Electrolyte management for electrochemical power storage

Patent metadata

Field	Value
Publication number	US-2025070435-A1
Application number	US-202418815825-A
Country	US
Kind code	A1
Filing date	Aug 26, 2024
Priority date	Aug 24, 2023
Publication date	Feb 27, 2025
Grant date	—

Abstract

According to one aspect, a system for electrochemical power storage may include at least one instance of a battery module, each instance of the battery module including a battery enclosure and a metal-air battery, the metal-air battery disposed in the battery enclosure; a reservoir including a volume of a liquid electrolyte; a supply conduit in fluid communication between the reservoir and the battery enclosure; a pump actuatable to move the liquid electrolyte from the reservoir into the battery enclosure via the supply conduit; and a return conduit in fluid communication between the battery enclosure and the reservoir, the liquid electrolyte movable from the battery enclosure to the reservoir, via the return conduit, with the metal-air battery immersed in the liquid electrolyte in the battery enclosure.

First claim

What is claimed is:

1 . A system for electrochemical power storage, the system comprising:
at least one instance of a battery module, each instance of the battery module including a battery enclosure and a metal-air battery, the metal-air battery disposed in the battery enclosure; a reservoir including a volume of a liquid electrolyte; a supply conduit in fluid communication between the reservoir and the battery enclosure; a pump actuatable to move the liquid electrolyte from the reservoir into the battery enclosure via the supply conduit; and a return conduit in fluid communication between the battery enclosure and the reservoir, the liquid electrolyte movable from the battery enclosure to the reservoir, via the return conduit, with the metal-air battery immersed in the liquid electrolyte in the battery enclosure.

2 . The system of claim 1 , wherein each instance of the metal-air battery includes a metal electrode, and the air electrode, and a vessel, the metal electrode and the air electrode are immersed in the liquid electrolyte in the vessel, and a headspace region is defined between the battery enclosure and the liquid electrolyte in the vessel in each instance of the battery module.

3 . The system of claim 2 , wherein an excess amount of the liquid electrolyte passively drains from the headspace region to the reservoir via the return conduit.

4 . The system of claim 3 , wherein the return conduit is angled between the battery enclosure and the reservoir such that gravity forces the liquid electrolyte through the return conduit to the reservoir.

5 . The system of claim 2 , wherein an outlet section of the supply conduit is coupled to a bottom portion of the vessel.

6 . The system of claim 2 , further comprising a controller and a sensor, the sensor arranged to detect overflow of the liquid electrolyte from the vessel, the controller communicatively coupled to the sensor and the pump, and the controller configured to receive, from the sensor, a signal indicative of the liquid electrolyte overflowing the vessel and to control actuation of the pump, based on the signal from the sensor, such that the pump fills the vessel with the electrolyte until the liquid electrolyte overflows the vessel, enters the return conduit, and returns to the reservoir.

7 . The system of claim 1 , wherein each instance of the battery module further includes a float valve disposed in the battery enclosure, and the float valve is actuatable, according to a level of the liquid electrolyte in the battery enclosure, to control a flow of water from a water source into the respective instance of the battery enclosure.

8 . The system of claim 1 , further comprising an inlet valve actuatable to control a flow of water from a water source into the volume of the electrolyte in the reservoir.

9 . The system of claim 8 , further comprising a level sensor arranged to detect a filling level of the volume of the liquid electrolyte in the reservoir; and
a controller communicatively coupled to the level sensor and the inlet valve, the controller configured to receive, from the level sensor, a signal indicative of the filling level of the volume of the liquid electrolyte in the reservoir and to actuate the inlet valve to control the flow of water from the water source into the volume of the liquid electrolyte in the reservoir such that the filling level of the volume of the liquid electrolyte in the reservoir is maintained between a maximum and minimum filling level.

10 . The system of claim 1 , further comprising a vent conduit in fluid communication with the supply conduit, wherein gas is releasable from the supply conduit via the vent conduit.

11 . The system of claim 1 , further comprising a filter in fluid communication with the supply conduit, wherein precipitants from the liquid electrolyte moving through the supply conduit are removable by the filter.

12 . The system of claim 1 , wherein, in each instance of the battery module, the metal-air battery includes an iron-air type battery cell, zinc-air type battery cell, a lithium-air battery cell, or a combination thereof.

13 . The system of claim 1 , wherein
the at least one instance of the battery module includes a plurality of instances of the battery module, the supply conduit comprises a supply manifold in fluid communication, in parallel, with the reservoir and each instance of the battery enclosure, and the return conduit includes a return manifold in fluid communication, in parallel, with the reservoir and each instance of the battery enclosure.

14 . The system of claim 13 , further comprising a controller communicatively coupled to the pump, wherein the controller is configured to actuate the pump to move the liquid electrolyte through the supply manifold until the respective vessel of each of the plurality of instances of the battery modules is filled with the liquid electrolyte to a predetermined level.

15 . The system of claim 14 , wherein an excess amount of the liquid electrolyte is drainable from the respective battery enclosure of each one of the plurality of instances of the battery module via the return manifold.

16 . A system for electrochemical power storage, the system comprising:
a battery module including a battery enclosure and a metal-air battery, the metal-air battery disposed in the battery enclosure; a reservoir comprising a volume of a liquid electrolyte; a transfer conduit, the reservoir in fluid communication with the battery enclosure via the transfer conduit; and a plunger disposed in the reservoir and movable in the reservoir to control a flow of the liquid electrolyte between the battery enclosure and the reservoir via the transfer conduit.

17 . The system of claim 16 , wherein the plunger is movable between a raised position and a lowered position to control the flow of the liquid electrolyte between the battery enclosure and the reservoir via the transfer conduit, the plunger in the raised position moves an excess amount of the liquid electrolyte from the battery enclosure, through the transfer conduit, and into the reservoir, and
the plunger in the lowered position forces the liquid electrolyte in the reservoir through the transfer conduit and into the battery enclosure.

18 . The system of claim 17 , wherein, the reservoir defines an opening, the reservoir is in fluid communication with the transfer conduit through the opening, the plunger in the raised position is disposed above the opening such that an excess amount of the liquid electrolyte flows in a direction from the battery module and into the reservoir via the transfer conduit, and the plunger in the lowered position is disposed below the opening such that the liquid electrolyte in the reservoir is forced out of the opening, through the transfer conduit, and into the battery module.

19 . The system of claim 18 , further comprising an inlet valve actuatable to control a flow of water from a water source into the volume of the liquid electrolyte in the reservoir.

20 . The system of claim 19 , wherein
when the plunger is in the raised position, water received from the water source is collected below the plunger, and when the plunger is in the lowered position, the water and the liquid electrolyte is forced from the reservoir and into the battery enclosure.

21 . A system for electrochemical power storage, the system comprising:
a plurality of instances of a battery module, each instance of the battery module including a battery enclosure a

Assignees

• Form Energy Inc

Inventors

• Smith Danielle Cassidy
• Friesen Grant Harrison
• Mckibben Nicholas
• Riveria Angel Ruben
• Vasavada Jhalak Joshipura

Classifications

• H01M12/08

  composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type · CPC title

• H01M10/484

  for measuring electrolyte level, electrolyte density or electrolyte conductivity · CPC title

• H01M50/691

  Arrangements or processes for draining liquids from casings; Cleaning battery or cell casings · CPC title

• H01M50/673

  Containers for storing liquids; Delivery conduits therefor · CPC title

• H01M10/425

  Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00) · CPC title