Abstract: An arrangement usable in an electrochemical generator and elsewhere comprises a compartment defined by an envelope in a portion of which there is a recess external to the compartment, said recess surrounding an opening in which a conduit is arranged. The arrangement is characterized by the fact that the conduit comprises a shoulder resting against the bottom of the recess and is further characterized by the fact that a weld material disposed in the recess on the outside of the shoulder forms an assembly between the envelope and the conduit, the shoulder resting against the bottom of the recess either directly or via a thin film of the weld material.

Abstract: A cathode current collector for a sodium sulphur cell is formed of a metal substrate, for example of a nickel alloy such as Inconel 600, which is provided with a firmly adherent coating of carbon which is produced by decomposition of a carbon-containing gas in a glow discharge with the substrate heated to a temperature of 200.degree. C. to 1000.degree. C. in an electric field, conveniently a radio frequency field employed for inductively heating the substrate.

Abstract: A sulfur electrode container is described which includes a metallic liner in foil form with at least two full windings within an outer casing. The liner is substantially corrosion resistant to liquid sulfur, while the outer casing is readily corroded by liquid sulfur. One method of making a sulfur electrode container includes forming a metallic liner in foil form into at least two full windings within the outer casing. Another method of making a sulfur electrode container includes wrapping a metallic liner in foil form into at least two full windings around a sulfur-carbon plug, after which the plug surrounded by the foil, is positioned within an outer casing.

Abstract: Electrochemical storage cell of the alkali metal and chalcogen type with an anode and a cathode chamber separated by a solid electrolyte wall and confined by a metal wall. A first current collector has an outer sub-part which extends outside the reactant chamber enclosed by the solid electrolyte, and an inner sub-part which extends into the interior of this reactant chamber. The outer sub-part and the inner sub-part are connected to an electrically conducting contact element which melts at a predetermined temperature exceeding the operating temperature of the cell. A second current collector is formed by part of the metal wall which confines the other reactant chamber.

Abstract: Certain sodium borophosphate glasses containing 0 to 11 mole percent of one or more oxides selected from the group consisting of ZrO.sub.2, MgO and Al.sub.2 O.sub.3 are good ionic conductors and are resistant to molten sodium at about 300.degree. C. Exemplary is a glass consisting of 55 mole percent of Na.sub.2 O, 25 mole percent of B.sub.2 O.sub.3, 20 mole percent of P.sub.2 O.sub.5 and 5 mole percent of ZrO.sub.2.

Abstract: Electrochemical storage cell with an anode chamber and a cathode chamber separated by a solid electrolyte. At least one of the chamber adjacent to the solid electrolyte and a supply chamber shield from both the solid electrolyte and the reaction chamber. At least one connected between the reaction chamber and the supply chamber for flow of reactants, and temperature controlled shut-off means for closing off the connection when a predetermined temperature above the operating temperature of the cell is reached.

Abstract: Molten sodium is filled into a reservoir insert container including a closed ended tubular portion and the sodium is solidified and the container sealed. Then the container is placed into the sodium compartment of a sodium sulfur cell so that the tubular portion extends into the electrolytic separator tube of the cell and is spaced apart therefrom forming an annular chamber. To activate the cell, the sodium is melted and an opening is formed in the insert container permitting flow of molten sodium from the container into the thus-formed chamber.

Abstract: This invention is directed to a seal for a sodium sulfur battery in which the sealing is accomplished by a radial compression seal made on a ceramic component of the battery which separates an anode compartment from a cathode compartment of the battery.

Abstract: This invention is directed to a seal for a sodium sulfur battery in which a flexible diaphragm sealing elements respectively engage opposite sides of a ceramic component of the battery which separates an anode compartment from a cathode compartment of the battery.

Abstract: Certain sodium aluminum borate glasses containing about 2-11 mole percent of ZrO.sub.2, P.sub.2 O.sub.5 or SiO.sub.2 are good ionic conductors and are resistant to corrosion by molten sodium at about 300.degree. C. Exemplary is a glass consisting of 46 mole percent Na.sub.2 O, 46 mole percent B.sub.2 O.sub.3, 8 mole percent Al.sub.2 O.sub.3, 3.3 mole percent P.sub.2 O.sub.5 and 3.3 mole percent of ZrO.sub.2.

Abstract: Molten sodium is filled into a reservoir insert container including a closed ended tubular portion and the sodium is solidified and the container sealed. Then an open port is provided for the insert container. The container is placed into the sodium compartment of a sodium-sulfur cell so that the tubular portion extends into the electrolytic separator tube of the cell and is spaced apart therefrom forming an annular chamber. To activate the cell, the sodium is melted and flows through the open port into the annular chamber.

Abstract: In a sodium-sulfur battery, surfaces of electrically conducting aluminum in contact with sulfur-polysulfide mixtures or potentially subject to contact with such mixtures are protected from the formation of a nonconductive aluminum sulfide coating by a thin coat of electrically-conducting phenolic or poly(arylacetylene) resin which is inert to the sulfur-polysulfide mixture and adheres strongly to the aluminum surface under the conditions of use of the aluminum substrate.

Abstract: An improved sodium-sulfur cell having a sulfur electrode for a physically-large battery cell comprises in its pre-emplaced condition at temperatures below operating temperature at least one preformed solid composite structure defining a plug conforming to the interior shape of an electrolyte containment structure. The plug segments are constructed of fibrous electrically conductive material in a compressed elastic condition having a relatively thin layer of electrically resistive material along the face of the segment which will confront the electrolyte. The conductive material and the resistive material are permeated with a binder of molten sulfur which has been solidified. The sulfur electrode is adapted to be inserted within a battery cell container and subsequently melted so that the structure can expand and compress against the inner walls of the containment structure.

Abstract: An electrochemical storage cell or battery with at least one anode filled with a molten alkali metal as the anolyte and at least one cathode chamber filled with a sulfur-containing catholyte substance with the anode chamber and the cathode chamber separated from each other by an alkali-ion-conducting solid electrolyte. To the catholyte substance is added an additive which converts the sulfur chains into an electrically charged state for obtaining electromigration of the sulfur phase. This induces mobilization of the sulfur phase in the cathode chamber and prevents major accumulation of liquid sulfur as an insulator. As a result the cell can be repeatedly recharged with large currents to a greater capacity. Additives are a dienophilic compound or a reaction product of a dienophilic compound and sulfur.

Abstract: Certain sodium aluminum phosphate glasses containing up to 11 mole percent of ZrO.sub.2, MgO or SiO.sub.2 are good ionic conductors and are resistant to corrosion by molten sodium at about 300.degree. C. Exemplary is a glass consisting of 50 mole percent Na.sub.2 O, 38 mole percent P.sub.2 O.sub.5, 12 mole percent Al.sub.2 O.sub.3 2 mole percent MgO and 4 mole percent SiO.sub.2.

Abstract: In a sodium-sulphur cell, a cathode current collector, which extends into the cathodic region to provide a high conductivity current path, is formed of aluminium with a sheath over the surface of the aluminium or with finned elements secured to the aluminium, the sheath or fins being of a corrosion-resistant metal and being secured to the aluminium by bonding through a protective coating over the surface of the aluminium which serves to protect the aluminium from the cathodic reactant.

Abstract: Cured arylene sulfide polymers such as cured poly(phenylene sulfide) perform effectively in sealing or coating internal elements of alkali metal-sulfur energy conversion devices. The sealing or coating materials retain satisfactory corrosion resistance properties at elevated temperatures exceeding 300.degree. C. and can be placed in contact with both molten alkali metal and molten sulfur. Adding carbon particles, carbon fibers, graphite, powdered metals or metal fibers renders the sealing or coating materials electrically conductive. Novel energy conversion device reactant containers and novel energy conversion devices are also disclosed.

Abstract: There is disclosed a method of selectively plugging broken fibers included in a bundle of hollow fibers having open ends protruding from a tubesheet and closed ends distal from the tubesheet. The protruding open ends are immersed in a curable, fluid sealant and capillary attraction is utilized to draw the sealant into the broken fibers. The resistance to compression of the gases in the unbroken fibers is such that the sealant does not move into the latter fibers so far that they will not be open after the protruding ends are removed. The imbibed sealant is cured in place and the protruding fiber ends are cut off flush with the final surface of the tubesheet. This method is of particular value in preparing tubesheet-fiber assemblies for use in high temperature alkali metal-sulfur battery cells, wherein the hollow fibers function as an electrolyte-separator.

Abstract: This disclosure relates to a hermetically sealed alkali metal battery container. The battery includes a ceramic ring having upper and lower contoured surfaces thereon located on its outer circumferential surface. Outer metal casings defining an upper battery container and a lower battery container are formed so as to have a bell-shaped open end on each one. The bell-shaped open end of respective casings are located adjacent the contoured surfaces formed on the ceramic ring. Each bell-shaped open end of a metal casing has associated therewith a sealing band which engages the open end of the casing to compress the same into engagement with an associated contoured surface of the ceramic ring to form a hermetic seal therebetween.

Abstract: This invention is directed to a seal for a sodium sulfur battery in which the sealing is accomplished by two radial compression seals located one above the other on a ceramic component of the battery which separates an anode compartment from a cathode compartment of the battery.

Abstract: A sulfur electrode for a sodium-sulfur secondary battery comprises a carbonized chopped graphite fiber-resin composite structure impregnated with sulfur.

Abstract: In the manufacture of a sodium sulphur cell, the sodium is gas-pressurized to force it upwardly over a surface of the electrolyte by means of a capsule of material, e.g. sodium azide, which releases an inert gas on heating, so enabling the cell to be sealed before the sodium is pressurized.

Abstract: An improved secondary battery or cell of the type having: (A) an anodic reaction zone containing a molten alkali metal reactant-anode in electrical contact with an external circuit; (B) one or more cathodic reaction zones containing a cathodic reactant which, when said battery or cell is at least partially discharged, is selected from the group consisting of (i) a single phase composition comprising molten polysulfide salts of said anodic reactant and (ii) a two-phase composition comprising molten sulfur and molten sulfur saturated polysulfide salts of said anodic reactant; (C) a cation-permeable barrier to mass liquid transfer interposed between and in contact with said anodic and cathodic reaction zones; and (D) a current collector which at least partially exposed to said cathodic reactant and which is in electrical contact with both said cation-permeable barrier and said external circuit.

Abstract: The present invention relates to the preparation of essentially silica-free glasses which can be melted at low temperatures and which have compositions within the Li.sub.2 O--Al.sub.2 O.sub.3 and/or F--B.sub.2 O.sub.3 system. The glasses exhibit very high lithium ion mobility which, resulting in low electrical resistivity, has led to their consideration as solid membrane electrolyte-separators in such devices as the lithium metal-sulfur battery.

Abstract: An improved electrically conductive current collector suitable for use in high temperature applications in the presence of corrosive environments comprising: (A) a high strength, noncorrosive electronically conductive ceramic member which serves as the primary load bearing element for said current collector; and (b) a highly electronically conductive metal cladding intimately attached to a substantial portion of one surface of said ceramic member and adapted to direct current flow through said ceramic member and to shunt said current between said member and an external contact. The disclosed current collectors are ideally suited for use as current collectors and current collector/containers for electrical conversion devices such as the sodium/sulfur battery and the like. Also disclosed are two processes for preparing tantalum or niobium doped rutile titanium dioxide.

Abstract: An improved method and means for allowing a sodium sulfur cell to become more fully charged employs a wrapping of a plain-woven natural fabric reduced in a vacuum furnace to carbon. The wrapping of woven carbon is interposed between a sulfurous electrolyte and the outside surface of a sodium electrolyte container.

Abstract: An electrochemical storage cell or battery based on an alkali metal and sulfur having at least one anode chamber and at least one cathode chamber separated from each other by an ion-conducting solid electrolyte, and felt with course-pores and/or low electric conductivity and felt with fine-pores and/or higher electric conductivity located in the cathode chamber, with the felt of coarse-pores and/or low conductivity disposed near the solid electrolyte and the felt of fine-pores and/or higher conductivity disposed further away from the solid electrolyte. This permits rapid and more complete recharging of the cell for covering peak loads in electrical networks.

Abstract: A sulfur electrode is described which includes a sulfur-carbon plug with a central aperture extending partially therethrough, and at least one layer of an electronically insulating plain woven mesh material positioned within the central aperture and having its exterior surface in contiguous relation with the wall of the central aperture. A sulfur electrode container includes the above sulfur electrode positioned within an outer metallic casing which is substantially corrosion resistant to liquid sulfur and polysulfides. Methods are also described for making sulfur electrode containers.

Abstract: A battery formed of sodium sulphur cells has each cell coated with an intumescent paint which is heated to produce a carbonaceous foam. This foam fills an outer housing around the cells or a separate containment around each cell and serves to confine material that might leak out of any damaged cell.

Abstract: A solid ion-conductive electrolyte body has a solid ion-conductive electrolyte portion with opposite major faces, and a textured surface on at least one major face providing an increased surface area. A method is disclosed also forming a solid ion-conductive electrolyte body with an increased surface area.

Abstract: A plurality of sulfur electrode container constructions characterized by mild steel containers and discrete anti-corrosive liners disposed within the containers and method of manufacturing each.

Abstract: In a sodium sulphur cell, the cathode current collector in the sulphur/polysulphide cathodic reactant comprises an impermeable tube, e.g. a carbon or graphite tube which is inert to the cathodic reactant and contains a solid metal core, e.g. an aluminium core, and a deformable electronic conductor, e.g. graphite felt, as a conducting interface between the impermeable tube and the core. In a preferred construction, the current collector is axially located within a cylindrical electrolyte tube, the space between the electrolyte tube and impermeable tube containing the sulphur/polysulphides and a graphite felt. The outer surface of the impermeable tube in this case has grooves or recesses to form a sulphur reservoir.

Abstract: An electrochemical storage cell or battery based on an alkali metal and sulfur having at least one anode chamber and at least one cathode chamber separated from each other by an ion-conducting solid electrolyte, a felt fabric with capillary activity located in the cathode chamber, and an additive lowering the viscosity of the sulfur in the cathode chamber. Preferred additives are selenium, boron and iodine. Lowering the viscosity of the sulfur permits recharging the cell to a greater capacity.

Abstract: A sulfur electrode for a sodium-sulfur secondary battery comprises a mixture of chopped graphite fibers and sulfur formed into a solid composite structure.

Abstract: The invention relates to a sodium-sulphur electric cell. It comprises a cathode tank containing sulphur, a solid electrolyte tube being disposed in this tank and containing sodium, said cathode tank being lined with a continuous strip of felt or fabric, more particularly of graphite wound in a spiral one of whose ends is in contact with the wall of the cathode tank, at least one of the turns of said spiral having a plurality of holes, the other end of the strip being in contact with either the electrolyte tube or a conductive grid surrounding the tube and disposed at a predetermined distance from that tube. The invention is implemented in electric vehicles.

Abstract: A new seal for a sodium-sulfur battery is disclosed herein. The sodium-sulfur battery uses two cylindrical containers for containing sulfur and sodium in molten states and a beta-alumina electrolyte tube located primarily within the sulfur container. The battery disclosed herein includes a novel header, preferably a metal header, between the containers and through which the beta-alumina tube extends. In order to prevent either the sulfur or sodium from passing between the header and tube, the header includes an inner circumferential surface which forms a continuous mechanical seal around and against the tube to prevent the sulfur or sodium from passing therebetween. The header is attached to, but must electrically isolate, the two containers.

Abstract: An arrangement for controlling the charge and/or discharge cycles of an alkali-metal/sulphur cell or battery has detecting means for detecting predetermined high and/or low levels of alkali-metal in the anode compartment of a cell or in an alkali-metal reservoir communicating with the anode compartment whereby the end of the charge and/or discharge cycles is determined. Alternatively, similar detecting means can be associated with an alkali-metal/alkali-metal cycling device which is connected electrically in series with a group of series-connected cells of an alkali-metal/sulphur battery to determine the end of the charge and/or discharge cycles of the battery.

Abstract: In a sodium sulphur cell having a cathodic region containing sulphur/polysulphides forming a cathodic reactant between a solid electrolyte and a cathode current collector, the electronically conductive matrix containing the cathode reactant is formed of a porous metal structure, preferably metal fibres, coated with graphite or carbon to form an electronically conductive protective coating.

Abstract: In a sodium sulphur cell having a porous matrix forming an electronic conductor in the cathodic region and extending between the surface of the solid electrolyte and a cathode current collector, this matrix is a composite comprising a first material formed of graphite or carbon of a material coated with graphite or carbon, which first material is intimately mixed with a second material, such as alumina fibres, which is more easily wetted by the polysulphides than is the first material.

Abstract: An improved electrical conversion device of the type comprising:(A) a container-current collector consisting essentially of an inner, load bearing, high strength, noncorrosive and electrically conductive ceramic member clad with a metal exterior;(B) a cation-permeable barrier to mass liquid transfer which is disposed within said container-current collector;(C) a molten alkali metal reactant-anode within the anodic reaction zone;(D) a cathodic reactant within the cathodic reaction zone; and(E) a cathodic electrode; the improvement of the invention comprises adapting the metal clad ceramic member of the device to serve not only as a container-current collector, but also as the cathodic electrode by shaping the metal clad ceramic member such that (i) the inner surface of the electrically conductive ceramic member is disposed in close proximity to at least a portion of the surface of the cation-permeable barrier, and (ii) there are a plurality of open spaces for channels within the cathodic reaction zone through

Abstract: In a sodium-sulphur cell having a solid electrolyte separating sodium from a cathodic region containing sulphur/polysulphides in a graphite felt, a cathode current collector is formed of an aluminium substrate on which is an interstrate layer of nickel-chromium alloy covered by a coating of titanium oxide or other electronically conductive oxide intrinsically inert to the cathodic reactant.

Abstract: A thermally activated reserve battery operable within a temperature range of about 165.degree. to 250.degree. C and composed of a lithium-aluminum alloy anode, a molybdenum pentachloride cathode and a separating electrolyte composed of sodium tetrachloroaluminate.

Abstract: Alkali metal/sulfur batteries in which the electrolyte-separator is a relatively fragile membrane are improved by providing means for separating the molten sulfur/sulfide catholyte from contact with the membrane prior to cooling the cell to temperatures at which the catholyte will solidify. If the catholyte is permitted to solidify while in contact with the membrane, the latter may be damaged. The improvement permits such batteries to be prefilled with catholyte and shipped, at ordinary temperatures.

Abstract: A method of preparing a composite body comprising a vitreous carbon substrate having a felt prepared from materials selected from the group consisting of metal, carbon and graphite bonded to a major surface thereof, wherein said method comprises(A) forming and curing a branched polyphenylene prepolymer having a number average molecular weight of between about 500 and 800 and bearing terminal acetylene functionality to form a shaped, crosslinked body; (B) preparing a solution of said branched polyphenylene prepolymer in an organic solvent in an amount ranging from about 1 to about 60 parts by weight of said prepolymer per 100 parts by weight of said solution; (C) preparing a composite of said shaped body and said felt to be bonded thereto with said solution interposed therebetween; and (D) firing said composite in an inert atmosphere at a temperature of at least about 800.degree. C.

Abstract: An improved hermetically sealed sodium-sulfur cell casing formed as a container of metal, the interior side wall of the container being characterized by an electrically conducting corrosion resistant electrolytically applied layer of material. Preferably the metal of the container comprises aluminum and the layer is chromium. A second embodiment includes a layer of electrolytically applied zinc to the aluminum and a layer of chromium electrolytically applied to the zinc layer.

Abstract: A lithium-bromine cell comprising a casing which can be of electrically conducting material and containing a lithium anode element from which a sealed conductor extends through the casing. A filling element which can be of electrically conducting material and which has a passage therethrough is fixed to the sealed casing with one end of the passage in communication with the interior of the casing and the other end externally exposed. Bromine is introduced through the passage to the interior of the casing into operative relationship with the lithium anode whereupon the passage is closed to complete the cell. The electrically conducting casing serves as a cathode current collector in operative contact with the bromine cathode, and after closing of the passage the electrically conducting filling element serves as an electrical terminal for the cell. An electrical potential difference exists between the terminal and the anode conductor during operation of the cell.

Abstract: The invention provides an electric cell having a compartment containing liquid anode, a compartment containing liquid cathode, a solid electrolyte which partially bounds each of the compartments, a ceramic support member which supports the solid electrolyte, and metallic closure members closing the compartments. The closure member closing the liquid anode compartment is joined to the support member by a brazed joint resistant to the liquid anode, and the closure member closing the liquid cathode compartment is joined to the support member or the solid electrolyte by a glass seal.

Abstract: An alkali metal-sulphur cell comprising an outer tube, an inner tube forming the solid electrolyte of the cell and dividing the interior of the outer tube into anode and cathode compartments adjacent respective sides of the inner tube, and an alkali metal reservoir communicating with the anode compartment, has a gas space above the alkali metal in the reservoir, such that at the operating temperature of the cell the gas pressure in the reservoir will force alkali metal to flow from the reservoir into the anode compartment to maintain the operative surface area of the inner tube covered with liquid alkali metal during discharge of the cell. An advantageous method of forming such a cell entails evacuating the anode compartment when empty of alkali metal. A further advantageous method feature is to form the reservoir with the contained alkali metal and gas space as a sub-assembly.

Abstract: Sodium ion conducting compositions are provided having (a) the formula Na.sub.5-x .quadrature..sub.x Gd.sub.1-y-x M.sub.y M'.sub.x Si.sub.4-z Ge.sub.z O.sub.12 whereinM is at least one of the rare earths or yttrium,M' is Zr.sup.4+, Hf.sup.4+, or Th.sup.4+,.quadrature. is a sodium vacancy to preserve charge neutrality,X is 0 to about 0.5 when Zr.sup.4+ or Hf.sup.4+ is included in M' and 0 to about 0.1 when Th.sup.4+ is included in M',y is 0 to 1, andZ is 0 to 4, with the proviso that y+x is no more than 1,And (b) the rhombohedral Na.sub.5 YSi.sub.4 O.sub.12 crystal structure with space group symmetry R3c. These compositions are useful as solid electrolytes in electrochemical cells such as galvanic cells and electrolytic cells.Certain of the sodium ion conducting compositions are novel compositions of matter.

Abstract: Electric accumulators of the type comprising an anode compartment containing an anode formed from at least one metal selected from the group consisting of metals belonging to Groups Ia, IIa, IIb and IIIb of the periodic table of elements; a cathode compartment containing a cathode formed at least partly from a conducting member comprising a substance capable of accepting electrons, to form anions by cathodic reduction, and an electrolyte consisting of a substance capable of dissolving the product or products generated during discharge of the accumulator; the anode compartment and cathode compartment being separated from each other by a wall impervious to fluids and formed from a solid mineral electrolyte capable of allowing selective migration of the anode metal, in the form of cations are improved by adding to the anode compartment a salt of the anode metal between the anode and the separation wall.