Low cost metal electrodes

Patent metadata

Field	Value
Publication number	US-2021028457-A1
Application number	US-202016938862-A
Country	US
Kind code	A1
Filing date	Jul 24, 2020
Priority date	Jul 26, 2019
Publication date	Jan 28, 2021
Grant date	—

Abstract

Systems and methods of the various embodiments may provide metal electrodes for electrochemical cells. In various embodiments, the electrodes may comprise iron. Various methods may enable achieving high surface area with low cost for production of metal electrodes, such as iron electrodes.

First claim

What is claimed is:

1 . A battery comprising:
a first electrode; an electrolyte; and a second electrode, wherein at least one of the first electrode and the second electrode comprises iron agglomerates.

2 . The battery of claim 1 , wherein the electrolyte comprises a soluble sulfide.

3 . The battery of claim 1 , wherein at least one of the first electrode and the second electrode further comprises a solid sulfide.

4 . The battery of claim 1 , wherein at least one of the first electrode or the second electrode is subjected to a compressive load.

5 . The battery of claim 4 , wherein the compressive load is applied on one side of at least one of the first electrode or second electrode by a current collecting member.

6 . The battery of claim 1 , wherein the iron agglomerates comprise at least one of magnetite, hematite, or wustite.

7 . The battery of claim 1 , wherein the electrolyte comprises a corrosion inhibitor.

8 . The battery of claim 1 , wherein the iron agglomerates have an average length ranging from about 50 um to about 50 mm.

9 . The battery of claim 1 , wherein the iron agglomerates have an average internal porosity ranging from about 10% to about 90% by volume.

10 . The battery of claim 1 , wherein the iron agglomerates have an average specific surface area ranging from about 0.1 m 2 /g to about 25 m 2 /g.

11 . The battery of claim 1 , wherein the electrolyte is infiltrated between the iron agglomerates.

12 . The battery of claim 11 , wherein the electrolyte comprises 1-octanethiol.

13 . The battery of claim 11 , wherein the electrolyte comprises a molybdate anion and a sulfide anion.

14 . The battery of claim 11 , wherein the iron agglomerates are supported within a metal textile mesh providing compressive force and current collection for the iron agglomerates.

15 . The battery of claim 11 , wherein the iron agglomerates are bonded to one another and bonded to a current collector.

16 . A battery comprising:
a first electrode; an electrolyte; and a second electrode, wherein at least one of the first electrode and the second electrode comprises atomized metal powder.

17 . A method of making an electrode, comprising:
electrochemically producing metal powder; and forming the metal powder into an electrode.

18 . The method of claim 17 , wherein electrochemically producing the metal powder comprises electrochemically producing the metal powder at least in part using a molten salt electrochemistry.

19 . The method of claim 17 , wherein electrochemically producing the metal powder comprises electrochemically producing the metal powder at least in part using gas atomization.

20 . The method of claim 17 , wherein electrochemically producing the metal powder comprises electrochemically producing the metal powder at least in part using water atomization.

21 . A bulk energy storage system, comprising:
one or more batteries, wherein at least one of the one or more batteries comprises:
a first electrode;
an electrolyte; and
a second electrode,
wherein at least one of the first electrode and the second electrode comprises iron agglomerates.

22 . The bulk energy storage system of claim 21 , wherein the bulk energy storage system is a long duration energy storage (LODES) system.

23 . The bulk energy storage system of claim 21 , wherein the electrolyte comprises a soluble sulfide.

24 . The bulk energy storage system of claim 21 , wherein at least one of the first electrode and the second electrode further comprises a solid sulfide.

25 . The bulk energy storage system of claim 21 , wherein at least one of the first electrode or the second electrode is subjected to a compressive load.

26 . The bulk energy storage system of claim 25 , wherein the compressive load is applied on one side of at least one of the first electrode or second electrode by a current collecting member.

27 . The bulk energy storage system of claim 21 , wherein the iron agglomerates comprise at least one of magnetite, hematite, or wustite.

28 . The bulk energy storage system of claim 21 , wherein the electrolyte comprises a corrosion inhibitor.

29 . The bulk energy storage system of claim 21 , wherein the iron agglomerates have an average length ranging from about 50 um to about 50 mm.

30 . The bulk energy storage system of claim 21 , wherein the iron agglomerates have an average internal porosity ranging from about 10% to about 90% by volume.

31 . The bulk energy storage system of claim 21 , wherein the iron agglomerates have an average specific surface area ranging from about 0.1 m 2 /g to about 25 m 2 /g.

32 . The bulk energy storage system of claim 21 , wherein the electrolyte is infiltrated between the iron agglomerates.

33 . The bulk energy storage system of claim 32 , wherein the electrolyte comprises 1-octanethiol.

34 . The bulk energy storage system of claim 33 , wherein the electrolyte comprises a molybdate anion and a sulfide anion.

35 . The bulk energy storage system of claim 33 , wherein the iron agglomerates are supported within a metal textile mesh providing compressive force and current collection for the iron agglomerates.

36 . The bulk energy storage system of claim 33 , wherein the iron agglomerates are bonded to one another and bonded to a current collector.

37 . A bulk energy storage system, comprising:
one or more batteries, wherein at least one of the one or more batteries comprises:
a first electrode;
an electrolyte; and
a second electrode,
wherein at least one of the first electrode and the second electrode comprises atomized metal powder.

38 . The bulk energy storage system of claim 15 , wherein the bulk energy storage system is a long duration energy storage (LODES) system.

Assignees

• Form Energy Inc

Inventors

• Newhouse Jocelyn Marie
• Milshtein Jarrod David
• Chakraborty Rupak
• Kharey Amelie Nina
• Woodford William Henry
• Chiang Yet-Ming
• Gibson Michael
• Thompson Annelise Christine
• Smith Weston
• Pantano Joseph Anthony
• Caruso Isabella
• Hultman Benjamin Thomas
• Chu Max Rae
• Su Liang
• Perkins Nicholas
• Wehner Florian
• Eisenach Rebecca
• Westwood Mitchell Terrance
• Gilbert Tristan
• Liotta Andrew
• Conry Thomas
• Mumma Rachel Elizabeth
• Uber Brandon
• Weber Eric
• Smith Danielle Cassidy
• Wojeski Brooke

Classifications

• H01M2300/0014

  Alkaline electrolytes · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M10/26

  Selection of materials as electrolytes · CPC title

• H01M10/0468 Primary

  Compression means for stacks of electrodes and separators · CPC title

• H01M4/661

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title