Stationary semi-solid battery module and method of manufacture

A method of manufacturing an electrochemical cell, the method comprising:

• disposing an anode injection nozzle in an anode compartment, the anode compartment defined at least in part by an anode current collector and a separator spaced from the anode current collector;
• transferring an anode semi-solid suspension to the anode compartment through the anode injection nozzle;
• withdrawing the anode injection nozzle from the anode compartment during at least a portion of the transferring;
• disposing a cathode injection nozzle in a cathode compartment, the cathode compartment defined at least in part by a cathode current collector and the separator spaced from the cathode current collector;
• transferring a cathode semi-solid suspension to the cathode compartment through the cathode injection nozzle;
• and
• withdrawing the cathode injection nozzle from the cathode compartment during at least a portion of the transferring.

A method of manufacturing an electrochemical cell, the method comprising:

• transferring to an anode compartment an anode semi-solid suspension, the anode compartment defined at least in part by an anode current collector and a separator, and including an anode support member disposed and configured to maintain the separator spaced from the anode current collector, the anode support member including a plurality of pins configured to resist displacement of the separator toward the anode current collector;
• transferring to a cathode compartment a cathode semi-solid suspension, the cathode compartment defined at least in part by a cathode current collector and the separator, and including a cathode support member disposed and configured to maintain the separator spaced from the cathode current collector, the cathode support member including a plurality of pins configured to resist displacement of the separator toward the cathode current collector, at least a portion of the plurality of pins of the anode support member being disposed in alignment with at least a portion of the plurality of pins of the cathode support member;
• maintaining the difference between a minimum distance between the anode current collector and the separator and a maximum distance between the anode current collector and the separator within a predetermined tolerance during the transferring to the cathode compartment;
• and
• sealing the anode compartment and the cathode compartment.

A method of manufacturing an electrochemical cell, the method comprising:

• transferring to an anode compartment an anode semi-solid suspension, the anode compartment defined at least in part by an anode current collector and a separator, and including an anode support member disposed and configured to maintain the separator spaced from the anode current collector, the anode support member including a plurality of posts configured to resist displacement of the separator toward the anode current collector;
• transferring to a cathode compartment a cathode semi-solid suspension, the cathode compartment defined at least in part by a cathode current collector and the separator, and including a cathode support member disposed and configured to maintain the separator spaced from the cathode current collector, the cathode support member including a plurality of posts configured to resist displacement of the separator toward the cathode current collector, at least a portion of the plurality of posts of the anode support member being disposed in alignment with at least a portion of the plurality of posts of the cathode support member;
• maintaining the difference between a minimum distance between the anode current collector and the separator and a maximum distance between the anode current collector and the separator within a predetermined tolerance during the transferring to the cathode compartment;
• and
• sealing the anode compartment and the cathode compartment.

A method of manufacturing an electrochemical cell, the method comprising:

• transferring to an anode compartment an anode semi-solid suspension, the anode compartment defined at least in part by an anode current collector and a separator, and including an anode support member disposed and configured to maintain the separator spaced from the anode current collector, the anode support member including a plurality of ridges configured to resist displacement of the separator toward the anode current collector;
• transferring to a cathode compartment a cathode semi-solid suspension, the cathode compartment defined at least in part by a cathode current collector and the separator, and including a cathode support member disposed and configured to maintain the separator spaced from the cathode current collector, the cathode support member including a plurality of ridges configured to resist displacement of the separator toward the cathode current collector, at least a portion of the plurality of ridges of the anode support member being disposed in alignment with at least a portion of the plurality of ridges of the cathode support member;
• maintaining the difference between a minimum distance between the anode current collector and the separator and a maximum distance between the anode current collector and the separator within a predetermined tolerance during the transferring to the cathode compartment;
• and
• sealing the anode compartment and the cathode compartment.

A method of manufacturing an electrochemical cell, the method comprising:

• transferring to an anode compartment an anode semi-solid suspension, the anode compartment defined at least in part by an anode current collector and a separator spaced from the anode current collector, wherein the anode compartment has an aspect ratio in the range of about 50 to about 2,500, and the anode semi-solid is transferred to the anode compartment via an edge of the anode compartment;
• transferring to a cathode compartment a cathode semi-solid suspension, the cathode compartment defined at least in part by a cathode current collector and the separator spaced from the cathode current collector while maintaining the difference between a minimum distance between the anode current collector and the separator and a maximum distance between the anode current collector and the separator within a predetermined tolerance;
• and
• sealing the anode compartment and the cathode compartment.