Device architectures for metal-air batteries

Patent metadata

Field	Value
Publication number	US-2025174770-A1
Application number	US-202418966998-A
Country	US
Kind code	A1
Filing date	Dec 3, 2024
Priority date	Jun 28, 2019
Publication date	May 29, 2025
Grant date	—

Abstract

Systems and methods of the various embodiments may provide device architectures for batteries. In various embodiments, these may be primary or secondary batteries. In various embodiments these devices may be useful for energy storage. Various embodiments may provide a battery including an Oxygen Reduction Reaction (ORR) electrode, an Oxygen Evolution Reaction (OER) electrode, a metal electrode; and an electrolyte separating the ORR electrode and the OER electrode from the metal electrode.

First claim

What is claimed is:

1 . A bulk energy storage system, the bulk energy storage system comprising:
one or more batteries, wherein at least one of the one or more batteries comprises: an Oxygen Reduction Reaction (ORR) electrode; an Oxygen Evolution Reaction (OER) electrode; a metal electrode; and an electrolyte separating the ORR electrode and the OER electrode from the metal electrode, the ORR electrode comprising discrete ORR electrode sections arranged vertically in a stack below a surface of the electrolyte, and each one of the discrete ORR electrode sections having the same pressure drop in a depth direction below the surface of the electrolyte.

2 . The bulk energy storage system of claim 1 , wherein the ORR electrode and the OER electrode are portions of a single air electrode.

3 . The bulk energy storage system of claim 1 , wherein the ORR electrode and the OER electrode are separate electrodes.

4 . The bulk energy storage system of claim 3 , wherein the ORR electrode is disposed on a surface of the electrolyte and the OER electrode is submerged in the electrolyte.

5 . The bulk energy storage system of claim 4 , further comprising a stackable vessel supporting the ORR electrode, the OER electrode, the metal electrode, and the electrolyte,
wherein the stackable vessel is self-stacking on other stackable vessels.

6 . The bulk energy storage system of claim 4 , wherein the ORR electrode is wavy or rippled.

7 . The bulk energy storage system of claim 4 , wherein a housing of at least one of the one or more batteries operates as a current conductor for the metal electrode.

8 . The bulk energy storage system of claim 3 , wherein the ORR electrode and the OER electrode are submerged in the electrolyte.

9 . The bulk energy storage system of claim 8 , wherein the ORR electrode is supported in a frame that displaces the electrolyte to create a gas volume at a depth below a surface of the electrolyte.

10 . The bulk energy storage system of claim 8 , wherein the ORR electrode comprises a box filled with air.

11 . The bulk energy storage system of claim 8 , wherein the ORR electrode is supplied air.

12 . The bulk energy storage system of claim 11 , wherein the ORR electrode is curved.

13 . The bulk energy storage system of claim 11 , wherein the ORR electrode is supported in a frame that traps the supplied air in an air chamber bounded by a surface of the ORR electrode.

14 . The bulk energy storage system of claim 11 , wherein the ORR electrode is tube shaped.

15 . The bulk energy storage system of claim 11 , wherein:
the ORR electrode includes a cylindrical core surrounded by the metal electrode; and the OER electrode includes a hexagonal tube surrounding and containing the metal electrode with the ORR electrode therein.

16 . The bulk energy storage system of claim 3 , wherein the metal electrode has a changeable position relative to the ORR electrode and the OER electrode.

17 . The bulk energy storage system of claim 1 , wherein
the OER electrode is rigid and the ORR electrode is a flexible ORR electrode, and the OER electrode and ORR electrode are electrically separable by presence or absence of airflow displacing the flexible ORR electrode.

18 . The bulk energy storage system of claim 1 , wherein the ORR electrode comprises a series of ORR sections, and each section is tuned to a different operating pressure that will be experienced by that section at its depth in the electrolyte.

19 . The bulk energy storage system of claim 1 , wherein the ORR electrode is an unsealed horizontal submerged (UHS) ORR electrode.

20 . The bulk energy storage system of claim 19 , wherein the metal electrode is a bed of direct reduced iron pellets.

Assignees

• Form Energy Inc

Inventors

• Weber Eric
• Westwood Mitchell Terrance
• Mumma Rachel Elizabeth
• Slocum Alexander H
• Su Liang
• Milshtein Jarrod David
• Woodford William Henry
• Chiang Yet-Ming
• Jaramillo Mateo Cristian
• Mckay Ian Salmon
• Brushett Fikile
• Van Benchoten Helen
• Gilbert Tristan
• Perkins Nicholas Reed
• Pantano Joseph Anthony
• Smith Weston
• Carlisle Kristen
• Caruso Isabella
• Hultman Benjamin Thomas
• Thompson Annelise Christine
• Smith Danielle
• Tarasov Vladimir
• Hartman Katherine
• Liotta Andrew Haynes
• Talu Onur
• Goulet Marc-Antoni
• Chakraborty Rupak
• Wehner Florian
• Mileson Bradley
• Rousseau Alexandra

Classifications

• H01M12/08 Primary

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

• H01M2250/10

  Fuel cells in stationary systems, e.g. emergency power source in plant · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• Y02E60/50

  Fuel cells · CPC title

• H01M4/8647

  consisting of more than one material, e.g. consisting of composites · CPC title