Electrode Stack Assembly for a Metal Hydrogen Battery

A method of forming a hydrogen metal battery, comprising:

• forming an electrode stack assembly, wherein forming the electrode stack assembly includes:
• assembling a plurality of cathode assemblies, each cathode assembly having cathode tabs attached to one or more cathode material layers,
• assembling a plurality of anode assemblies, each anode assembly having anode tabs coupled to one or more anode material layers,
• forming a plurality of separators from separator material,
• forming frame top portions and frame bottom portions,
• forming an anode feedthrough bridge assembly that includes an anode feedthrough terminal,
• forming a cathode feedthrough bridge assembly that includes a cathode feedthrough terminal,
• stacking the separators, anode assemblies, and cathode assemblies in alternate fashion between the frame top portion and the frame bottom portion to capture the electrodes between the frame top portion and the frame bottom portion,
• pressing the electrodes, the frame top portion, and the frame bottom portion,
• forming an electrode stack by attaching the frame top portion to the frame bottom portion to form a frame,
• attaching cathode tabs of the plurality of cathode assemblies in the electrode stack to the cathode feedthrough bridge assembly, and
• attaching anode tabs of the plurality of anode assembles in the electrode stack to the anode feedthrough bridge assembly;
• attaching an anode end cap to a vessel side wall;
• inserting the electrode stack assembly into the vessel side wall so that the anode feedthrough terminal engages with the anode end cap;
• attaching a cathode end cap to the vessel side wall such that the cathode feedthrough terminal passes through a feedthrough in the cathode end cap.