WO2019040683A1

WO2019040683A1 - Battery frame member and rechargeable batteries formed therefrom

Info

Publication number: WO2019040683A1
Application number: PCT/US2018/047627
Authority: WO
Inventors: Tadeusz W. Langner; Connor Burke; Benjamin Hertzberg
Original assignee: Eos Energy Storage, Llc
Priority date: 2017-08-24
Filing date: 2018-08-23
Publication date: 2019-02-28
Also published as: WO2019040683A8

Abstract

A frame member (102) for supporting an electrochemical cell of a rechargeable zinc- halogen battery (500) includes an outer undulating frame edge (104), an inner frame edge (106), a front face (108), a back face (109), and an inner flange (112). The inner frame edge opposes the outer frame edge. The back face opposes the front face. At least one of the front face or the back face defines a groove configured to receive a sealing member (128). The inner flange extends laterally inward from the inner frame edge and is configured to provide longitudinal support to an electrode plate (504) of the rechargeable battery. The front and back faces define a plurality of holes (114) formed in outer extending portions (116) of the frame within the outer frame edge. At least one of the front face or the back face defines a plurality of recesses (120).

Description

BATTERY FRAME MEMBER AND RECHARGEABLE BATTERIES FORMED

THEREFROM

CROSS REFERENCE TO RELATED APPLICATION

[0001] This PCT application claims the benefit of U.S. provisional application number 62/549,667, filed on August 24, 2017. This documents is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to a frame member for a zinc-halogen rechargeable battery. Specifically, this invention relates to frame members for zinc-halogen rechargeable batteries wherein the electrolyte remains sequestered in each battery cell throughout battery cycling and is not circulated between a reservoir and a reaction chamber during battery operation.

BACKGROUND

[0003] This section provides background information related to the present disclosure and is not necessarily prior art.

[0004] Battery frame assemblies and frame members are used to support battery electrodes and electrolyte and form a portion of the mechanical design of a battery. A frame member comprises a frame, often rectangular in shape, with an open inner space for positioning electrodes and filling with electrolyte. Frame assemblies may also include seals, such as O- rings, to provide a liquid-tight seal between adjacent frames. Frame assemblies should preferably provide one or more advantages, such as being low cost, being easy to

manufacture, contributing to the safety of the battery, contributing to the ease of operation of the battery, and contributing to the performance of the battery.

[0005] While known battery frame assemblies have proven useful for their intended purpose, there remains a need for continuous improvement in the pertinent art.

SUMMARY

[0006] One aspect of the present invention provides a frame member for supporting an electrode (e.g., a bipolar electrode) in a zinc-halogen rechargeable battery comprising an outer undulating frame edge; an inner frame edge opposing the outer undulating frame edge; a front face; a back face opposing the front face; and an inner flange extending laterally inward from the inner frame edge, wherein at least one of the front face or the back face defines a first groove configured to receive a sealing member, the front and back faces define a plurality of holes formed in outward extending portions of the frame member within the outer undulating frame edge, at least one of the front face or the back face defines a first plurality of recesses, and a first recess of the first plurality of recesses is disposed adjacent to a first hole of the plurality of holes.

[0007] In some embodiments, portions of the frame member surrounding the holes and recesses have a substantially even thickness.

[0008] In some embodiments, the frame member further comprises an outer portion that comprises a first material and an inner portion comprising a second material. In some examples, the first material is selected from polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (cPVC), acrylonitrile butadiene styrene (ABS), or any combination thereof. And, in some examples, the first material is filled with glass fibers or clay filler material. In other examples, the second material is selected from high density polyethylene (HDPE), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a high molecular chloro wax, PVC, or cPVC. In some embodiments, the inner portion is over- molded onto the outer portion.

[0009] In some embodiments, the outer portion of the frame member comprises a first plurality of locking recesses in the outer portion, a first plurality of locking portions in the inner portion, or both. For example, in some embodiments, the locking portions of the inner portion are configured to mate with the locking recesses in the outer portion.

[0010] In some embodiments, the frame member comprises a second plurality of recesses extending from the back face toward the front face and opposing the first plurality of recesses.

[0011] In some embodiments, the first plurality of recesses are molded in the inner portion and substantially surrounded by the outer portion.

[0012] In some embodiments, the frame member comprises a first sealing member disposed along the first groove. In some examples, the first sealing member is an O-ring. In other examples, the first sealing member is a U-channel seal.

[0013] In some embodiments, the frame member further comprises a second groove in the front face or back face and opposing the first groove, for receiving a second sealing member.

In some instances the second sealing member is an O-ring or a U-channel seal.

[0014] In some embodiments, the frame member further comprises a fill hole extending from the outward undulating frame edge through to the inner frame edge.

[0015] In some embodiments, the frame member further comprises a pressure relief valve located within a cavity in the frame member, wherein the cavity extends from the outward undulating frame edge through the inner frame edge. [0016] In some embodiments, the inner flange comprises an upper portion and a lower portion, wherein the upper portion of the inner flange has a greater inwardly extending length than the lower portion of the inner flange and defines an aperture and a channel, wherein the aperture and the channel are configured to allow fluid communication from the front face to the back face.

[0017] In some embodiments, the frame member further comprises a ramped protrusion along the inner frame edge adjacent to the upper portion of the inner flange.

[0018] Another aspect of the present invention provides a frame member for supporting an electrode in a zinc-halogen rechargeable battery comprising an outer undulating frame edge; an inner frame edge opposing the outer undulating frame edge; a front face; a back face opposing the front face; and an inner flange extending laterally inward from the inner frame edge and comprising an upper portion and a lower portion, wherein at least one of the front face or the back face defines a first groove configured to receive a first sealing member, wherein the upper portion of the inner flange has a greater inwardly extending length than the lower portion of the inner flange and defines an aperture and a channel, wherein the aperture and the channel are configured to allow fluid communication from the front face to the back face of the frame member.

[0019] In some embodiments, the aperture is positioned laterally above the channel.

[0020] In some embodiments, the channel is formed in a lower edge of the upper portion of the inner flange.

[0021] In some embodiments, the frame member further comprises a ramped protrusion along the inner frame edge adjacent to the upper portion of the inner flange.

[0022] Another aspect of the present invention provides a frame member for supporting an electrode in a zinc-halogen rechargeable battery comprising an outer undulating frame edge; an inner frame edge opposing the outer undulating frame edge; a front face; a back face opposing the front face; an inner flange extending laterally inward from the inner frame edge; a plurality of collars; and an outer rim, wherein at least one of the front face or the back face defines a first groove for receiving a sealing member, the front and back faces define a plurality of holes formed in outward extending portions of the frame member within the undulating outer frame edge, the plurality of collars extend longitudinally away from the holes, and the outer rim disposed along the outer undulating frame edge and extending longitudinally beyond the back face.

[0023] In some embodiments, the frame member further comprises one or more weep holes in a bottom portion of the outer undulating frame edge. [0024] In some embodiments, the collars are sleeved with PVC shrink wrap.

[0025] In some embodiments, the circumference of the collars decreases as the collars extend longitudinally away from the front face.

[0026] Another aspect of the present invention provides a frame member for supporting an electrode in a zinc-halogen rechargeable battery comprising an outer undulating frame edge; an inner frame edge opposing the outer undulating frame edge; a front face; a back face opposing the front face; an inner flange extending laterally inward from the inner frame edge; and a sloped surface, wherein at least one of the front face and the back face define a first groove for receiving a sealing member, and the sloped surface is disposed laterally across a bottom portion of the frame member and extends longitudinally away from the inner flange and slopes upward as it extends away from the inner flange.

[0027] In some embodiments, the sloped surface forms a concave profile as it extends longitudinally away from the inner flange.

[0028] In some embodiments, the frame member further comprises one or more inner members extending across a portion of the frame member from a first position on the inner flange to a second position of the inner flange to provide additional longitudinal support to the electrode.

[0029] Another aspect of the present invention provides a frame assembly comprising a first frame member comprising a first outer undulating frame edge, a first inner frame edge opposing the first outer undulating frame edge, a first front face, a first back face opposing the first front face, a first inner flange extending laterally inward from the first inner frame edge, a plurality of collars, and an outer rim, wherein the first front face defines a first groove for receiving a sealing member, the first front and back faces define a first plurality of holes formed in outward extending portions of the first frame member within the undulating outer frame edge, the plurality of collars extend longitudinally away from the holes, and the outer rim is disposed along the first outer undulating frame edge and extending longitudinally beyond the back face of the first frame member; a second frame member comprising a second outer undulating frame edge, a second inner frame edge opposing the outer undulating frame edge, a second front face, a second back face opposing the second front face and having a plurality of receiving portions that are configured to mate with the plurality of collars of the first frame member, a second inner flange extending laterally inward from the second inner frame edge, and an outer rim, wherein, the second front and back faces define a second plurality of holes formed in outward extending portions of the frame member within the undulating outer frame edge; and a sealing member that is seated in the first groove of the first frame member.

[0030] In some embodiments, the frame assembly further comprises tie rods extending through the first plurality of holes defined by the first front and back faces of the first frame member and the second plurality of holes defined by the second front and back faces of the second frame member.

[0031] Another aspect of the present invention provides a rechargeable zinc halogen battery comprising a first frame member comprising a first outer undulating frame edge, a first inner frame edge opposing the outer undulating frame edge, a first front face, a first back face opposing the front face, a first inner flange extending laterally inward from the inner frame edge, and a first sloped surface disposed laterally across a bottom portion of the frame member and extending longitudinally, wherein the first front face defines a first groove configured to receive a sealing member, the first front and back faces define a plurality of holes formed in outward extending portions of the frame member within the outer undulating frame edge, at least one of the first front face or the back face defines a first plurality of recesses, and a first recess of the first plurality of recesses is disposed adjacent to a first hole of the plurality of holes, and the first sloped surface slopes upward as it extends away from the first inner flange; and an electrode plate (e.g., a bipolar electrode plate), wherein the electrode plate is configured to be received within the first inner frame edge and to be supported by the inner flange of the first frame member.

[0032] In some embodiments, portions of the first frame member surrounding the holes and recesses have substantially even thickness.

[0033] In some embodiments, the first frame member further comprises an outer portion that comprises a first material and an inner portion comprising a second material. And, in some embodiments, the first material is selected from polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (cPVC), acrylonitrile butadiene styrene (ABS), or any combination thereof. In other embodiments, the first material is filled with glass fibers or clay filler material.

[0034] In some embodiments, the second material is selected from high density polyethylene (HDPE), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a high molecular chloro wax, PVC, or cPVC.

[0035] In some embodiments, the inner portion is over-molded onto the outer portion.

[0036] In some embodiments, the first sealing member is an O-ring or U-channel. [0037] In some embodiments, the first frame member further comprises a fill hole extending from the outward undulating frame edge through to the inner frame edge.

[0038] In some embodiments, the first frame member further comprises a pressure relief valve located within a cavity in the first frame member, wherein the cavity extends from the outward undulating frame edge through the inner frame edge.

[0039] In some embodiments, the first inner flange of the first frame member comprises an upper portion and a lower portion, wherein the upper portion of the first inner flange has a greater inwardly extending length than the lower portion of the inner flange and defines an aperture and a channel, wherein the aperture and the channel are configured to allow fluid communication from the front face to the back face of the first frame member, and the channel and the aperture are configured to be substantially unobstructed by the electrode plate, when the electrode plate is received by the first frame member.

[0040] In some embodiments, the first frame member further comprises a plurality of collars extending longitudinally away from the holes defined by the front face of the first frame member.

[0041] In some embodiments, the rechargeable battery further comprises a second frame member, wherein the second frame member comprises a second outer undulating frame edge, a second inner frame edge opposing the second outer undulating frame edge, a second front face, a second back face opposing the second front face, a second inner flange extending laterally inward from the second inner frame edge, and a second sloped surface disposed laterally across a bottom portion of the second frame member and extending longitudinally, wherein the second front face defines a second groove configured to receive a second sealing member, the second front and back faces define a plurality of holes formed in outward extending portions of the second frame member within the second outer undulating frame edge, at least one of the second front face or the back face defines a second plurality of recesses, and a second recess of the second plurality of recesses is disposed adjacent to a second hole of the plurality of holes, and the second sloped surface slopes upward as it extends away from the second inner flange.

[0042] In some embodiments, the second frame member further comprises a second plurality of collars extending longitudinally away from the holes defined by the front face of the second frame member.

[0043] In some embodiments, the first frame member further comprises a plurality of receiving portions that are defined by the back face of the first frame member and are configured to mate with the collars of the second frame member. [0044] In some embodiments, the second frame member further comprises a second plurality of receiving portions defined by the second back face that are configured to mate with the first plurality of collars of the first frame member.

[0045] In some embodiments, the rechargeable battery further comprises an electrolyte, wherein the electrolyte comprises zinc cations, zinc bromide, zinc chloride, or any combination thereof.

[0046] In some embodiments, the first frame member and the second frame member are horizontally stacked and vertically oriented, wherein the first outer edge of the first frame member is substantially coplanar with the second outer edge of the second frame member.

[0047] The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

DRAWINGS

[0048] The drawings described herein are by way of example and are not intended to limit the scope of the present invention.

[0049] FIG. 1 is a front view of a frame member according to one embodiment of the present invention.

[0050] FIG. 2 is a right side view of the frame member of FIG. 1.

[0051] FIG. 3 is a cross-sectional view of the frame member of FIG. 1 taken along line A-A of FIG. 1.

[0052] FIG. 4 is a back view of the frame member of FIG. 1.

[0053] FIG. 5 is a perspective view of the frame member of FIG. 1 with a sealing member shown in an exploded view.

[0054] FIG. 6 is a front view of another frame member according to one embodiment of the present invention, wherein this embodiment comprises a pressure relief valve.

[0055] FIG. 7 is a top view of the frame member of FIG. 6.

[0056] FIG. 8 is a cross-sectional view of the frame member of FIG. 6 taken along line B-B of FIG. 6.

[0057] FIG. 9 is a front view of another frame member according to one embodiment of the present invention, wherein this embodiment comprises a fill hole.

[0058] FIG. 10 is a top view of the frame member of FIG. 9.

[0059] FIG. 11 is a cross-sectional view of the frame member of FIG. 9 taken along lines C- C of FIG. 9. [0060] FIG. 12 is a front view of another frame member according to one embodiment of the present invention, wherein the frame member comprises two opposing sets of collars.

[0061] FIG. 13 is a side view of the frame member of FIG. 12.

[0062] FIG. 14 is a perspective, partially-exploded view of a rechargeable zinc-halogen battery according to the present invention, wherein the rechargeable battery comprises a plurality of stacked frame members and electrode plates received therein.

[0063] FIG. 15 is a side view of the fully assembled rechargeable battery of FIG. 14.

[0064] Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

[0065] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

[0066] I. DEFINITIONS

[0067] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and

"having," are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

[0068] When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or" comprises any and all combinations of one or more of the associated listed items.

[0069] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

[0070] The terms, upper, lower, above, beneath, right, left, etc. may be used herein to describe the position of various elements with relation to other elements. These terms represent the position of elements in an example configuration. However, it will be apparent to one skilled in the art that the frame member may be rotated in space without departing from the present disclosure and thus, these terms should not be used to limit the scope of the present disclosure.

[0071] As used herein, "undulating" refers to an outline having one or more outer curved sections that extend away from one or more inner sections and comprises wave-like, sinusoidal, or scalloped outlines.

[0072] As used herein, "over-molding" refers to a process of adding an additional layer of material by injection molding over an already existing piece or part.

[0073] As used herein, "plurality" refers to two or more of the element being described. In some embodiments, plurality refers to three or more, four or more, or five or more of the element being described.

[0074] As used herein, "chemically compatible" refers to a material that does not interfere with the chemistry of an electrochemical cell in a way that meaningfully negatively impacts the performance of the electrochemical cell. The chemically compatible material is chemically compatible with electrolyte (e.g., zinc-halide electrolyte, alkaline electrolyte) and anode and cathode materials. [0075] As used herein, "chemically inert" refers to a material that does not chemically react in any meaningful way with the electrolyte, anode, or cathode of an electrochemical cell.

[0076] II. FRAME MEMBER

[0077] Referring to FIG. 1, a battery frame member 102 (sometimes referred to as a "neutral- type" frame member or first frame member) is provided. As shown in FIG. 15, zinc-halogen rechargeable batteries of the present invention comprise at least one frame member, and in this illustration, a plurality of battery frame members 102, 202, 302, 402 are horizontally stacked together and vertically oriented to form a portion of a rechargeable battery 500.

Returning, to FIG. 1, as illustrated, the frame member 102 may include an outer undulating frame edge 104, an inner frame edge 106, a front face 108 and a back face 109 (illustrated in FIG. 4). The outer undulating frame edge 104 may include one or more outer curved (e.g., concave) sections 104a that extend away from one or more inner sections 104b and define a wave-like, sinusoidal, or scalloped outline. For example, as shown in FIG. 1, the outer undulating frame edge 104 has three curved sections 104c extending along each side of the frame member 102. Alternatively, the outer undulating frame edge 104 may have a single curved section 104c, two curved sections 104c, or more than three curved sections 104c (e.g., 4, 5, 6, etc.). The outer undulating frame edge 104 may also have a different number of undulations along different sides of the frame member 102.

[0078] A neutral -type frame member 102 is shown in FIG. 1 having a substantially rectangular shape. The frame member 102 may alternatively have a substantially square shape or other polygonal or curved shape. The shape of the frame member 102 may be configured to surround and/or receive an electrode plate (e.g., a bipolar electrode plate). For example, FIG. 14 shows the orientation of a bipolar electrode plate 505 within the frame member 102. As shown in FIG. 1, the inner frame edge 106 forms a substantially rectangular edge. The inner frame edge 106 may have an alternative shape (e.g., square, polygonal, circular, trapezoidal, oval, or the like), and may be configured to receive an electrode plate (e.g., a bipolar electrode plate). The inner frame edge 106 may provide outer lateral support to an electrode plate (e.g., a bipolar electrode plate) along one or more sides of the plate. The lateral directions may be defined by X- and Y-axes, as illustrated in FIG. 1. In this regard, the inner frame edge 106 may inhibit movement of the electrode plate along the X- and Y- axes.

[0079] A variety of features may be formed in the front face 108 or back face 109 of the neutral -type frame member 102. For example, a first groove 110 may be formed in the front face 108 of the frame member 102, and a second groove 111 may be formed in the back face 109. In some embodiments, the first groove 110 may oppose the second groove 111. For example, the first groove 110 may extend peripherally around the front face 108 and the second groove 111 may extend peripherally around the back face 109. The grooves 110, 111 may be defined by a pair of sidewalls 110a, 110b, 111a, 11 lb having a plurality of nubs 152 for holding a sealing member 128 (see FIG. 5), such as an O-ring or U-channel seal, for example, in the grooves 110, 111. The grooves 110, 111 may be defined by squared edges or may have a U-shaped cross section, as in a U-channel groove. The sealing member 128 (see FIG. 5) may be seated in the grooves 110, 111 and provide a fluid-tight seal between adjacent frame members 102 (i.e., of the frame assembly 501 of FIG. 15).

[0080] The neutral-type frame member 102 may also include an inner flange 112 extending laterally inward from the inner frame edge 106. For example, the inner flange 112 may extend inwardly along the X- and Y-axes relative to the frame edge 106. The inner flange 112 may also form a substantially rectangular edge for supporting an electrode plate.

Alternatively, the inner flange 112 may have a different shape (e.g., square, polygonal, curved). The inner flange 112 provides longitudinal support for an electrode plate. The longitudinal direction may be defined by the Z-axis, as illustrated in FIG. 1. In this regard, the inner flange 112 may inhibit movement of the electrode along the Z-axis. As shown in FIG. 14, an electrode plate 505 may rest (or be received) on the inner flange 112 and, optionally, may also be coupled to the inner flange 112. For example, the electrode plate 505 may optionally be coupled to the inner flange 112 with an adhesive.

[0081] With continued reference to FIG. 1, the inner flange 112 may be substantially longitudinally centered on the inner frame edge 106. In some embodiments, at least a portion of the inner flange 112 extends laterally inward from the frame edge 106 at a distance X. The inner flange 112 may have an upper portion 134. The upper portion 134 may extend laterally inward from the frame edge 106 at a distance Y. In some instances, the distance Y of the extension of the flange may be greater than the distance X of the extension of the flange. For example, the upper portion 134 may extend laterally inward at the distance Y, while left 134a, right 134c and bottom 134b portions of the flange may extend laterally inward at the distance X.

[0082] One or more apertures 136 and/or one or more channels 138 may be formed through the upper portion 134 of the flange. The one or more apertures 136 allow fluid

communication of gases and/or liquid from the front face of the frame member to the back face of the frame member and vice versa. In some embodiments, the one or more apertures 136 are configured to provide fluid communication of gases from one battery cell comprising a frame member and electrode plate to one or more immediately adjacent battery cells comprising another frame member and electrode plate when the frame members are stacked to assemble a rechargeable battery, the assembled battery is filled with sufficient volumes of liquid electrolyte to provide a head space in the assembled battery, and when apertures reside in the head space of the assembled battery. In these embodiments, the one or more apertures 136 allow pressure that builds in the battery cell comprising the frame member 102 to be dispersed evenly across multiple battery cells and to be dissipated through a pressure relief valve 230 (see FIG. 7) present in a subset (one or more) of the frame members 102 of the frame assembly 501 (see FIG. 15).

[0083] In some embodiments, the upper portion 134 of the flange also comprises one or more channels 138 that are configured to allow fluid communication of electrolyte between adjacent battery cells of the frame assembly 501 (see FIG. 15). The one or more channels 138 allow for filling the entire battery with electrolyte through a fill hole 332 (see FIG. 10) present in a subset (one or more) of the frame members of the frame assembly 501. The one or more channels 138 also allow for even distribution of electrolyte between adjacent battery cells. These features (e.g., apertures 136 and channels 138) allow for a frame assembly 501 to have many frame members 102, 202, 302, 402 but with only a subset of the frame members having a pressure relief valve 230 ("vent-type" frames 202, see FIG. 6) or a fill hole 332 ("fill-type" frames 302, see FIG. 9). For example, as shown in FIG. 15, a frame assembly 501 may consist of a large number (e.g., ten or more) of neutral-type frames 102, and a small number (e.g., one or two) vent-type frames 202 and fill-type frames 302

(discussed in more detail below). FIG. 1 shows the channels 138 formed along an inner edge 158 of the upper portion 134 of the inner flange 112. The channels 138 may be configured to align with corresponding holes (not shown) in an electrode plate 505 (FIG. 14) that is supported by the inner flange 112 to allow for an electrolyte to flow through the channels 138 and through the corresponding holes in the electrode plate 505.

[0084] The neutral -type frame member 102 may also include one or more inner members 150 that extend across from one position of the inner flange 112 to another position of the inner flange 112 and provide additional longitudinal support for an electrode plate. For example, the inner members 150 may extend from the upper portion 134 to the left and right portions 134a, 134c of the inner flange 112 and from the bottom portion 134b to the left and right portions 134a, 134c. In this regard, the inner members 150 may extend from one side of the inner flange 112 to an adjacent side of the inner flange 112. The inner members 150 may be curved along their major axis, and may collectively define a circular or oval shape. The inner members 150 may define a tubular shape having a thin, circular cross section.

[0085] The neutral -type frame member 102 may also include one or more ramped protrusions 140 formed along the inner frame edge 106. The ramped protrusion 140 may surround the opening of a fill hole 332 (FIG. 9) or cavity containing a pressure relief valve 230 (FIG. 6) on the inner frame edge 106. The ramped protrusion 140 may include a substantially flat central portion 163 (FIG. 3) and a sloped outer portion 164 (FIG. 3) extending laterally outwards from the flat central portion 162. The ramped protrusion 140 may function to keep the upper edge of an electrode positioned slightly away from the upper side of the inner frame edge 106. The ramped protrusion 140 may provide the benefit of faster filling times while avoiding the formation of an electrolyte film on metal surfaces.

[0086] The neutral-type frame member 102 may also include a plurality of holes 114. The holes 114 may be bolt holes configured to receive a tie rod 510 (see FIG. 14) that helps hold frames 102, 202, 302, 402 together (e.g., in a compressed configuration) in a frame assembly 501. The tie rod 510 that is received by the holes 114 may apply a longitudinal compressive force to the frame assembly 501. The holes 114 extend from, and through, the front face 108 to, and through, the back face 109. In some embodiments, the holes 114 may be formed in an outer extending portion 116 of the frame member 102 inside the undulating outer frame edge 104.

[0087] Adjacent to the holes 114, e.g., directly adjacent, the frame member 102 may also include a plurality of recesses 120. The recesses 120 extend at least partially longitudinally inward from the front 108 and/or back face 109 of the frame member 102. The holes 114 and recesses 120 may be shaped and sized so as to cover most (e.g., more than fifty percent) of the area of the outer extending portions 116 of the frame member 102. The remaining portions of the frame member 102 surrounding the holes and the recesses may have a substantially uniform thickness in between the holes 114 and recesses 120, and may also have a substantially uniform thickness between the holes 114, recesses 120, outer undulating frame edge 104 and a portion of the frame that is directly adjacent to and laterally outside of the groove 110. The substantially uniform thickness may be due to the relative size, shape and positioning of the holes 114 and recesses 120.

[0088] In some examples, each outer extending portion 116 of the frame has a hole 114 and two recesses 120 adjacent to the hole 114 (e.g., surrounding a substantial portion of the circumference of the hole). The recesses 120 may provide advantages such as mechanical strength, reduced weight, and evening frame member shrinkage upon cooling during the molding process for making the frame member. The recesses 120 may also be used as mechanical interlocking joints for a two-piece frame construction where a first inner piece 126 is joined with (or over-molded with) a second outer piece 124. One or more outer extending portions 116 (e.g., each outer extending portion) may have one bolt hole 114 and one, two, three or more recesses (e.g., two recesses) 120 that together span a majority, e.g., substantially all of, the outer extending portion 116. One or more outer extending portions 116 (e.g., each outer extending portion) may have a hole 114 that is substantially centered within the outer extending portion. One or more recesses (e.g., two recesses) 120 may be positioned adjacent to the substantially centered hole 114.

[0089] The neutral -type frame member 102 may include the outer piece 124 and the inner piece 126. The two pieces or portions may include different materials. For example, the first piece 124 may be an outer portion (e.g., surrounding the second piece 126) and may include a first material, and the second piece 126 may be an inner portion (e.g., disposed within the first piece 124) and may include a second material. The first material of the first piece 124 may include a structural, non-conductive, flame retardant material. In some examples, the first material of the first piece comprises polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (cPVC), acrylonitrile butadiene styrene (ABS), any combination thereof, or the like. And, in some instances, the first material is filled with a non-conductive filler material to improve its mechanical strength or impart the material with other beneficial properties. For example, the first material is filled with a filler material selected from glass fibers (e.g., D.P. glass fibers) or clay filler material. And, in some examples, the first material is unfilled polypropylene or polypropylene filled with glass fibers. The first piece 124 may include (or define) one or more of the following elements of the frame: the outer undulating frame edge 104, the outer extending portions 116, the holes 114, the collars 142, and the recesses 120.

[0090] The second material of the second piece 126 may be a chemically compatible material, such as a chemically inert, non-conductive material. In some examples, the second material of the second piece comprises a material that is substantially chemically inert to elemental bromine. For instance, the second material comprises high density polyethylene (HDPE), a fluoro elastomer (e.g., polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a high molecular chloro wax, PVC, cPVC, or the like. In some instances, the second material comprises HDPE. The second piece 126 may include or surround one or more of the following elements of the frame: the recesses 120, the groove(s) 110, 111, the inner frame edge 106, the inner flange 112, the sloped surface 148 and the inner members 150. [0091] In some configurations, the inner piece 126 and outer piece 124 are interlocked via locking portions 160 of the inner piece 126 that lock into recesses 120 in the outer piece 124. The locking portions 160 of the inner piece 126 may also be recessed to form the recesses 120. The locking portions 160 of the inner piece 126 may be connected to the remainder of the inner piece 126 by a connector 162 that extends through a corresponding slot 162a in the outer piece 124.

[0092] The inner piece 126 and/or outer piece 124 may be manufactured by injection molding. The inner piece 126 may be over-molded onto the outer piece 124. Alternatively, the outer piece 124 may be over-molded onto the inner piece 126. For example, the material of the inner piece 126 may be injection molded over at least a portion of the outer piece 124. And alternatively, the material of the outer piece 124 may be injection molded over at least a portion of the outer piece 126.

[0093] The neutral-type frame member 102 may also include a sloped surface 148 along a bottom portion of the inner frame edge 106. The sloped surface 148 may extend laterally across the bottom frame portion of the inner frame edge 106 and longitudinally away from the inner flange 112 and slope upward as it extends away from the inner flange 112. The sloped surface 148 may be at an angle from about 1 degree to about 89 degrees relative to (i.e., above) the longitudinal axis (Z). For example the sloped surface 148 may be at an angle of from about 5 degrees to about 60 degrees. The sloped surface 148 may also have a curved (e.g., concave) slope that steepens as it extends away from the inner flange 112.

[0094] Referring now to FIG. 2, a side view of the neutral -type frame member 102 of FIG. 1 is provided. The frame member 102 may have a plurality of collars 142 (also shown as 142 in FIG. 1) extending longitudinally away from the plurality of holes 114. The collars 142 may decrease in circumference as they extend away from the holes 114 so as to form a tapered- or frustoconically-shaped collar. The frame member 102 may also have an outer rim 144 disposed along a back edge of the outer undulating frame edge 104. The outer rim 144 may extend longitudinally beyond the back face 109 of the frame member 102. The outer rim 144 may also extend laterally beyond the outer undulating frame edge 104. In an assembled configuration, the outer rim 144 of a frame (e.g., frame member 102, 202, 302, 402) may receive and laterally support a portion of the outer undulating frame edge 104 of an adjacent frame member (e.g., frame member 102, 202, 302, 402).

[0095] Referring to FIG. 3, a cross-sectional view taken along line A-A of FIG. 1 shows the shape of the ramped protrusion 140. The ramped protrusion 140 may include a flat portion 163 in its center and sloped outer portions 164 on the sides that slope back to the inner frame edge 106. The cross-sectional view of FIG. 3 also shows the slope of the sloped surface 148. In some embodiments, the sloped surface 148 has a concave upward slope that increases in steepness as it extends longitudinally away from the inner flange 112.

[0096] Referring to FIG. 4, a back view of the neutral -type frame member 102 of FIG. 1 shows the back face 109 of the frame member 102. The frame member 102 may also include one or more weep holes 146. The weep holes 146 may be formed in the outer undulating frame edge 104 at the apex of the outer extending portions 116. The weep holes 146 may extend from the bottom edge of the holes 114 to the outer undulating frame edge 104 along the bottom edge of the frame member 102. The weep holes 146 may allow electrolyte that leaks beyond the sealing member to exit the frame assembly 501. As such, the weep holes 146 may direct the leaked electrolyte away from the bolt holes and tie rods of the battery to avoid shorting of the battery and alleviate safety issues related to leaking of the electrolyte.

[0097] The plurality of holes 114 may each have a receiving portion 154 configured to sealingly receive the plurality of collars 142 (e.g., tapered collars). The receiving portion 154 extends partially through from the back face 109 to the front face 108, e.g., about halfway through. The receiving portion 154 may have a circumference greater than the remainder of the hole 114 to receive the collars 142. When a collar 142 of a first of the frame members (e.g., frame member 102, 202, 302, 402) is inserted in the receiving portion 154 of a second of the frame members (e.g., frame member 102, 202, 302, 402), a uniform opening may be formed that is configured to sealingly receive a bolt. The back of the sloped surface 148 is also illustrated in FIG. 4, showing the greatest height of the sloped surface 148 at its point farthest away from the inner flange 112.

[0098] Referring to FIG. 5, a perspective view of the neutral -type frame member 102 of FIG. 1, with an exploded view of sealing members 128, 129 is provided. The sealing members 128, 129 are shown in an exploded view lined up longitudinally with their configuration within the grooves 110, 111. The sealing member 128 may be an O-ring or U-channel seal. In an assembled configuration, the sealing member 128 will be seated within the groove 110 and held in place by a compressive force from the nubs 152. In some configurations, the groove may have a U-shape and may be a so-called U-channel groove. The sealing member 128 may be held within the groove 110 by an adhesive. The perspective view of FIG. 5 also illustrates the inner portion 126 and outer portion 124.

[0099] Referring to FIG. 6, another frame member 202 (sometimes referred to as a "vent- type" frame member or third frame member) for use with the frame assembly 501 (FIG. 15) is illustrated. The vent-type frame member 202 may be substantially similar to the neutral- type frame member 102 except as otherwise shown or described herein. Accordingly, the structure and function of similar features will not be described again in detail.

[0100] The vent-type frame member 202 may include a pressure relief valve 230. The pressure relief valve 230 may be located in a cavity 232 that extends from an outer undulating frame edge 204 to an inner frame edge 206. The cavity 232 may be equivalent to the fill hole 332 discussed below, with a pressure relief valve 230 disposed therein. A through-channel 231 may be formed in an inner flange 212 adjacent to the pressure relief valve 230. The through-channel 231 may allow for fluid communication between the inside of the frame member 202 and the pressure relief valve 230. For example, head space gas inside the frame member 202 may be in fluid communication with the pressure relief valve 230 via the through-channel 231.

[0101] Referring to FIG. 7, the pressure relief valve 230 may be located in the top side of the outer undulating frame edge 204 and extend laterally beyond the outer undulating frame edge 204. The outer undulating frame edge 204 may have a substantially flat portion 204d in which the pressure relief valve 230 is located. The pressure relief valve 230 may be any suitable pressure relief valve that releases pressure from inside the frame member 202.

Pressure may build up as a result of gases trapped inside the frame assembly 501, including air released during filling from within the pores of a carbon felt material affixed to the electrode plate. Electrochemical reactions may also generate gases and pressure within the frame assembly 501 that may be released via the pressure relief valve 230. The pressure relief valve 230 may be an umbrella-type pressure relief valve, screw-type pressure relief valve or other form of pressure relief valve. Pressure may be relieved through the pressure relief valve 230 of one or more frame members 202 of a frame assembly 501 including a plurality of frames, 102, 202, 302, 402.

[0102] Referring to FIG. 8, a cross-sectional view taken along lines B-B of FIG. 6 shows the configuration of the pressure relief valve 230 through the frame member 202.

[0103] Referring to FIG. 9, another frame member 302 (sometimes referred to as a "fill-type" frame member or second frame member) for use with the frame assembly 501 (FIG. 15) is illustrated. The frame member 302 may be substantially similar to the frame member 202 except as otherwise shown or described herein. Accordingly, the structure and function of similar features will not be described again in detail.

[0104] The fill-type frame member 302 includes a fill feature (e.g., a fill hole) 332. In this regard, the fill-type frame member 302 may be substantially similar to the neutral-type frame member 102 but with a fill feature 332. The fill hole 332 may be in substantially the same location as the pressure relief valve 230 on the vent-type frame member 202. The fill hole 332 may be located in the top side of the outer undulating frame edge 304 and extend through to the inner frame edge 306. The outer undulating frame edge 304 may have a substantially flat portion 304d in which the fill hole 332 is located. A through-channel 331 may be formed in the inner flange 312 adjacent to the fill hole 332. The through-channel 331 may allow for fluid communication between the inside of the frame member 302 and the fill hole 332. For example, the frame assembly 510 of a rechargeable battery may be filled with electrolyte through the fill hole 332 of a fill-type frame member 302 and enter the inside of the fill-type frame member 302 via the through-channel 331. The fill-type frame member 302 may further include a cap that plugs the fill hole 332 after filling with electrolyte to close the cell. The cap may be threaded and configured to screw into corresponding female threads in the fill hole 332. The cap may provide an air-tight seal when plugging the fill hole 332.

[0105] Referring to FIG. 10, a top view of a fill-type frame member 302 is shown. The fill- type frame member 302 includes a fill hole 332. The outer undulating frame edge 304 may have a substantially flat portion 304d in which the fill hole 332 is located. Electrolyte may fill the frame assembly 501 through a fill hole 332 in one or more fill-type frame members 302 of a frame assembly 501 including a plurality of frames members 102, 202, 302, 402.

[0106] Referring to FIG. 11, a cross-sectional view taken along line C-C of FIG. 9 shows the configuration of the fill hole 332 through the frame member 302. A ramped protrusion 340, having a flat portion 362 and a sloped portion 364, may function to allow for filling the frame assembly 501 of a rechargeable battery with electrolyte with faster fill times while avoiding other problems such as shorting of the battery and pressure build up.

[0107] Referring now to FIG. 12, another frame member 402 (sometimes referred to as a "negative-type" frame member or fourth frame member) for use in the frame assembly 501 (FIG. 15) is illustrated. The negative-type frame member 402 may be substantially similar to the neutral -type frame member 102 except as otherwise shown or described herein.

Accordingly, the structure and function of similar features will not be described again in detail.

[0108] As illustrated in FIG. 13, the negative-type frame member 402 may include collars 442, 456 extending in opposite longitudinal directions away from the frame member 402. The negative-type frame member 402 may sit adjacent to a negative terminal of a battery and provide mechanical connection on one side for a frame member 102, 202, 302 and on the opposite side for an end plate, terminal, terminal insulator, and/or compression plate. For example, in an assembled configuration, the first collars 442, may be disposed within, or otherwise received by, a receiving portion 154 of an adjacent frame member 102, 202, 302; and the second collars 456 may be disposed within, or otherwise received by, an end plate, terminal, terminal insulator and/or compression plate. The negative-type frame member 402 may lack an outer rim 144. Other features of the negative-type frame member 402 may be consistent with the other frames members 102, 202, 302 described herein.

[0109] III. RECHARGEABLE ZINC-HALOGEN BATTERIES

[0110] Referring now to FIG. 14 a battery 500 is shown having a frame assembly 501. The frame assembly 501 comprises one or more (e.g., a plurality) of frames (102, 202, 302, 402) from FIGS. 1-13. The frame assembly 501 may be a horizontal stack (i.e., stacked along a horizontal, longitudinal axis) with the frame members that are vertically oriented (i.e., oriented in vertical alignment with a vertical, lateral axis). The horizontal, longitudinal axis is defined by the dashed line Z. The horizontal, lateral axis is defined by the dashed line X. The vertical, lateral axis is defined by the dashed line Y. A plurality 502 of neutral-type frames 102 (i.e., having no fill hole and no pressure relief valve) may be stacked together. The collars 142 of each neutral -type frame member 102 are inserted into a receiving portion 154 of the holes 114 in the adjacent frame. In some embodiments, one or more vent-type frames 202 with a pressure relief valve 230 are included in the frame assembly 501, being stacked with the other frames. For example, one or two vent-type frame members 202 may be included in a frame assembly 501 with ten or more, twenty or more, or thirty or more neutral-type frames 102. For example, a pair 506 of vent-type frame members 202 may be stacked in the frame assembly 501 and may be located near the terminals 520, 521 of the rechargeable battery 500. In another embodiment, one or more fill-type frame members 302 with a fill hole 332 are included in the frame assembly 501, being stacked with the other frames. For example, one or two fill-type frame members 302 may be included in a frame assembly with ten or more, twenty or more, or thirty or more neutral-type frame members 102. For example, a single 508 fill-type frame member 302 may be stacked in the frame assembly 501 and may be located near a terminal 521 of the rechargeable battery 500.

[0111] In some embodiments, an electrode plate 504 (e.g., a bipolar electrode plate) is disposed within each frame (102, 202, 302, 402), the electrode plate 504 being longitudinally supported by the inner flange 112 and laterally supported by the inner frame edge 106.

Electrolyte (not shown) comprising zinc (e.g., zinc cations), a salt of zinc (e.g., zinc chloride, zinc bromide, or any combination thereof) or any combination thereof is filled within the frame assembly 501 and sealed within the frame assembly 501 by the sealing members 128, 129 in the first and second grooves 108, 109. The electrolyte is filled in the space directly adjacent to the electrode plate 504 and contacts the electrode plate 504 and an electrode plate of an adjacent battery cell (which comprises a frame member and an electrode plate). The electrolyte may less than completely fill the frame assembly 501 so as to leave a head space of air and/or other gas within the frame assembly 501 above the electrolyte. Tie rods 510 are inserted through the plurality of holes 114 in the frame assembly 501 and corresponding holes in other parts of the battery 500 (e.g., the endplates 516, and terminal insulator 518). The tie rods 510 are held by nuts 514 and washers 512 at the terminal ends of the battery 500. End plates 516 and terminal insulators 518 may also be stacked at the terminal ends of the battery 500 and may held in place by the tie rods 510 and by mechanical interlocking with collars 142 of the frame members of the frame assembly 501.

[0112] Referring to FIG. 15, a side view of the rechargeable battery 500 and frame assembly 501 of FIG. 14 is shown. The frame assembly 501 comprises a plurality of frames 102, 202, 302, 402. The side view illustrates the horizontal stacking of the frame assembly 501 with each frame member (102, 202, 302, 402) in a vertical configuration.

[0113] In some embodiments, the rechargeable battery 500 may be comprise an aqueous electrolyte (e.g., an aqueous zinc-halogen electrolyte) and a bipolar electrode plate. In some embodiments, the bipolar electrode plate comprises a titanium plate comprising a titanium carbide coating. In some instances, the electrode plate has an anode surface that is treated (e.g., sand blasted, scuffed, or etched) and a cathode surface on to which a graphite block or carbon cloth (e.g., a carbon felt) is attached or adhered. The anode surface of a bipolar plate is adjacent to (and in electrical communication with) the cathode surface of a bipolar plate in an adjacent battery cell. The electrolyte may be a zinc-halogen electrolyte, i.e., an electrolyte containing a zinc-halogen salt mixed or dissolved therein. In some embodiments, the titanium plate of the bipolar electrode plate may be supported against the inner flange 112. In some embodiments, the rechargeable battery is a high power battery adapted for grid-scale energy storage.

OTHER EMBODIMENTS

[0114] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular

configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

WHAT IS CLAIMED IS:

1. A frame member (102, 202, 302, 402) for supporting an electrode in a zinc-halogen rechargeable battery (500) comprising:

an outer undulating frame edge (104, 204, 304);

an inner frame edge (106, 206, 306) opposing the outer undulating frame edge (104, 204, 304);

a front face (108);

a front face (109) opposing the front face (108); and

an inner flange (112, 212, 312) extending laterally inward from the inner frame edge (106, 206, 306),

wherein at least one of the front face (108) or the front face (109) defines a first groove (110) configured to receive a sealing member (128), the front and back faces (108, 109) define a plurality of holes (114) formed in outward extending portions of the frame member (102, 202, 302, 402) within the outer undulating frame edge (104, 204, 304), at least one of the front face (108) or the front face (109) defines a first plurality of recesses (120), and a first recess (120) of the first plurality of recesses (120) is disposed adjacent to a first hole (114) of the plurality of holes (114).

2. The frame member (102, 202, 302, 402) of claim 1, wherein portions of the frame member (102, 202, 302, 402) surrounding the holes (114) and recesses (120) have a substantially even thickness.

3. The frame member (102, 202, 302, 402) of either of claims 1 or 2, further comprising an outer portion (124) that comprises a first material and an inner portion (126) comprising a second material.

4. The frame member (102, 202, 302, 402) of claim 3, wherein the first material is selected from polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (cPVC), acrylonitrile butadiene styrene (ABS), or any combination thereof.

5. The frame member (102, 202, 302, 402) of claim 4, wherein the first material is filled with glass fibers or clay filler material.

6. The frame member (102, 202, 302, 402) of any one of claims 3-5, wherein the second material is selected from high density polyethylene (HDPE), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a high molecular chloro wax, PVC, or cPVC.

7. The frame member (102, 202, 302, 402) of any one of claims 3-6, wherein the inner portion (126) is over-molded onto the outer portion (124).

8. The frame member (102, 202, 302, 402) of any one of claims 3-7, further comprises a plurality of recesses (120) in the outer portion (124) and a plurality of locking portions (160) in the inner portion (126) disposed within the recesses (120).

9. The frame member (102, 202, 302, 402) of any one of claims 1-8, further comprising a second plurality of recesses (120) extending from the back face (109) toward the front face

(108) and opposing the first plurality of recesses (120).

10. The frame member (102, 202, 302, 402) of any one of claims 1-9, further comprising a first sealing member (128) disposed along the first groove (110).

11. The frame member (102, 202, 302, 402) of claim 10, wherein the first sealing member (128) comprises an O-ring.

12. The frame member (102, 202, 302, 402) of any one of claims 1-11, further comprising a second sealing member (129) and a second groove (111) in the front face (108) or back face

(109) and opposing the first groove (110), the second groove (111) configured to receive the second sealing member (129).

13. The frame member (102, 202, 302, 402) of any one of claims 1-12, further comprising a fill hole (332) extending from the outward undulating frame edge (304) through to the inner frame edge (306).

14. The frame member (102, 202, 302, 402) of any one of claims 1-12, further comprising a pressure relief valve (230 located within a cavity (232) in the frame member (102, 202, 302, 402), wherein the cavity (232) extends from the outward undulating frame edge (204) through the inner frame edge (206).

15. The frame member (102, 202, 302, 402) of any one of claims 1-14, wherein the inner flange (112, 212, 312) comprises an upper portion (134) and a lower portion (134b), wherein the upper portion (134) of the inner flange (112, 212, 312) has a greater inwardly extending length than the lower portion (134b) of the inner flange (112, 212, 312) and defines an aperture (136) and a channel (138), wherein the aperture (136) is configured to allow fluid communication of gas from the front face (108) to the back face (109) in a head-space defined by the frame member (102, 202, 302, 402) and an adjacent frame member (102, 202, 302, 402), the channel (138) configured to allow fluid communication from the front face (108) of the of electrolyte between the frame member (102, 202, 302, 402)and an adjacent frame member (102, 202, 302, 402).

16. The frame member (102, 202, 302, 402) of any one of claims 1-15, further comprising a ramped protrusion (140) along the inner frame edge (106, 206, 306) adjacent to the upper portion (134) of the inner flange (112, 212, 312).

17. A frame member (102, 202, 302, 402) for supporting an electrode in a zinc-halogen rechargeable battery (500) comprising:

an outer undulating frame edge (104, 204, 304);

a front face (108);

a back face (109) opposing the front face (108); and

an inner flange (112, 212, 312) extending laterally inward from the inner frame edge (106, 206, 306) and comprising an upper portion (134) and a lower portion (134b),

wherein at least one of the front face (108) or the back face (109) defines a first groove (110) configured to receive a first sealing member (128), wherein the upper portion (134) of the inner flange (112, 212, 312) has a greater inwardly extending length than the lower portion (134b) of the inner flange (112, 212, 312) and defines an aperture (136) and a channel (138), wherein the aperture (136) and the channel (138) are configured to allow fluid communication from the front face (108) to the back face (109) of the frame member (102, 202, 302, 402).

18. The frame member (102, 202, 302, 402) of claim 17, wherein the aperture (136) is positioned laterally above the channel (138).

19. The frame member (102, 202, 302, 402) of either of claims 17 or 18, wherein the channel (138) is formed in an inner edge (158) of the upper portion (134) of the inner flange (112, 212, 312).

20. The frame member (102, 202, 302, 402) of any one of claims 17-19, further comprising a ramped protrusion (140) along the inner frame edge (106, 206, 306) adjacent to the upper portion (134) of the inner flange (112, 212, 312).

21. A frame member (102, 202, 302, 402) for supporting an electrode in a zinc-halogen rechargeable battery (500) comprising:

an outer undulating frame edge (104, 204, 304);

a front face (108);

a back face (109) opposing the front face (108);

an inner flange (112, 212, 312) extending laterally inward from the inner frame edge (106, 206, 306);

a plurality of collars (142); and

an outer rim (144),

wherein at least one of the front face (108) or the back face (109) defines a first groove (110) for receiving a sealing member, the front and back faces (108, 109) define a plurality of holes (114) formed in outward extending portions (116) of the frame member (102, 202, 302, 402) within the outer undulating frame edge (104, 204, 304), the plurality of collars (142) extend longitudinally away from the holes (114), and the outer rim (144) disposed along the outer undulating frame edge (104, 204, 304) and extending longitudinally beyond the back face (109).

22. The frame member (102, 202, 302, 402) of claim 21, further comprising one or more weep holes (146) in a bottom portion (134b) of the outer undulating frame edge (104, 204, 304).

23. The frame member (102, 202, 302, 402) of either of claim 21 or 22, wherein the collars (142) are sleeved with PVC shrink wrap.

24. The frame member (102, 202, 302, 402) of any one of claims 21-23, wherein the circumference of the collars (142) decreases as the collars (142) extend longitudinally away from the front face (108).

25. A frame member (102, 202, 302, 402) for supporting an electrode in a zinc-halogen rechargeable battery comprising:

an outer undulating frame edge (104, 204, 304);

a front face (108);

a back face (109) opposing the front face (108);

an inner flange (112, 212, 312) extending laterally inward from the inner frame edge (106, 206, 306); and

a sloped surface (148),

wherein at least one of the front face (108) and the back face (109) define a first groove (110) for receiving a sealing member (128), and the sloped surface (148) is disposed laterally across a bottom portion (134b) of the frame member (102, 202, 302, 402) and extends longitudinally away from the inner flange (112, 212, 312) and slopes upward as it extends away from the inner flange (112, 212, 312).

26. The frame member (102, 202, 302, 402) of claim 25, wherein the sloped surface (148) forms a concave profile as it extends longitudinally away from the inner flange (112, 212, 312).

27. The frame member (102, 202, 302, 402) of either of claims 25 or 26, further comprising one or more inner members extending across a portion of the frame member (102, 202, 302, 402) from a first position on the inner flange (112, 212, 312) to a second position of the inner flange (112, 212, 312) to provide additional longitudinal support to the electrode.

28. A frame assembly (501) comprising: a first frame member (102, 202, 302, 402) comprising a first outer undulating frame edge (104, 204, 304), a first inner frame edge (106, 206, 306) opposing the first outer undulating frame edge (104, 204, 304), a first front face (108), a first back face (109) opposing the first front face (108), a first inner flange (112, 212, 312) extending laterally inward from the first inner frame edge (106, 206, 306), a plurality of collars (142), and an outer rim (144), wherein the first front face (108) defines a first groove (110) for receiving a sealing member (128), the first front and back faces (108, 109) define a first plurality of holes (114) formed in outer extending portions (116) of the first frame member (102, 202, 302, 402) within the outer undulating frame edge (104, 204, 304), the plurality of collars (142) extend longitudinally away from the holes (114), and the outer rim (144) is disposed along the first outer undulating frame edge (104, 204, 304) and extending longitudinally beyond the back face (109) of the first frame member (102, 202, 302, 402);

a second frame member (102, 202, 302, 402) comprising a second outer undulating frame edge (104, 204, 304), a second inner frame edge (106, 206, 306) opposing the outer undulating frame edge (104, 204, 304), a second front face (108), a second back face (109) opposing the second front face (108) and having a plurality of receiving portions (154) that are configured to mate with the plurality of collars (142) of the first frame member (102, 202, 302, 402), a second inner flange (112, 212, 312) extending laterally inward from the second inner frame edge (106, 206, 306), and an outer rim (144), wherein, the second front and back faces (108, 109) define a second plurality of holes (114) formed in outer extending portions (116) of the frame member (102, 202, 302, 402) within the outer undulating frame edge (104, 204, 304); and

a sealing member (128) that is seated in the first groove (110) of the first frame member (102, 202, 302, 402).

29. The frame assembly (501) of claim 28, further comprising tie rods (510) extending through the first plurality of holes (114) defined by the first front and back faces (108, 109) and the second plurality of holes (114) defined by the second front and back faces (108, 109).

30. A rechargeable zinc halogen battery (500) comprising:

a first frame member (102, 202, 302, 402) comprising a first outer undulating frame edge (104, 204, 304), a first inner frame edge (106, 206, 306) opposing the outer undulating frame edge (104, 204, 304), a first front face (108), a first back face (109) opposing the front face (108), a first inner flange (112, 212, 312) extending laterally inward from the inner frame edge (106, 206, 306), and a first sloped surface (148) disposed laterally across a bottom portion (134b) of the frame member (102, 202, 302, 402) and extending longitudinally, wherein the first front face (108) defines a first groove (110) configured to receive a sealing member (128), the first front and back faces (108, 109) define a plurality of holes (114) formed in outer extending portions (116) of the frame member (102, 202, 302, 402) within the outer undulating frame edge (104, 204, 304), at least one of the first front face (108) or the back face (109) defines a first plurality of recesses (120), and a first recess (120) of the first plurality of recesses (120) is disposed adjacent to a first hole (114) of the plurality of holes (114), and the first sloped surface (148) slopes upward as it extends away from the first inner flange (112, 212, 312);

an electrode plate (504); and

a carbon material affixed to the electrode plate (504),

wherein the electrode plate (504) is configured to be received within the first inner frame edge (106, 206, 306) and to be supported by the inner flange (112, 212, 312) of the first frame member (102, 202, 302, 402), and wherein the carbon material comprises a graphite block or carbon felt.

31. The rechargeable battery (500) of claim 30, wherein portions of the first frame member (102, 202, 302, 402) surrounding the holes (114) and recesses (120) have

substantially even thickness.

32. The rechargeable battery (500) of either of claims 30 or 31, further comprising an outer portion (124) that comprises a first material and an inner portion (126) comprising a second material.

33. The rechargeable battery (500) of claim 32, wherein the first material is selected from polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (cPVC), acrylonitrile butadiene styrene (ABS), or any combination thereof.

34. The rechargeable battery (500) of either of claims 32 or 33, wherein the first material is filled with glass fibers or clay filler material.

35. The rechargeable battery (500) of any one of claims 32-34, wherein the second material is selected from high density polyethylene (HDPE), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a high molecular chloro wax, PVC, or cPVC.

36. The rechargeable battery (500) of any one of claims 32-35, wherein the inner portion (126) is over-molded onto the outer portion (124).

37. The rechargeable battery (500) of any one of claims 30-36, wherein the first sealing member (128) comprises an O-ring.

38. The rechargeable battery (500) of any one of claims 30-37, wherein the first frame member (102, 202, 302, 402) further comprises a fill hole (332) extending from the outward undulating frame edge (104, 204, 304) through to the inner frame edge (106, 206, 306).

39. The rechargeable battery (500) of any one of claims 30-38, wherein the first frame member (102, 202, 302, 402) further comprises a pressure relief valve (230) located within a cavity (232) in the first frame member (102, 202, 302, 402), wherein the cavity (232) extends from the outward undulating frame edge (104, 204, 304) through the inner frame edge (106, 206, 306).

40. The rechargeable battery (500) of any one of claims 30-39, wherein the first inner flange (112, 212, 312) comprises an upper portion (134) and a lower portion (134b), wherein the upper portion (134)of the first inner flange (112, 212, 312) has a greater inwardly extending length than the lower portion (134b) of the inner flange (112, 212, 312) and defines an aperture (136) and a channel (138), wherein the aperture (136) and the channel (138) are configured to allow fluid communication from the front face (108) to the back face (109) of the first frame member (102, 202, 302, 402), and the channel (138) and the aperture (136) are configured to be substantially unobstructed by the electrode plate (504), when the electrode plate (504) is received by the first frame member (102, 202, 302, 402).

41. The rechargeable battery (500) of any one of claims 30-40, wherein the first frame member (102, 202, 302, 402) further comprises a plurality of collars (142) extending longitudinally away from the holes (114) defined by the front face (108) of the first frame member (102, 202, 302, 402).

42. The rechargeable battery (500) of any one of claims 30-41, further comprising a second frame member (102, 202, 302, 402), wherein the second frame member (102, 202, 302, 402) comprises a second outer undulating frame edge (104, 204, 304), a second inner frame edge (106, 206, 306) opposing the second outer undulating frame edge (104, 204, 304), a second front face (108), a second back face (109) opposing the second front face (108), a second inner flange (112, 212, 312) extending laterally inward from the second inner frame edge (106, 206, 306), and a second sloped surface (148) disposed laterally across a bottom portion of the second frame member (102, 202, 302, 402) and extending longitudinally, wherein the second front face (108) defines a second groove (111) configured to receive a second sealing member (129), the second front and back faces (108, 109) define a plurality of holes (114) formed in outer extending portions (116) of the second frame member (102, 202, 302, 402) within the second outer undulating frame edge (104, 204, 304), at least one of the second front face (108) or the back face (109) defines a second plurality of recesses (120), and a second recess (120) of the second plurality of recesses (120) is disposed adjacent to a second hole (114) of the plurality of holes (114), and the second sloped surface (148) slopes upward as it extends away from the second inner flange (112, 212, 312).

43. The rechargeable battery (500) of claim 42, wherein the second frame member (102, 202, 302, 402) further comprises a second plurality of collars (142) extending longitudinally away from the holes (114) defined by the front face (108) of the second frame member (102, 202, 302, 402).

44. The rechargeable battery (500) of claim 43, wherein the first frame member (102, 202, 302, 402) further comprises a first plurality of receiving portions (154) that are defined by the back face (109) of the first frame member (102, 202, 302, 402) and are configured to mate with the collars (142) of the second frame member (102, 202, 302, 402).

45. The rechargeable battery (500) of claim 43, wherein the second frame member (102, 202, 302, 402) further comprises a second plurality of receiving portions (154) defined by the second back face (109) that are configured to mate with the first plurality of collars (142) of the first frame member (102, 202, 302, 402).

46. The rechargeable battery (500) of any one of claims 30-43, further comprising an electrolyte, wherein the electrolyte comprises zinc cations, zinc bromide, zinc chloride, or any combination thereof.

47. The rechargeable battery (500) of any one of claims 42-46, wherein the first frame member (102, 202, 302, 402) and the second frame member (102, 202, 302, 402) are horizontally stacked and vertically oriented, wherein the first outer edge of the first frame member (102, 202, 302, 402) is substantially coplanar with the second outer edge of the second frame member (102, 202, 302, 402).