Low cost metal electrodes

Patent metadata

Field	Value
Publication number	US-2025096261-A1
Application number	US-202418968032-A
Country	US
Kind code	A1
Filing date	Dec 4, 2024
Priority date	Jul 26, 2019
Publication date	Mar 20, 2025
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, at least one of the first electrode and the second electrode including a current collecting sheet and a bed of iron agglomerates, and the current collecting sheet applying a compressive load to the bed of iron agglomerates on at least one side of the first electrode or the second electrode.

2 . The battery of claim 1 , wherein the electrolyte comprises a 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 the iron agglomerates comprise at least one of magnetite, hematite, or wustite.

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

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

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

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

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

10 . The battery of claim 9 , wherein the electrolyte comprises 1-octanethiol.

11 . The battery of claim 1 , wherein the iron agglomerates are supported within a metal textile mesh providing compressive force and current collection for the iron agglomerates.

12 . A bulk energy storage system, comprising:
one or more batteries, at least one of the one or more batteries including
a first electrode,
an electrolyte, and
a second electrode, at least one of the first electrode and the second electrode including a current collecting sheet and a bed of iron agglomerates, the current collecting sheet applying a compressive load to the bed of iron agglomerates on at least one side of the first electrode or the second electrode.

13 . The bulk energy storage system of claim 12 , wherein the iron agglomerates comprise at least one of magnetite, hematite, or wustite.

14 . The bulk energy storage system of claim 12 , wherein the electrolyte comprises a corrosion inhibitor.

15 . The bulk energy storage system of claim 12 , wherein the iron agglomerates have an average length ranging from 50 μm to 50 mm.

16 . The bulk energy storage system of claim 12 , wherein the iron agglomerates have an average internal porosity ranging from 10% to 90% by volume.

17 . The bulk energy storage system of claim 12 , wherein the iron agglomerates have an average specific surface area ranging from 0.1 m 2 /g to 25 m 2 /g.

18 . The bulk energy storage system of claim 12 , wherein the iron agglomerates are supported within a metal textile mesh providing compressive force and current collection for the iron agglomerates.

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 Reed
• Wehner Florian
• Eisenach Rebecca
• Westwood Mitchell Terrance
• Gilbert Tristan
• Liotta Andrew Haynes
• Conry Thomas
• Mumma Rachel Elizabeth
• Uber Brandon
• Weber Eric
• Smith Danielle Cassidy
• Wojeski Brooke

Classifications

• H01M4/0438

  by electrochemical processing (electroless electrochemical plating C23C18/54) · CPC title

• H01M10/26

  Selection of materials as electrolytes · CPC title

• H01M4/661

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

• H01M2004/021

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

• H01M4/628

  Inhibitors, e.g. gassing inhibitors, corrosion inhibitors · CPC title