts 3032 in alternating order.
  • first, third, and fifth half electrodes are positive half electrodes 3044; and second, fourth, and sixth half electrodes are negative half electrodes 3042,
  • the three consecutive neighboring pairs of negative and positive half electrodes are connected via three wirings. That is, as shown in image 3003, three pairs respectively consisting of the first and second half electrodes, the third and fourth half electrodes, and the fifth and sixth half electrodes are each connected via a wiring 3046 (of which, in Fig. 3 OA, all wirings are shown and only the first wiring has been labeled). Each such connected pair forms a bipole electrode 3048 (of which, in Fig. 30A, only the first one has been labeled). Electrode layer 3040, therefore, includes three bipole electrodes 3048.
  • linage 3004 shows a second separator layer 3050 that is formed around electrode layer 3040 upon performing one roll of winding the ceil stacks around the central mandrel.
  • Separator layer 3050 includes six separator half parts 3052. Each separator half part 3052 corresponds to one of the six ceil stacks 3010.
  • Image 3005 shows a second electrode layer 3060 that is formed around separator layer 3050 upon performing one roll of winding the cell stacks around the central mandrel.
  • Electrode layer 3060 includes three negative half electrodes 3062, and three positive half electrodes 3064, laid over the six separator half parts 3052, in an alternating order that is a reverse of the order in electrode layer 3040. That is, each negative half electrode 3062 is Said over a separator half part 3052 that is itself laid over a positive half electrode 3044. Conversely, each positive half electrode 3064 is laid over a separator half part 3052 that is itself laid over a negative half layers 3042. Therefore, as shown in image 3005 of Fig. 30A (assuming that the six half electrodes of electrode layer 3060 are numbered from left to right) first, third, and fifth half electrodes are negative half electrodes 3062; and second, fourth, and sixth half electrodes are positive half electrodes 3064,
  • Cell pack 3000 as shown in stage 3005 of Fig. 30A, thus includes six ceil stacks 3010 rol led around central mandrel 3020,
  • First, third, and fifth ceil stacks each include, in order from top to bottom, a negative half electrode 3062, a separator 3052, a positive half electrode 3044, and another separator 3032.
  • second, fourth, and sixth cell stacks each include, in order from top to bottom, a positive half electrode 3064, a separator 3052, a negative half electrode 3042, and another separator 3032.
  • first and second stacks are connected via a wiring 3046
  • third and fourth stacks are connected via another wiring 3046
  • fifth and sixth stacks are connected via another wiring 3046.
  • second and third stacks are connected via a wiring 3066
  • fourth and fifth stacks are connected via another wiring 3066
  • first and sixth stacks are each connected to th outside via a terminal wiring 3068.
  • the length of ceil stacks are such that they are wound further around the central mandrel. Each additional rolling generates another set of cell stacks similar and on top of those shown In Fig. 30A, image 3005.
  • arrow 3072 depicts that, in the sixth stack 3010, the electrons flow from the positive half electrode 3064 through the separator 3052 to the negative half electrode 3042, and then flow to the positive half electrode 3044 of the fifth stack 3010 through the wiring 3046 that connects the sixth stack to the fifth stack
  • Arrow 3073 depicts that the electron flow continues in the fifth stack 3010 in which the electrons flow from the positive half electrode 3044 through the separator 3052 to the negative half electrode 3062, and then flow to the positive half electrode 3064 of the fourth stack 3010 through the wiring 3066 that connects the fifth stack to the fourth stack.
  • Arrows 3074 and 3076 electron flow paths in the fourth and second stacks, respectively, in a manner similar to that shown by arrow 3072, Further, arrow 3075 shows an electron flow path in the third stack in a manner similar to that shown by arrow 3073, Finally, arrow 3076 also depicts that in the first stack, the electrons flow from positive half electrode 3044 through separator 3052 to negative half electrode 3062,
  • the above-discussed design is used in solid-state batteries, lead acid batteries, fuel cell batteries, or some other types of electrochemical batteries.
  • Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.
  • various elements or components of the disclosed embodiments may be combined with other elements or components of other embodiments, as appropriate for the desired application.
  • the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.

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  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Secondary Cells (AREA)
  • Battery Electrode And Active Subsutance (AREA)
  • Electric Double-Layer Capacitors Or The Like (AREA)
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Abstract

L'invention concerne un dispositif de stockage électrochimique qui comporte une pluralité d'électrodes de couche, chaque électrode de couche comprenant un premier secteur chargé et un second secteur chargé, le second secteur chargé étant chargé de manière opposée par rapport au premier secteur chargé, la pluralité des électrodes de couche étant assemblées les unes avec les autres de telle sorte que le premier secteur chargé d'une première plaque de la pluralité des électrodes de couche est maintenu au-dessous du second secteur chargé d'une seconde plaque de la pluralité des électrodes de couche situées immédiatement au-dessus de la première plaque, les charges des premiers secteurs chargés des première et seconde plaques ayant un premier signe et les charges des seconds secteurs chargés des première et seconde plaques ayant un second signe opposé au premier signe. Ledit dispositif comporte également un secteur de séparateur positionné, et permettant un échange de charges ioniques, entre le premier secteur chargé de la première plaque et le second secteur chargé de la seconde plaque.
PCT/US2013/021287 2012-01-13 2013-01-11 Conception de batterie acide-plomb ayant un facteur de forme polyvalent WO2013106748A1 (fr)

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JP2014552345A JP2015507330A (ja) 2012-01-13 2013-01-11 多用途フォームファクタを有する鉛酸電池設計
CN201380013469.2A CN104160526A (zh) 2012-01-13 2013-01-11 具有通用外形要素的铅酸蓄电池设计
MX2014008544A MX2014008544A (es) 2012-01-13 2013-01-11 Diseño de bateria de plomo-acido que tiene factor de forma versatil.
EP13735954.3A EP2803097A4 (fr) 2012-01-13 2013-01-11 Conception de batterie acide-plomb ayant un facteur de forme polyvalent
AU2013207761A AU2013207761A1 (en) 2012-01-13 2013-01-11 Lead-acid battery design having versatile form factor
IN6227DEN2014 IN2014DN06227A (fr) 2012-01-13 2013-01-11
KR1020147022506A KR20140121439A (ko) 2012-01-13 2013-01-11 다목적 폼 팩터를 갖는 납 축전지 디자인
BR112014017333A BR112014017333A8 (pt) 2012-01-13 2013-01-11 modelo de bateria de chumbo-ácido que tem fator de forma versátil
US13/766,991 US8808914B2 (en) 2012-01-13 2013-02-14 Lead-acid battery design having versatile form factor
US14/145,692 US20140113177A1 (en) 2012-01-13 2013-12-31 Lead-acid battery design having versatile form factor
US14/326,784 US20150010807A1 (en) 2012-01-13 2014-07-09 Lead-acid battery design having versatile form factor
HK15104767.6A HK1204391A1 (en) 2012-01-13 2015-05-19 Lead-acid battery design having versatile form factor
US14/753,478 US20150303436A1 (en) 2012-01-13 2015-06-29 Method of manufacturing a lead-acid battery

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US13/350,686 US20130183572A1 (en) 2012-01-13 2012-01-13 Lead-acid battery design having versatile form factor
US13/350,686 2012-01-13
US13/626,426 2012-09-25
US13/626,426 US9263721B2 (en) 2012-01-13 2012-09-25 Lead-acid battery design having versatile form factor

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CN107026287B (zh) * 2016-06-24 2020-12-22 巨江电源科技有限公司 一种铅酸水平电池的制作方法
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HK1204391A1 (en) 2015-11-13
WO2013106419A1 (fr) 2013-07-18
KR20140121439A (ko) 2014-10-15
AU2013207761A1 (en) 2014-08-14
EP2803097A4 (fr) 2016-02-17
EP2803097A1 (fr) 2014-11-19
CN104160526A (zh) 2014-11-19
BR112014017333A2 (pt) 2017-06-13
JP2015507330A (ja) 2015-03-05
BR112014017333A8 (pt) 2017-07-04
MX2014008544A (es) 2015-02-12

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