Patent Application
20240047810
Embodiments described herein relate to methods of formation of electrochemical cells and electrochemical cell stacks.
Existing lithium-ion manufacturing systems utilize individual cell formation systems where thousands or millions of cells are handled and processed via a formation process. Cells are then aged and degassed prior to installation. This processing is generally inefficient. Power systems for building electrochemical cells often operate at 0V-5V DC channels with very low power conversion efficiency. If the energy from discharge is not incorporated back into the grid, then 1 MWh of energy can be lost in the charging of each electrochemical cell. Additionally, conversion efficiency from a building grid to a production channel can be about 50-60%. Discharge system losses can also be about 5%. Conveyors and handling also add additional power load. Heating, ventilation, and air conditioning (HVAC) loading for removal of all the dissipated energy for discharge of the cells can add 1 MWh to the HVAC heat loading for the building, increasing tonnage for building systems. Total losses in a production system can be about 2.1 MWh for each 1 MWh produced, plus each additional 600 tons of refrigeration capacity may be necessary, assuming 1 MWh in Work in Progress (WIP). Capital cost is also a significant consideration. All of the equipment and machinery to move cells from one location to another during the formation process (e.g., conveyors, trays, baskets, fixtures, test channels, floorspace for formation aging and post-test) is an important aspect of the manufacture of each cell. Multiple locations and moves for each cell also increase the process complexity for the system and the cost of that system. The system size, complexity and cost are significant drivers for the inability to manufacture battery cells efficiently. Therefore, there is a need for more efficient systems and methods to store and transfer energy for manufacturing of electrochemical cells.
Embodiments described herein relate to systems and methods for forming electrochemical cells and electrochemical cell modules connected in series. In some aspects, a method of forming an electrochemical cell, the electrochemical cell including an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, and a separator disposed between the anode material and the cathode material, includes transferring energy from an energy storage system to a battery formation system to charge the electrochemical cell, and transferring energy from the electrochemical cell to the energy storage system to prevent heat energy dissipation into the formation system, wherein the energy transferred is direct current (DC).
In some aspects, a system for forming an electrochemical cell module includes a first electrochemical cell module and a second electrochemical cell module connected in series, the first electrochemical cell module and the second electrochemical cell module configured to receive energy via an energy storage system; a first switch connected in series with the first electrochemical cell module and a second switch connected in parallel with the first electrochemical cell module. The first switch and the second switch have (1) a first configuration in which the first switch is closed and the second switch is open such that current moves through the first electrochemical cell module, and (2) a second configuration in which the first switch is open and the second switch is closed such that current moves directly to the second electrochemical cell module, bypassing the first electrochemical cell module. The system further includes a controller configured to transition the first switch and the second switch between the first configuration and the second configuration, thereby directing current flow to charge and discharge the first electrochemical cell module and second electrochemical cell module.
In some aspects, a system includes an energy storage system configured to receive energy from one or more power sources, and a formation system including a plurality of electrochemical cells connected in series and configured to control current flow through the plurality of electrochemical cells via a controller electrically coupled to a plurality of switches. The plurality of electrochemical cells connected to the energy storage system via a DC electrical connection such that energy is transferred between the plurality of electrochemical cells and the energy storage system without an AC transformer.
Embodiments described herein describe production of electrochemical cells as part of a module build. Module building can include a method of bypassing components of the battery formation system with current flow during formation of the electrochemical cell. High voltage cells, module and packs can be built and then the cells can be formed in higher voltage system blocks. Modules can be assembled and sent to formation area, where connected in series to achieve a higher total voltage (e.g., 500 V). However, any intermediate voltage may be selected based on building, safety, process, grid, or battery formation-test machine needs. Limitations on voltage can also be based on available DC/DC or AC/DC conversion technologies based on cost or conversion efficiencies. A control system for bypassing energy (charge, discharge both) around modules, cells, or packs can ensure safe operation, preventing overcharge and allowing for full formation of each cell. A safety system can monitor temperature, current, and/or voltage to prevent cell damage and thermal runaway due to over-temperature, over-charge or over-discharge.
Embodiments described herein can include algorithms to detect cell level failure, internal shorts, and other failure modes using sensors. Sensing can be used to sense or determine cell voltage, temperature, current, module level voltage, module level temperature, module level current, pack level voltage, pack level temperature, and/or pack level current. Algorithms can then be used to diagnose the functional status of each cell in the system. In some cases, sensing can be accomplished via a battery management system (BMS), test system sensing, secondary sensing systems, or any combination thereof. Safety systems can include area temperature (hot spot), fire detection, smoke detection, hydrogen detection, carbon monoxide (CO) detection, carbon dioxide (CO2) detection, volatile organic compound (VOC) detection, or other detection methods to ensure the systems are not damaged or to prevent damage to the system, batteries and facilities during formation. Safety systems can include fire suppression systems to prevent facility damage, active venting systems to prevent facility damage and personal injury, and protection systems to provide propagation protection between cells, modules, and/or battery packs under formation.
In some embodiments, an energy storage system can store and circulate power to and from formation systems. In some embodiments, the energy storage system can include a storage device. In some embodiments, the energy storage system can distribute DC power at a building or campus level. The energy storage system can also reduce parasitic losses due to transformers, power factor correction systems, and/or other AC components. A dual use of an energy storage system as a facility backup for critical systems is also applicable. In some embodiments, the energy storage system can function as a dry room backup to protect WIP from damage due to a loss of system power. In some embodiments, an energy system can include bi-directional power conversion between AC and DC in order to share power to and from a building grid, either in front of or behind an electrical meter. In some embodiments, an energy storage system can include bi-directional power conversion between AC and DC in order to share power to and from the building grid in a secondary or remote location to control the total power conversion at a campus or grid scale. In some embodiments, an energy storage system can include a bi-directional power conversion between AC and DC in order to share power to and from the building grid in a secondary or remote location to control total power conversion at a facility, multiple facilities, a campus, a micro grid, and/or a macro grid in order to create a secondary AC grid for power distribution.
In some embodiments, an energy storage system can include a bi-directional power conversion between DC and DC in order to share power to and from the formation system without additional AC conversion loss. In some embodiments, the energy storage system can include a bi-directional power conversion between DC and DC in order to share power to create a common DC power distribution within a single facility. In some embodiments, an energy storage system can include bi-directional power conversion between DC and DC in order to share power to create a common DC power distribution between two or more facilities. In some embodiments, an energy storage system can include bi-directional power conversion between DC and DC in order to share power to create a common DC distribution at a campus, a micro grid, or a macro grid level. In some embodiments, renewable power can provide energy to make up for conversion losses in the formation system, generating an off-grid formation system or a low power formation system.
In some embodiments, an energy storage system can include a grid or renewable connection for metering energy to the formation system and providing energy to account for efficiency losses. In some embodiments, an energy storage system with building controls can monitor power needs throughout the facility and campus to provide demand load, frequency regulation, peak shaving, load leveling, and/or other grid firming operations. In some embodiments, an energy storage system can serve a formation system and/or other secondary renewable uses, such as charging station power for plug-in-hybrid-electric vehicles (PHEV's), electric vehicles (EV's), or any other suitable implementations.
Monitoring voltage at various points throughout cells or electrodes can be an important aspect of building an energy storage system. Differences in voltage gradients or inflection points can help identify problematic cells or electrodes. Identifying these faulty elements during production or even during operation can significantly limit the downtime of the energy storage system during repair or replacement.
In some embodiments, electrodes described herein can include conventional solid electrodes. In some embodiments, the solid electrodes can include binders. In some embodiments, electrodes described herein can include semi-solid electrodes. Semi-solid electrodes described herein can be made: (i) thicker (e.g., greater than 100 μm-up to 2,000 μm or even greater) due to the reduced tortuosity and higher electronic conductivity of the semi-solid electrode, (ii) with higher loadings of active materials, and (iii) with a simplified manufacturing process utilizing less equipment. These relatively thick semi-solid electrodes decrease the volume, mass and cost contributions of inactive components with respect to active components, thereby enhancing the commercial appeal of batteries made with the semi-solid electrodes. In some embodiments, the semi-solid electrodes described herein are binderless and/or do not use binders that are used in conventional battery manufacturing. Instead, the volume of the electrode normally occupied by binders in conventional electrodes, is now occupied by: 1) electrolyte, which has the effect of decreasing tortuosity and increasing the total salt available for ion diffusion, thereby countering the salt depletion effects typical of thick conventional electrodes when used at high rate, 2) active material, which has the effect of increasing the charge capacity of the battery, or 3) conductive additive, which has the effect of increasing the electronic conductivity of the electrode, thereby countering the high internal impedance of thick conventional electrodes. The reduced tortuosity and a higher electronic conductivity of the semi-solid electrodes described herein, results in superior rate capability and charge capacity of electrochemical cells formed from the semi-solid electrodes. Since the semi-solid electrodes described herein, can be made substantially thicker than conventional electrodes, the ratio of active materials (i.e., the semi-solid cathode and/or anode) to inactive materials (i.e., the current collector and separator) can be much higher in a battery formed from electrochemical cell stacks that include semi-solid electrodes relative to a similar battery formed form electrochemical cell stacks that include conventional electrodes. This substantially increases the overall charge capacity and energy density of a battery that includes the semi-solid electrodes described herein.
In some embodiments, the electrode materials described herein can be a flowable semi-solid or condensed liquid composition. In some embodiments, the electrode materials described herein can be binderless or substantially free of binder. A flowable semi-solid electrode can include a suspension of an electrochemically active material (anodic or cathodic particles or particulates), and optionally an electronically conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. Said another way, the active electrode particles and conductive particles are co-suspended in an electrolyte to produce a semi-solid electrode. Examples of battery architectures utilizing semi-solid suspensions are described in U.S. Patent Publication No. 2022/0238923 (“the '923 publication”), filed Jan. 21, 2022 and titled “Production of Semi-Solid Electrodes Via Addition of Electrolyte to Mixture of Active Material, Conductive Material, and Electrolyte Solvent,” and U.S. patent application Ser. No. 18/212,414 (“the '414 application”), filed Jun. 21, 2023 and titled “Electrochemical Cells with High-Viscosity Semi-solid Electrodes, and Methods of Making the Same,” the entire disclosures of which are hereby incorporated by reference.
In some embodiments, power management systems described herein can include any of the aspects described in U.S. Pat. No. 10,153,651 (“the '651 patent”), filed Oct. 9, 2015, and titled, “Systems and Methods for Battery Charging,” the disclosure of which is hereby incorporated by reference in its entirety. In some embodiments, battery management systems described herein can include any of the aspects described in U.S. patent application Ser. No. 17/743,631 (“the '631 application”), filed Nov. 20, 2020, and titled, “Electrochemical Cells Connected in Series in a Single Pouch and Methods of Making the Same,” the disclosure of which is hereby incorporated by reference in its entirety.
As used in this specification, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, the term “a member” is intended to mean a single member or a combination of members, “a material” is intended to mean one or more materials, or a combination thereof.
The term “substantially” when used in connection with “cylindrical,” “linear,” and/or other geometric relationships is intended to convey that the structure so defined is nominally cylindrical, linear or the like. As one example, a portion of a support member that is described as being “substantially linear” is intended to convey that, although linearity of the portion is desirable, some non-linearity can occur in a “substantially linear” portion. Such non-linearity can result from manufacturing tolerances, or other practical considerations (such as, for example, the pressure or force applied to the support member). Thus, a geometric construction modified by the term “substantially” includes such geometric properties within a tolerance of plus or minus 5% of the stated geometric construction. For example, a “substantially linear” portion is a portion that defines an axis or center line that is within plus or minus 5% of being linear.
As used herein, the term “set” and “plurality” can refer to multiple features or a singular feature with multiple parts. For example, when referring to a set of electrodes, the set of electrodes can be considered as one electrode with multiple portions, or the set of electrodes can be considered as multiple, distinct electrodes. Additionally, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered as multiple, distinct electrochemical cells or as one electrochemical cell with multiple portions. Thus, a set of portions or a plurality of portions may include multiple portions that are either continuous or discontinuous from each other. A plurality of particles or a plurality of materials can also be fabricated from multiple items that are produced separately and are later joined together (e.g., via mixing, an adhesive, or any suitable method).
As used herein, the term “semi-solid” refers to a material that is a mixture of liquid and solid phases, for example, such as a particle suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle.
As used herein, the terms “activated carbon network” and “networked carbon” relate to a general qualitative state of an electrode. For example, an electrode with an activated carbon network (or networked carbon) is such that the carbon particles within the electrode assume an individual particle morphology and arrangement with respect to each other that facilitates electrical contact and electrical conductivity between particles and through the thickness and length of the electrode. Conversely, the terms “unactivated carbon network” and “unnetworked carbon” relate to an electrode wherein the carbon particles either exist as individual particle islands or multi-particle agglomerate islands that may not be sufficiently connected to provide adequate electrical conduction through the electrode.
As used herein, the terms “energy density” and “volumetric energy density” refer to the amount of energy (e.g., MJ) stored in an electrochemical cell per unit volume (e.g., L) of the materials included for the electrochemical cell to operate such as, the electrodes, the separator, the electrolyte, and the current collectors. Specifically, the materials used for packaging the electrochemical cell are excluded from the calculation of volumetric energy density.
As used herein, the terms “high-capacity materials” or “high-capacity anode materials” refer to materials with irreversible capacities greater than 300 mAh/g that can be incorporated into an electrode in order to facilitate uptake of electroactive species. Examples include tin, tin alloy such as Sn—Fe, tin mono oxide, silicon, silicon alloy such as Si—Co, silicon monoxide, aluminum, aluminum alloy, mono oxide metal (CoO, FeO, etc.) or titanium oxide.
As used herein, the term “composite high-capacity electrode layer” refers to an electrode layer with both a high-capacity material and a traditional anode material, e.g., a silicon-graphite layer.
As used herein, the term “solid high-capacity electrode layer” refers to an electrode layer with a single solid phase high-capacity material, e.g., sputtered silicon, tin, tin alloy such as Sn—Fe, tin mono oxide, silicon, silicon alloy such as Si—Co, silicon monoxide, aluminum, aluminum alloy, mono oxide metal (CoO, FeO, etc.) or titanium oxide.
Electrochemical cells and electrochemical cell modules typically undergo formation, which involves an initial round of charging and discharging, as part of the manufacturing process. Battery formation systems (hereinafter “formation systems”) are systems or apparatuses for forming electrochemical cells. A formation system typically resides in a battery manufacturing facility, the battery manufacturing facility including a variety of other amenities for battery manufacturing such as, for example, electrochemical cell assembly lines, manufacturing rooms, dry rooms, heating, ventilation, and air conditioning (HVAC) systems for cooling, equipment for moving supplies, etc. On a higher level, a battery manufacturing campus (hereinafter “campus”) can include an aggregate of battery manufacturing facilities and other resources useful for battery manufacturing, but is not limited to battery manufacturing. Streamlined transfer of energy between elements at the formation system level, the manufacturing facility level, and the campus level is important for significantly reducing costs and materials and improving overall efficiency of manufacturing.
In some embodiments, the energy storage system 350 may provide energy for a facility, a campus, or a macro grid level DC supply with a low voltage (i.e., a voltage of about 0V to about 100 V). The energy storage system 350 may provide a voltage supply of no more than about 400 V, no more than about 350 V, no more than about 300 V, no more than about 250 V, no more than about 200 V, no more than about 150 V, no more than about 100 V, no more than about 95 V, no more than about 90 V, no more than about 85 V, no more than about 80 V, no more than about 75 V, no more than about 70V, no more than about 65 V, no more than about 60 V, no more than about 55 V, no more than about 50 V, no more than about 45 V, no more than about 40 V, no more than about 35 V, no more than about 30 V, no more than about 25 V, no more than about 20 V, no more than about 15 V, or no more than about 10 V.
In some embodiments, the energy storage system 350 may provide energy for a facility, a campus, or a macro grid level DC supply with a high voltage (a voltage of greater than about 250V). The energy storage system 250 may provide a voltage supply of at least about 200V, at least about 250 V, at least about 300 V, at least about 350 V, at least about 400 V, at least about 410 V, at least about 420 V, at least about 430 V, at least about 440 V, at least about 450 V, at least about 460 V, at least about 470 V, at least about 480 V, at least about 490 V, at least about 500 V, at least about 510 V, at least about 520 V, at least about 530 V, at least about 540 V, at least about 550 V, at least about 600 V, at least about 700 V, or at least about 800 V.
In some embodiments, the energy storage system 350 may allocate energy stored (such as excess energy generated by formation of the battery modules 310) to power one or more of the additional loads 340. With this energy storage system 350, DC energy is stored, which reduces the number of transformers used in the facility 300a, thereby reducing overall energy consumption. In other words, the energy storage system 350 may transfer DC energy to the formation system 320 without an AC transformer. The energy storage system may receive and store energy from renewable or sustainable power sources, reducing a total grid power requirement to enable lower cost renewable energy offset and to mitigate carbon footprint of the total grid. In addition, the facilities 300a-c may operate by pulling less energy at a given time from the power grid. Energy loss from AC/DC conversion increases when a larger starting voltage is converted; therefore, reducing the voltage transferred to the facilities 300a-300c at a given time reduces energy lost due to AC/DC conversion, thereby reducing overall energy consumption of the facility and campus.
The formation system 420 may also include switches 421a, 421b,- . . . 421n, 423a, 423b,- . . . 423n (e.g., contactors, relays, transistors, etc.), corresponding to each battery module 410a-n and configured to control the current through each battery module 410a, 410b,- . . . 410n. For example, a first switch 421a may be connected in series with a first battery module 410a and a second switch 423a may be connected in parallel with the first battery module 410a such that when the first switch 421a is closed and the second switch 423a is open, current moves through the first battery module 410a towards subsequent battery modules 410b-n in series. In contrast, when the first switch 421a is open and the second switch 423a is closed, current is directed away from the first battery module 410a and to different battery modules 410b-n in the formation system that may need charging. In some embodiments, both the first switch 421a and the second switch 423a may be closed such that current is blocked from flowing through the first battery module 410a and any subsequent battery modules 410b-n in series. In some embodiments, both the first switch 421a and the second switch 423a may be open such that current may flow through the first battery module 410a as well as subsequent battery modules 410b-n in series. The switches 421a-n, 422a-n may switch between an open configuration and a closed configuration in response to a signal from the controller 424 via relay control lines 426. The battery modules 410a-n are each connected to a battery management system 429a, 429b,- . . . 429n for monitoring voltage and battery health of the battery module. The battery management system 429a-n is coupled to a current source 425a, 425b,- . . . 425n to control the current through the respective battery module 410a-n. While the switches 421-423 are shown in this configuration, the switches 421-423 may be arranged in any suitable arrangement such that current flow may be directed away from a battery module 410 if needed.
The arrangement of switches 421a-n, 423a-n, allows for the removal of faulty battery modules 410a-n from the flow path of current such that formation of healthy battery modules may continue, thereby increasing formation efficiency. Additionally, fully charged battery modules may be removed from the flow path of current if needed. For example, the controller 424 may detect a faulty battery module 410a-n from voltage measurements received from the battery management system 429a-n. The controller 424 in turn may send a signal to open the first switch 421a-n such that current is blocked from flowing through the faulty battery module, and instead moves directly to the second battery module 410a-n. The controller 424 may also sense (via the battery management system 429a-n) that one of the battery modules 410a-n no longer needs to charge. The controller 424 may then send a signal to configure the switches 421a-n, 423a-n such that charge is drawn from the charged battery module and redirected toward a different battery module 410a-n that needs charge. In some embodiments, the formation system 420 blocks current flow through a faulty battery module 410a-n automatically. In some embodiments, the formation system 420 blocks current flow through a fully charged battery module 410a-n automatically. In some embodiments, the formation system 420 draws current from a fully charged battery module 410a-n automatically. Energy may be transferred out of the formation system 420 via a DC electrical to the DC load 428 back to the energy storage system 450.
In some embodiments, the formation system 420 can include a range of about 1 to about 1000 battery modules 410. In some embodiments, the formation system 420 can include at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, at least about 10, at least about 20, at least about 30, at least about 40, at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, at least about 600, at least about 700, at least about 800, or at least about 900 battery modules 410. In some embodiments, the formation system 420 can include no more than about 1,000, no more than about 900, no more than about 800, no more than about 700, no more than about 600, no more than about 500, no more than about 400, no more than about 300, no more than about 200, no more than about 100, no more than about 90, no more than about 80, no more than about 70, no more than about 60, no more than about 50, no more than about 40, no more than about 30, no more than about 20, no more than about 10, no more than about 9, no more than about 8, no more than about 7, no more than about 6, no more than about 5, no more than about 4, no more than about 3 battery modules 410. Combinations of the above-referenced numbers of battery modules 410 are also possible (e.g., at least about 2 and no more than about 1,000 or at least about 4 and no more than about 50), inclusive of all values and ranges therebetween. In some embodiments, the formation system 420 can include about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 100, about 200, about 300, about 400, about 500, about 600, about 700, about 800, about 900, or about 1,000 battery modules 420.
In some embodiments, the formation system 420 can include a range of about 1 to about 1000 battery management systems 429. In some embodiments, the formation system 420 may include a range of about 1 to about 1000 current sources 425. In some embodiments, the formation system 420 has the same number of battery management systems 429 as battery modules 410. In some embodiments, the formation system 420 has the same number of current sources 425 as battery modules 410. In some embodiments, the formation system 420 may include a range of about 1 to about 3000 switches 421, 422, 423. In some embodiments, the formation system 420 can include at least about 2, at least about 4, at least about 6, at least about 8, at least about 10, at least about 20, at least about 40, at least about 60, at least about 80, at least about 100, at least about 200, at least about 400, at least about 600, at least about 800, at least about 1000, at least about 2000, at least about 2200, at least about 2400 switches 421, 422, 423. In some embodiments, the formation system 620 can include no more than about 3000, no more than about 2400, no more than about 2200, no more than about 2000, no more than about 1000, no more than about 800, no more than about 600, no more than about 400, no more than about 200, no more than about 100, no more than about 80, no more than about 60, no more than about 40, no more than about 20, no more than about 10, no more than about 8, no more than about 6, or no more than about 4 switches 421, 422, 423. Combinations of the above-referenced numbers of battery switches 421, 422, 423 are also possible (e.g., at least about 2 and no more than about 1,000 or at least about 4 and no more than about 50), inclusive of all values and ranges therebetween.
As shown, a solar power generator 506 delivers DC energy to the facilities 500a, 500b, 500c. Facility 500a includes one or more energy storage systems 550a, 550b,- . . . 550n (collectively referred to as energy storage systems 550), which may transfer energy through a DC/DC power converter 536 to a DC charge 527, which delivers current to a formation system 520. As shown, the formation system 520 includes four battery modules 510a, 510b, 510c, 510d connected in series and electrically coupled to respective battery management systems 529a, 529b, 529c, 529d and current sources 525a, 525b, 525c, and 525d. The formation system 520 includes main switches 522a and 522b as well as switches 521a, 521b, 521c, 521d and switches 523a, 523b, 523c, 523d controlled by a controller 524 and relay control lines 526. The battery modules 510a-d, the battery management system 520a-d, the current sources 525a-d, the main switches 522a-b, the switches 521a-d and 523a-d, the controller 524, and the relay control lines 526 may be substantially similar in function and/or structure to the battery modules 410a-n, the battery management system 420a-n, the current sources 425a-n, the main switch 422, the switches 421a-d and 423a-n, the controller 424, and the relay control lines 426, and therefore certain aspects of the battery modules 510a-d, the battery management system 520a-d, the current sources 525a-d, the main switches 522a-b, the switches 521a-d and 523a-d, the controller 524, and the relay control lines 526 will not be described with respect to
In some embodiments, the solar energy generator may transfer energy into the power distribution control station 580. As shown, a wind power generator 507 transfers energy to a power distribution control station 580. The energy from the wind power generator 507 may either be transferred (1) from the power distribution control center 580 through load transfer switches 560 to power additional loads of the facility 500a including a dry room 542, a manufacturing line 544, an HVAC system 546, or other loads 548; or (2) through an AC/DC power converter 535 to the energy storage systems 550 for later use. A campus grid connection 508 may provide energy to facilities 500a-c. In facility 500a, the energy from the campus grid connection 508 is transferred through a facility meter 590 and then through load transfer switches 560. The energy may then be either (1) used to power the additional loads; or (2) sent through the AC/DC power converter 535 and stored in the energy storage systems 550 for later use. If backup AC energy (i.e., resilient AC) is needed to power the additional loads, energy stored in the energy storage systems 550 may be transferred through a DC/AC converter 535, to the load transfer switches 560, and then to the additional loads. The resilient AC may also be transferred to the other facilities in the campus 500b, 500c if needed. The power distribution control center 580, the facility meter 590, the load transfer switches 560, and the energy storage systems 550 may be configured to communicate to regulate energy flow throughout the campus 5000.
The load transfer switches 560 include AC transformers. Because the formation system 520 is powered by DC energy stored in the energy storage systems 550, the load transfer switches 560 may include less AC transformers. For instance, the facility 500a may only include the AC transformers needed to support the dry room 542, the manufacturing line 544, the HVAC system 546, and/or other loads 548. Therefore, the facility 500a may include a lower number of AC transformers, which lowers the overall energy consumption of the facility 500a. In some embodiments, the facilities 500b and 500c may also include an energy storage system that allows for use of fewer AC transformers.
In some embodiments, energy losses from the formation of electrochemical cells are reduced by at least about 50%, at least about 75%, at least about 100%, at least about 125%, at least about 150%, at least about 175%, at least about 200%, at least about 225%, or at least about 250% of a full capacity of each electrochemical cell, as compared to the formation of an individual electrochemical cell.
In some embodiments, the energy storage system 650 can provide building power backup energy. As shown, the energy storage system 650 can transfer energy through a DC/AC converter 635 to provide AC backup energy. In some embodiments, the energy storage system 650 can provide DC backup energy as well.
In some embodiments, the electrochemical cell system, the battery module, the energy storage system, and the formation system can be substantially similar to and/or the same as any electrochemical cell, battery module, energy storage system, and formation system described above. Thus, the electrochemical cell, the battery module, the energy storage system, and the formation system are not described in further detail herein.
In some embodiments, the power source can transfer energy to the energy storage system during battery charging or discharging. For example, the power source can provide makeup power to the energy storage system if the controller detects that the amount of energy in the energy storage system drops below a threshold. In another example, during discharge, the controller can estimate the amount of energy to be released from discharge and determine whether the amount of energy is sufficient for the next round of battery charging. If not, the controller can direct the power source to transfer supplemental energy to the energy storage system.
Various concepts may be embodied as one or more methods, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. Put differently, it is to be understood that such features may not necessarily be limited to a particular order of execution, but rather, any number of threads, processes, services, servers, and/or the like that may execute serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, and/or the like in a manner consistent with the disclosure. As such, some of these features may be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovations, and inapplicable to others.
In addition, the disclosure may include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file additional applications, continuations, continuations-in-part, divisional s, and/or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments. Depending on the particular desires and/or characteristics of an individual and/or enterprise user, database configuration and/or relational model, data type, data transmission and/or network framework, syntax structure, and/or the like, various embodiments of the technology disclosed herein may be implemented in a manner that enables a great deal of flexibility and customization as described herein.
All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.
As used herein, in particular embodiments, the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.
The phrase “and/or,” as used herein in the specification and in the embodiments, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.
As used herein in the specification and in the embodiments, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the embodiments, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.
As used herein in the specification and in the embodiments, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.
In the embodiments, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.
While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure. Where methods and steps described above indicate certain events occurring in a certain order, those of ordinary skill in the art having the benefit of this disclosure would recognize that the ordering of certain steps may be modified and such modification are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. The embodiments have been particularly shown and described, but it will be understood that various changes in form and details may be made.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/394,341 entitled, “Electrochemical Cells and Electrochemical Cell Stacks with Series Connections and Methods of Producing, Operating, and Monitoring the Same,” filed Aug. 2, 2022; the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63394341 | Aug 2022 | US |
