Devices, systems, and methods for molten fluid electrode apparatus management

• US 10,461,311 B1
• Filed: 05/17/2018
• Issued: 10/29/2019
• Est. Priority Date: 05/17/2018
• Status: Active Grant

• Current Assignee: Vissers Battery Corporation
• Original Assignee: Vissers Battery Corporation
• Inventors: Vissers, Daniel R., Tenorio, Manoel
• Primary Examiner(s): Marks, Jacob B
• Application Number:
  US15/982,497
• Publication Number:
  US 20190355967A1
• Time in Patent Office: 530 Days
• CPC Class Codes: H01M 10/39 working at high temperature
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 2300/0068 inorganic
• CPC Class Codes: H01M 4/0476 with molten material
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An apparatus comprises a plurality of negative electrode reservoirs configured to contain a negative electrode material, a plurality of positive electrode reservoirs configured to contain a positive electrode material and a reaction chamber. A heating system is configured to heat negative electrode material within a selected negative electrode material reservoir and to heat positive electrode material in a selected positive electrode material reservoir to maintain the electrode materials in the selected reservoirs in a fluid state while maintaining, in a non-fluid state, negative electrode material in a non-selected negative electrode reservoir and positive electrode material in a non-selected positive electrode reservoir. An electrode material distribution system is configured to cycle fluid positive electrode material between the selected positive electrode reservoir and the reaction chamber and configured to transfer, during a discharge state of the apparatus, fluid negative electrode material from the selected negative electrode reservoir to the reaction chamber.

Claims

1. An apparatus comprising:

a plurality of negative electrode reservoirs configured to contain a negative electrode material;

a plurality of positive electrode reservoirs configured to contain a positive electrode material;

a heating system configured to heat negative electrode material within a selected negative electrode reservoir of the plurality of negative electrode reservoirs to maintain the negative electrode material contained in the selected negative electrode reservoir in a fluid state and configured to heat positive electrode material in a selected positive electrode reservoir to maintain the positive electrode material contained in the selected positive electrode reservoir in the fluid state while maintaining, in a non-fluid state, negative electrode material in a non-selected negative electrode reservoir and positive electrode material in a non-selected positive electrode reservoir;

a reaction chamber comprising a solid electrolyte positioned in the reaction chamber to form a positive electrode region on a first side of the solid electrolyte and to form a negative electrode region on a second side of the solid electrolyte; and

an electrode material distribution system configured to cycle fluid positive electrode material between the selected positive electrode reservoir and the positive electrode region and configured to transfer, during a discharge state of the apparatus, fluid negative electrode material from the selected negative electrode reservoir to the negative electrode region.

2. The apparatus of claim 1, wherein the negative electrode material comprises lithium (Li), the positive electrode material comprises sulfur (S), and the solid electrolyte comprises lithium (Li).

3. The apparatus of claim 2, wherein the solid electrolyte comprises lithium iodide (LiI).

4. The apparatus of claim 3, wherein the electrode material distribution system is further configured to transfer, during a charge state of the apparatus, fluid negative electrode material from the negative electrode region to the selected negative electrode reservoir.

5. The apparatus of claim 4, wherein the electrode material distribution system comprises a negative electrode material distribution system comprising a plurality of negative material distribution valves wherein each negative material distribution valve is connected between a negative electrode material reservoir of the plurality of electrode material reservoirs and the negative electrode region, the negative material distribution valves configured to be opened and closed such that a selected negative material distribution valve connected between the selected negative electrode material reservoir and the negative electrode region is open.

6. The apparatus of claim 5, wherein fluid negative electrode material flows from the selected negative electrode reservoir to the negative electrode region at least partially due to gravity during the discharge state of the apparatus.

7. The apparatus of claim 5, wherein the electrode material distribution system comprises a positive electrode material distribution system comprising:

a pump connected to the positive electrode region;

a plurality of positive material distribution valves comprising a positive material distribution valve connected to each of the plurality of positive electrode material reservoirs.

8. The apparatus of claim 5, wherein the electrode material distribution system comprises a positive electrode material distribution system comprising:

a supply pump connected to the positive electrode region;

a return pump connected to the positive electrode region;

a plurality of positive material distribution supply valves comprising a positive material distribution supply valve connected between each positive electrode material reservoir of the plurality of positive electrode material reservoirs and the supply pump;

a plurality of positive material distribution return valves comprising a positive material distribution return valve connected between each positive electrode material reservoir of the plurality of positive electrode material reservoirs and the return pump, wherein the plurality of positive material distribution supply valves and the plurality of positive material distribution return values are configured such that a selected positive material distribution supply valve connected between the selected positive electrode material reservoir and the supply pump is open and wherein a selected positive material distribution return valve connected between the selected positive electrode material reservoir and the return pump is open.

9. The apparatus of claim 8, further comprising:

a controller configured to;

cause the heating system to heat a standby negative electrode material reservoir to maintain negative electrode material within the standby negative electrode material reservoir in a fluid state;

open a standby negative material distribution valve between the standby negative electrode material reservoir and the negative electrode region;

close the selected negative material distribution valve; and

cause the heating system to stop heating the selected negative electrode material reservoir.

10. The apparatus of claim 9, wherein the controller is configured to:

cause the heating system to heat the standby negative electrode material reservoir in response to a first negative discharge threshold; and

in response to a second negative discharge threshold, to open the standby negative material distribution valve, close the selected negative material distribution valve, and cause the heating system to stop heating the selected negative electrode material reservoir.

11. The apparatus of claim 10, wherein the first negative discharge threshold is related to a first volume of negative electrode material in the selected negative electrode material reservoir and wherein the second negative discharge threshold is related to a second volume of negative electrode material in the selected negative electrode material reservoir.

12. The apparatus of claim 11, further comprising at least one current sensor providing current data to the controller, the controller configured to determine the volume of negative electrode material in the selected negative electrode material reservoir at least partially based on the current data.

13. The apparatus of claim 12, the controller configured to determine the volume of negative electrode material in the selected negative electrode material reservoir by integrating a current level produced by the reaction chamber over time to determine a total charge transferred through the reaction chamber, and correlating the total charge transferred to a volume of negative electrode material removed from the negative electrode material reservoir.

14. The apparatus of claim 8, further comprising:

a controller configured to;

cause the heating system to heat a standby positive electrode material reservoir to maintain positive electrode material within the standby positive electrode material reservoir in a fluid state;

open a standby positive material distribution supply valve between the standby positive electrode material reservoir and the positive electrode region;

open a standby positive material distribution return valve between the standby positive electrode material reservoir and the positive electrode region;

close the selected positive material distribution supply valve;

close the selected positive material distribution return valve; and

cause the heating system to stop heating the selected positive electrode material reservoir.

15. The apparatus of claim 14, wherein the controller is configured to:

cause the heating system to heat the standby positive electrode material reservoir in response to a first positive discharge threshold; and

in response to a second positive discharge threshold, to open the standby positive material distribution supply valve, to open the standby positive material distribution return valve, close the selected positive material distribution supply valve, close the selected positive material distribution return valve, and cause the heating system to stop heating the selected positive electrode material reservoir.

16. The apparatus of claim 15, wherein the first positive discharge threshold is related to a first volume of positive electrode material in the selected positive electrode material reservoir and wherein the second positive discharge threshold is related to a second volume of positive electrode material in the selected positive electrode material reservoir.

17. The apparatus of claim 16, further comprising at least one current sensor providing current data to the controller, the controller configured to determine the volume of positive electrode material in the selected negative electrode material reservoir at least partially based on the current data.

18. The apparatus of claim 17, the controller configured to determine the volume of positive electrode material in the selected positive electrode material reservoir by integrating a current level produced by the reaction chamber over time to determine a total charge transferred through the reaction chamber, and correlating the total charge transferred to a volume of positive electrode material removed from the negative electrode material reservoir.

19. The apparatus of claim 1, further comprising:

a negative electrode material reservoir housing enclosing the plurality of negative electrode material reservoirs;

a positive electrode material reservoir housing enclosing the plurality of positive electrode material reservoirs; and

a reaction chamber housing enclosing the reaction chamber.

20. The apparatus of claim 19, wherein the negative electrode material reservoir housing, the positive electrode material reservoir housing and the reaction chamber housing have interiors under vacuum.

21. The apparatus of claim 19, wherein the negative electrode material reservoir housing, the positive electrode material reservoir housing and the reaction chamber housing have interiors comprising air.

22. The apparatus of claim 19, wherein the negative electrode material reservoir housing, the positive electrode material reservoir housing and the reaction chamber housing have interiors comprising argon gas.

23. The apparatus of claim 19, further comprising a main housing enclosing the negative electrode material reservoir housing, the positive electrode material reservoir housing, and the reaction chamber housing.

24. The apparatus of claim 23, wherein an interior surface of the negative electrode material reservoir housing, an interior surface of the positive electrode material reservoir housing, an interior surface of the reaction chamber housing, and an interior surface of the main housing are coated with a coating material configured to protect the interiors surfaces from chemical attack from the electrode materials.

25. The apparatus of claim 1, further comprising:

a reaction chamber container comprising;

a negative electrode container portion and forming, with the solid electrolyte, the negative electrode region, the negative electrode container portion having an inner surface coated with a negative electrode coating material configured to protect the negative electrode container portion from chemical attack from the negative electrode material; and

a positive electrode container portion forming, with the solid electrolyte, the positive electrode region, the positive electrode container portion having an inner surface coated with a positive electrode coating material configured to protect the positive electrode container portion from chemical attack from the positive electrode material.

26. The apparatus of claim 25, wherein the negative electrode coating material and the positive electrode coating material are non-electrically conductive.

27. The apparatus of claim 26, further comprising:

a negative electrode current collector positioned within the negative electrode region and having a surface coated with a negative electrically conductive coating material configured to protect the negative electrode current collector from chemical attack from the negative electrode material; and

a positive electrode current collector positioned within the positive electrode region and having a surface coated with a positive electrically conductive coating material configured to protect the positive electrode current collector from chemical attack from the positive electrode material.

28. The apparatus of claim 27, wherein the positive non-electrically conductive coating material is the same as the negative non-electrically conductive coating material.

29. The apparatus of claim 25, wherein:

the negative electrode container portion is electrically conductive and forms a negative electrode current collector;

the positive electrode container portion is electrically conductive and forms a positive electrode current collector; and

the negative electrode coating material and the positive electrode coating material are electrically conductive.

30. The apparatus of claim 1, wherein a total fluid electrode material comprises the fluid positive electrode material and the fluid negative electrode material, the apparatus further comprising a thermal runaway mitigation system configured to, in response to a thermal runaway trigger, cool at least a portion of the total fluid electrode material.

31. The apparatus of claim 30, wherein the thermal runaway mitigation system is configured to cool at least the portion of the fluid electrode material to a temperature below the melting point of the at least the portion of the fluid electrode material to maintain the at least the portion of fluid electrode material in a solid state.

32. The apparatus of claim 30, wherein the thermal runaway mitigation system is configured to cool at least a portion of the fluid negative electrode material and at least a portion of the fluid positive electrode material.

33. The apparatus of claim 32, wherein the thermal runaway mitigation system is configured to cool at least the portion of the fluid negative electrode material to a negative electrode freezing temperature below the melting point of the at least the portion of fluid negative electrode material and to cool at least the portion of the fluid positive electrode material to a positive electrode freezing temperature below the melting point of the at least the portion of fluid positive electrode material.

34. The apparatus of claim 30, wherein the thermal runaway mitigation system is configured to direct a cooling heat transfer fluid to an area that allows the cooling heat transfer fluid to be thermally conductive with the at least the portion fluid electrode material.

35. The apparatus of claim 1, further comprising an auxiliary power supply configured to provide power to the heating system during a startup procedure where:

the reaction chamber is heated to bring negative fluid electrode material within the negative electrode region from a negative electrode initial temperature that is below a negative material melting point to a negative electrode operating temperature above the negative material melting point; and

the reaction chamber is heated to bring positive fluid electrode material within the positive electrode region from a positive electrode initial temperature that is below a positive material melting point to a positive electrode operating temperature above the positive material melting point.

36. The apparatus of claim 33, wherein during the startup procedure:

the selected negative reservoir is heated to bring negative fluid electrode material within the selected negative reservoir from a negative reservoir initial temperature that is below the negative material melting point to a negative reservoir operating temperature above the negative material melting point; and

the selected positive reservoir is heated to bring positive fluid electrode material within the selected positive reservoir from a positive reservoir initial temperature that is below the positive material melting point to a positive reservoir operating temperature above the positive material melting point.

37. The apparatus of claim 1, wherein the solid electrolyte has a lithium iodide lattice comprising a plurality of lithium cations, a plurality of iodide anions and a plurality of defects.

38. The apparatus of claim 37, wherein the plurality of defects comprises a plurality of grain boundary defects associated with introduction of a plurality of nanoparticles to lithium iodide forming the lithium iodide.

39. The apparatus of claim 38, the plurality of grain boundary defects comprising at least one of:

a plurality of nanoparticle grain boundary defects resulting at grain boundaries of the plurality of nanoparticles; and

a plurality of pinned grain boundary defects formed prior to the introduction of the plurality of nanoparticles and maintained in the lithium iodide lattice at least partially as a result of the introduction of the plurality of nanoparticles.

40. A molten electrode battery system comprising:

a plurality of negative electrode reservoirs configured to contain a negative electrode material;

a plurality of positive electrode reservoirs configured to contain a positive electrode material;

a heating system configured to heat negative electrode material within a plurality of selected negative electrode reservoirs of the plurality of negative electrode reservoirs to maintain the negative electrode material contained in the selected plurality of negative electrode reservoirs in a fluid state and configured to heat positive electrode material in a plurality of selected positive electrode reservoirs to maintain the positive electrode material contained in the selected positive electrode reservoirs in a fluid state while maintaining, in a non-fluid state, negative electrode material in a non-selected negative electrode reservoir and positive electrode material in a non-selected positive electrode reservoir;

a plurality of reaction chambers, each reaction chamber comprising a solid electrolyte positioned in the reaction chamber to form a positive electrode region on a first side of the solid electrolyte and to form a negative electrode region on a second side of the solid electrolyte; and

an electrode material distribution system configured to;

cycle fluid positive electrode material between a first selected positive electrode reservoir of the plurality of selected positive electrode reservoirs and the positive electrode region of a first reaction chamber of the plurality of reaction chambers;

transfer, during a discharge state of the apparatus, fluid negative electrode material from a first selected negative electrode material reservoir of the selected negative electrode reservoirs to the negative electrode region of the first reaction chamber;

cycle fluid positive electrode material between a second selected positive electrode reservoir of the plurality of selected positive electrode reservoirs and the positive electrode region of a second reaction chamber of the plurality of reaction chambers; and

transfer, during a discharge state of the apparatus, fluid negative electrode material from a second negative electrode material reservoir of the selected negative electrode reservoirs to the negative electrode region of the second reaction chamber.

41. A flow battery system comprising:

a plurality of negative electrode reservoirs configured to contain a negative electrode material;

a plurality of positive electrode reservoirs configured to contain a positive electrode material;

a heating system configured to heat negative electrode material within a plurality of selected negative electrode reservoirs of the plurality of negative electrode reservoirs to maintain the negative electrode material contained in the selected plurality of negative electrode reservoirs in a fluid state and configured to heat positive electrode material in a plurality of selected positive electrode reservoirs to maintain the positive electrode material contained in the selected positive electrode reservoirs in a fluid state while maintaining, in a non-fluid state, negative electrode material in a non-selected negative electrode reservoir and positive electrode material in a non-selected positive electrode reservoir;

a plurality of reaction chambers, each reaction chamber comprising a solid electrolyte positioned in the reaction chamber to form a positive electrode region on a first side of the solid electrolyte and to form a negative electrode region on a second side of the solid electrolyte, each reaction chamber connected to at least one of the plurality of selected negative electrode reservoirs and at least one of the plurality of selected positive electrode reservoirs;

a negative electrode material reservoir housing enclosing the plurality of negative electrode material reservoirs and having an interior under vacuum;

a positive electrode material reservoir housing enclosing the plurality of positive electrode material reservoirs and having an interior under vacuum; and

a reaction chamber housing enclosing the reaction chamber and having an interior under vacuum.

42. The battery system of claim 41, further comprising a main housing enclosing the negative electrode material reservoir housing, the positive electrode material reservoir housing, and the reaction chamber housing.

43. The battery system of claim 42, wherein an interior surface of the negative electrode material reservoir housing, an interior surface of the positive electrode material reservoir housing, an interior surface of the reaction chamber housing, and an interior surface of the main housing are coated with a coating material configured to protect the interior surfaces from chemical attack from the contained electrode materials.

44. A battery system comprising:

a plurality of negative electrode reservoirs configured to contain a negative electrode material;

a plurality of positive electrode reservoirs configured to contain a positive electrode material;

a heating system configured to heat negative electrode material within a plurality of selected negative electrode reservoirs of the plurality of negative electrode reservoirs to maintain the negative electrode material contained in the selected negative electrode reservoirs in a fluid state and configured to heat positive electrode material in a plurality of selected positive electrode reservoirs of the plurality of positive electrode reservoirs to maintain the positive electrode material contained in the selected positive electrode reservoirs in a fluid state while maintaining, in a non-fluid state, negative electrode material in at least one non-selected negative electrode reservoir and positive electrode material in at least one non-selected positive electrode reservoir;

a plurality of reaction chambers, each reaction chamber comprising a solid electrolyte positioned in the reaction chamber to form a positive electrode region on a first side of the solid electrolyte and to form a negative electrode region on a second side of the solid electrolyte, the reaction chamber configured to receive fluid negative electrode material in the negative electrode region from at least one of the selected negative electrode reservoirs and to receive fluid positive electrode material in the positive electrode region from at least one of the selected positive electrode reservoirs.

45. The battery system of claim 44, wherein the second side is opposite the first side.

46. The battery system of claim 45, wherein the negative electrode material comprises lithium (Li), the positive electrode material comprises sulfur (S), and the solid electrolyte comprises lithium (Li).

47. The battery system of claim 46 wherein the solid electrolyte comprises lithium iodide (LiI).

48. The battery system of claim 46, wherein the positive electrode material comprises phosphorous (P).

49. The battery system of claim 44, wherein the heating system is configured to heat the selected positive electrode reservoirs to maintain the temperature of the positive electrode material within the selected positive electrode reservoirs between 115°

C. and 469°

C. and to heat the selected negative electrode reservoirs to maintain the temperature of the negative electrode material within the selected negative electrode reservoirs between 115°

C. and 469°

C.

50. The battery system of claim 49, wherein the heating system is configured to heat the selected positive electrode reservoirs to maintain the temperature of the positive electrode material within the selected positive electrode reservoirs between 365°

C. and 469°

C. and to heat the selected negative electrode reservoirs to maintain the temperature of the negative electrode material within the selected negative electrode reservoirs between 365°

C. and 469°

C.

51. The battery system of claim 50, wherein the heating system is configured to heat the selected positive electrode reservoirs to maintain the temperature of the positive electrode material within the selected positive electrode reservoirs between 365°

C. and 444°

C. and to heat the selected negative electrode reservoirs to maintain the temperature of the negative electrode material within the selected negative electrode reservoirs between 365°

C. and 444°

C.

52. The battery system of claim 51, wherein the heating system is configured to heat the selected positive electrode reservoirs to maintain the temperature of the positive electrode material within the selected positive electrode reservoirs between 375°

C. and 425°

C. and to heat the selected negative electrode reservoirs to maintain the temperature of the negative electrode material within the selected negative electrode reservoirs between 375°

C. and 425°

C.

53. The battery system of claim 46, wherein the heating system is configured to heat the selected positive electrode reservoirs to maintain the temperature of the positive electrode material within the selected positive electrode reservoirs at approximately 400°

C. and to heat the selected negative electrode reservoirs to maintain the temperature of the negative electrode material within the selected negative electrode reservoirs at approximately 400°

C.

54. The battery system of claim 44, wherein a total number of reaction chambers is at least 14.

55. The battery system of claim 54, wherein a total number of negative electrode material reservoirs is at least 280.

56. The battery system of claim 55, wherein a total number of positive electrode material reservoirs is at least 140.