Redox and plating electrode systems for an all-iron hybrid flow battery

• US 9,614,244 B2
• Filed: 09/05/2013
• Issued: 04/04/2017
• Est. Priority Date: 09/05/2012
• Status: Active Grant

• Current Assignee: ESS Tech, Inc.
• Original Assignee: ESS Tech, Inc.
• Inventors: Evans, Craig, Song, Yang
• Primary Examiner(s): Ruddock, Ula C
• Assistant Examiner(s): PARSONS, THOMAS H
• Application Number:
  US14/019,488
• Publication Number:
  US 20140065460A1
• Time in Patent Office: 1,307 Days
• CPC Class Codes: H01M 50/60 Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
• CPC Class Codes: H01M 8/04186 of liquid-charged or electrolyte-charged reactants
• CPC Class Codes: H01M 8/188 by recharging of redox couples containing fluids; Redox flow type batteries
• CPC Class Codes: H01M 8/20 Indirect fuel cells, e.g. fuel cells with redox couple being irreversible H01M8/18 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 137/4757 Battery or electrolytic cell replenishment

Abstract

A system for a flow cell for a hybrid flow battery, comprising: a redox plate comprising a plurality of electrolyte flow channels; conductive inserts attached to the redox plate between adjacent electrolyte flow channels; a redox electrode attached to a surface of the redox plate; a plating electrode, comprising: a plurality of folded fins with an oscillating cross-section, the plurality of folded fins comprising: a first planar surface; a second planar surface, parallel to the first planar surface; a plurality of ridges intersecting the first and second planar surfaces such that the plurality of ridges divide the first planar surface into a first plurality of strips, and divide the second planar surface into a second plurality of strips; and a membrane barrier. In this way, the capacity and performance of hybrid flow batteries may be maximized, through decreasing the reaction kinetics, mass transport and ohmic resistance losses at both electrodes.

Claims

1. A system for a flow cell for a hybrid flow battery, comprising:

one or more electrolyte inlets;

one or more electrolyte outlets;

a redox plate, comprising;

a plurality of electrolyte flow channels;

conductive inserts attached to the redox plate between adjacent electrolyte flow channels; and

a redox electrode attached to a surface of the redox plate;

where the conductive inserts have a long edge parallel to a long edge of the electrolyte flow channels, the long edge of the conductive inserts extending along a first side of a polymeric plate;

a plating electrode, comprising a plurality of folded fins with an oscillating cross-section, the plurality of folded fins comprising;

a first planar surface;

a second planar surface, parallel to the first planar surface and displaced from the first planar surface in a first direction, the first direction being normal to the first and second planar surfaces and extending from the first planar surface toward the second planar surface;

a plurality of ridges intersecting the first and second planar surfaces such that the plurality of ridges divides the first planar surface into a first plurality of strips, and divides the second planar surface into a second plurality of strips;

a first plurality of flow channels adjacent to the first plurality of strips in the first direction; and

a second plurality of flow channels adjacent to the second plurality of strips in a second direction, the second direction being opposite the first direction; and

a membrane barrier located between the redox electrode and the plating electrode.

2. The system of claim 1, wherein the electrolyte flow channels and conductive inserts form flow ribs that form a first edge of a first channel and a second edge of an adjacent second channel.

3. The system of claim 1, wherein the plurality of folded fins comprises a plurality of perforations.

4. A system for an electrolyte flow plate for a hybrid flow battery, comprising:

a polymeric plate comprising a plurality of electrolyte flow channels; and

a plurality of conductive inserts attached to the polymeric plate between adjacent electrolyte flow channels;

where a length of the conductive inserts is greater than a width of the conductive inserts, the length extending along a first side of the polymeric plate;

wherein the electrolyte flow channels are voids comprising a long edge extending the length of the first side of the polymeric plate.

5. The system of claim 4, wherein the conductive inserts comprise rectangular prisms having a long edge parallel to the long edge of the electrolyte flow channels, and extending the length of the first side of the polymeric plate.

6. The system of claim 5, wherein the electrolyte flow channels and conductive inserts form flow ribs that form a first edge of a first channel and a second edge of an adjacent second channel.

7. The system of claim 6, wherein the electrolyte flow channels are sloped from a base of the polymeric plate to a top face of the polymeric plate.

8. The system of claim 6, wherein the electrolyte flow channels include two or more steps from a base of the polymeric plate to a top face of the polymeric plate.

9. The system of claim 4, where the electrolyte flow channels are interdigitated or partially interdigitated.

10. The system of claim 4, wherein the conductive inserts are Carbon/Graphite composite inserts.

11. A plating electrode for a battery, comprising:

a plurality of folded fins with an oscillating cross-section, the plurality of folded fins comprising;

a first planar surface;

a second planar surface, parallel to the first planar surface, and displaced from the first planar surface in a first direction, the first direction being normal to the first and second planar surfaces and extending from the first planar surface toward the second planar surface;

a plurality of ridges intersecting the first and second planar surfaces such that the plurality of ridges divides the first planar surface into a first plurality of strips, and divides the second planar surface into a second plurality of strips;

a first plurality of flow channels adjacent to the first plurality of strips in the first direction; and

a second plurality of flow channels adjacent to the second plurality of strips in a second direction, the second direction being opposite the first direction.

12. The plating electrode of claim 11, where the plurality of ridges is perpendicular to the first and second planar surfaces.

13. The plating electrode of claim 12, where the plurality of ridges includes a plurality of serrations.

14. The plating electrode of claim 11, where the first plurality of strips has a first width, and the second plurality of strips has a second width, the second width being greater than the first width.

15. The plating electrode of claim 11, where the plurality of folded fins comprises a plurality of perforations.

16. The plating electrode of claim 11, where the first planar surface is coated with a non-conductive material.

17. The plating electrode of claim 11, where the plurality of folded fins is fabricated from iron, an iron alloy, stainless steel, titanium, or carbon.

18. The plating electrode of claim 11, further comprising:

a base plate coupled to the second planar surface such that the base plate, the plurality of ridges, and the first plurality of strips form a plurality of channels.

19. The plating electrode of claim 18, further comprising:

one or more interdigitation or partial interdigitation plates, each interdigitation or partial interdigitation plate being perpendicular to the base plate and intersecting with a first end of the plurality of channels such that a flow of an electrolyte is restricted through the first end of the plurality of channels.