# US 2025/0096261 A1 · Low cost metal electrodes

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- Number: US 2025/0096261 A1
- Document ID: US20250096261A1
- Status: Published application
- Kind: A1
- Application number: 18/968,032
- Filed: 2024-12-04
- Published: 2025-03-20
- Earliest claimed: 2019-07-26
- Assignees: Form Energy, Inc.
- Applicants: Form Energy, Inc.
- Inventors: Jocelyn Marie NEWHOUSE; Jarrod David MILSHTEIN; Rupak CHAKRABORTY; Amelie Nina KHAREY; William Henry WOODFORD; Yet-Ming CHIANG; Michael GIBSON; Annelise Christine THOMPSON; Weston SMITH; Joseph Anthony PANTANO; Isabella CARUSO; Benjamin Thomas HULTMAN; Max Rae CHU; Liang SU; Nicholas Reed PERKINS; Florian WEHNER; Rebecca EISENACH; Mitchell Terrance WESTWOOD; Tristan GILBERT; Andrew Haynes LIOTTA; Thomas CONRY; Rachel Elizabeth MUMMA; Brandon UBER; Eric WEBER; Danielle Cassidy SMITH; Brooke WOJESKI
- Web page: https://patentgrep.com/patent/US20250096261A1

## CPC

- H01M 4/58: of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
- H01M 4/5815: {Sulfides}
- H01M 4/0438: {by electrochemical processing (electroless electrochemical plating C23C18/54)}
- H01M 4/248: {Iron electrodes}
- H01M 4/38: of elements or alloys
- H01M 4/628: {Inhibitors, e.g. gassing inhibitors, corrosion inhibitors}
- H01M 4/661: {Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence)}
- H01M 10/0468: {Compression means for stacks of electrodes and separators}
- H01M 10/26: Selection of materials as electrolytes
- H01M 2004/021: {Physical characteristics, e.g. porosity, surface area}
- H01M 2300/0014: Alkaline electrolytes
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## 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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

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

### Claim 6 (depends on 1)

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

### Claim 7 (depends on 1)

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

### Claim 8 (depends on 1)

The battery of claim 1, wherein the iron agglomerates have an average specific surface area ranging from 0.1 m2/g to 25 m2/g.

### Claim 9 (depends on 1)

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

### Claim 10 (depends on 9)

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

### Claim 11 (depends on 1)

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.

### Claim 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.

### Claim 13 (depends on 12)

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

### Claim 14 (depends on 12)

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

### Claim 15 (depends on 12)

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

### Claim 16 (depends on 12)

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

### Claim 17 (depends on 12)

The bulk energy storage system of claim 12, wherein the iron agglomerates have an average specific surface area ranging from 0.1 m2/g to 25 m2/g.

### Claim 18 (depends on 12)

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.