US 10,381,674 B2Granted

High-throughput manufacturing processes for making electrochemical unit cells and electrochemical unit cells produced using the same

AssigneeLockheed Martin Energy, LLC

InventorsCurtis Warrington, Thomas H. Madden, Srivatsava Puranam

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Abstract

Flow batteries can be constructed by combining multiple electrochemical unit cells together with one another in a cell stack. High-throughput processes for fabricating electrochemical unit cells can include providing materials from rolled sources for forming a soft goods assembly and a hard goods assembly, supplying the materials to a production line, and forming an electrochemical unit cell having a bipolar plate disposed on opposite sides of a separator. The electrochemical unit cells can have configurations such that bipolar plates are shared between adjacent electrochemical unit cells in a cell stack, or such that bipolar plates between adjacent electrochemical unit cells are abutted together with one another in a cell stack.

Claims16

Dependent claims

An electrochemical unit cell comprising:

a separator disposed between a first electrode and a second electrode;
wherein the first electrode and the second electrode are sized and positioned such that
first and second perimeter regions that are not in contact with the first and second electrodes exist on opposing sides of the separator;
a first bipolar plate in contact with the first electrode;
a second bipolar plate in contact with the second electrode;
a first compressible seal disposed on the separator in the first perimeter region;
a second compressible seal disposed on the separator in the second perimeter region;
a first frame layer and a second frame layer defined about an outer perimeter of the first compressible seal and the second compressible seal;
a third frame layer in contact with the first compressible seal and with the first frame layer;
a fourth frame layer in contact with the second compressible seal and with the second frame layer;
a fifth frame layer adjacent to the third frame layer;
a sixth frame layer adjacent to the fourth frame layer;
a seventh frame layer adjacent to the fifth frame layer;
wherein the first bipolar plate is adhered to the seventh frame layer and occludes a window therein;
and
an eighth frame layer adjacent to the sixth frame layer;
wherein the second bipolar plate is adhered to the eighth frame layer and occludes a window therein;
and
wherein each of the frame layers comprises a non-conductive material.

16 more elements

An electrochemical unit cell (200) comprising:

a separator (102) having first and second opposing faces, each having respective areas, the separator being disposed between a first electrode (104) and a second electrode (106);
wherein the first electrode (104) and the second electrode (106) each have surface areas that are less than the respective areas of the first and second opposing faces of the separator and the first electrode (104) and second (106) are positioned to define a first non-contact perimeter region (108) and second non-contact perimeter region (108′) on the first and second surfaces of the separator, respectively;
a first bipolar plate (160) in contact with the first electrode (104);
a second bipolar plate (160′) in contact with the second electrode (106);
a first frame layer(120) directly adhered to the separator in the first perimeter region (108), the first frame layer having a first window (122) therewithin;
a second frame layer (120′) directly adhered to the separator in the second perimeter region (108′), the second frame layer having a second window (122′) therewithin;
a third frame layer (130) adjacent to the first frame layer (120), the third frame layer having a third window (132) therewithin;
a fourth frame layer (130′) adjacent to the second frame layer (120′), the fourth frame layer having a fourth window (132′) therewithin;
a fifth frame layer (140) adjacent to the third frame layer(130), the fifth frame layer having a fifth window (142) therewithin;
a sixth frame layer(140′) adjacent to the fourth frame layer (130′), the sixth frame layer having a sixth window (142′) therewithin;
a seventh frame layer (150) adjacent to the fifth frame layer(140), the seventh frame layer having a seventh window (142′) therewithin;
wherein the first window (122), the third window (132), and the fifth window (142) are sized such that the first frame layer (120), the third frame layer(130), and the fifth frame layer (140) frame the first bipolar plate (160);
and
wherein the second window (122′), the fourth window (132′), and the sixth window (142′) are sized such that the second frame layer (120′), the fourth frame layer (130′), and the sixth frame layer(140′) frame the second bipolar plate (160′);
and
wherein the first bipolar plate (160) is adhered to the seventh frame layer (150) and occludes a window (152) therein;
and
an eighth frame layer (150′) adjacent to the sixth frame layer (140′);
wherein the second bipolar plate (160′) is adhered to the eighth frame layer (150′) and occludes a window (152′) therein;
and
wherein each of the frame layers comprises a non-conductive material.

18 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/093,598Filed 7 Apr 2016
Published: US 2017/0294672 A112 Oct 2017
Granted: 13 Aug 2019
Term ends: Not estimatedThe source records don’t support an estimate.

Classification12 codes

H01M 8/2404
Grouping of fuel cells, e.g. stacking of fuel cells: processes or apparatus for grouping fuel cells
H01M 8/0273
Sealing or supporting means around electrodes, matrices or membranes: with sealing or supporting means in the form of a frame
H01M 8/0286
Sealing or supporting means around electrodes, matrices or membranes: processes for forming seals
H01M 8/188
Regeneration by electrochemical means: by recharging of redox couples containing fluids; Redox flow type batteries