Patents Assigned to FORM ENERGY, INC.
  • Patent number: 12261281
    Abstract: Systems and methods of the various embodiments may provide metal air electrochemical cell architectures. Various embodiments may provide a battery, such as an unsealed battery or sealed battery, with an open cell arrangement configured such that a liquid electrolyte layer separates a metal electrode from an air electrode. In various embodiments, the electrolyte may be disposed within one or more vessel of the battery such that electrolyte serves as a barrier between a metal electrode and gaseous oxygen. Systems and methods of the various embodiments may provide for removing a metal electrode from electrolyte to prevent self-discharge of the metal electrode. Systems and methods of the various embodiments may provide a three electrode battery configured to operate each in a discharge mode, but with two distinct electrochemical reactions occurring at each electrode.
    Type: Grant
    Filed: June 28, 2019
    Date of Patent: March 25, 2025
    Assignee: FORM ENERGY, INC.
    Inventors: Jarrod David Milshtein, Mitchell Terrance Westwood, William Henry Woodford, Yet-Ming Chiang, Mateo Cristian Jaramillo, Ian Salmon Mckay, Rachel Elizabeth Mumma, Eric Weber, Liang Su, Amelie Nina Kharey, Marco Ferrara, Theodore Alan Wiley
  • Publication number: 20250079473
    Abstract: A composition includes a compound of the formula AxMyOz, wherein A is an A-site element and includes Ba, Ca, Cu, Dy, Er, Gd, La, Nd, Pr, Sm, Sr, Y, or Yb, or a combination thereof, M is an M-site element and includes Co, Cu, Fe, Mn, Ni, Ti, Sc, or P, or a combination thereof, and 0<x?1, 0<y?2, (3??)?z?(4??), and 1<?<1. Use of the composition as a catalyst composition, for example an oxygen reduction reaction catalyst composition, in gas diffusion electrodes, and in metal-air batteries is also described.
    Type: Application
    Filed: August 30, 2024
    Publication date: March 6, 2025
    Applicant: Form Energy, Inc.
    Inventors: Mauricio PAZ, Danielle Marie BUTTS, Liang Su, Vlad TARASOV, Glenn DONAHEY
  • Patent number: 12237548
    Abstract: Systems and methods of the various embodiments may provide a battery including a rolling diaphragm configured to move to accommodate an internal volume change of one or more components of the battery. Systems and methods of the various embodiments may provide a battery housing including a rolling diaphragm seal disposed between an interior volume of the battery and an electrode assembly within the battery. Various embodiments may provide an air electrode assembly including an air electrode supported on a buoyant platform such that the air electrode is above a surface of a volume of electrolyte when the buoyant platform is floating in the electrolyte.
    Type: Grant
    Filed: June 28, 2019
    Date of Patent: February 25, 2025
    Assignee: FORM ENERGY, INC.
    Inventors: Mitchell Terrance Westwood, Alexander H. Slocum, William Henry Woodford, Yet-Ming Chiang, Ian Salmon McKay, Mateo Cristian Jaramillo, Eric Weber, Jarrod David Milshtein, Liang Su, Rupak Chakraborty, Rachel Elizabeth Mumma, Marc-Antoni Goulet, Brian Beggan, Marco Ferrara, Theodore Alan Wiley
  • Patent number: 12191702
    Abstract: A stationary hybrid battery back-up system incorporates two different battery units that differ in terms of recharging efficiency, cycle life, power capability, depth of discharge threshold, temperature threshold, internal impedance threshold, charger rate efficiency and/or stand-by efficiency. The battery back-up system of the present invention comprises an auxiliary power supply that can be used to charge the first and second batteries and/or provide power to a load. When the operating voltage of the system drops, due to a power failure of a power source, the control system may couple the first and/or second battery unit to a load. The control system may have voltage threshold limits wherein it engages the first and second battery units to support the load demand. The first and second battery units may be charge by the auxiliary power supply when the operating voltage is above a threshold level.
    Type: Grant
    Filed: April 26, 2023
    Date of Patent: January 7, 2025
    Assignee: FORM ENERGY, INC.
    Inventors: Ramkumar Krishnan, Shawn Fink
  • Patent number: 12155047
    Abstract: In an aspect, provided is an alkaline rechargeable battery comprising: i) a battery container sealed against the release of gas up to at least a threshold gas pressure, ii) a volume of an aqueous alkaline electrolyte at least partially filling the container to an electrolyte level; iii) a positive electrode containing positive active material and at least partially submerged in the electrolyte; iv) an iron negative electrode at least partially submerged in the electrolyte, the iron negative electrode comprising iron active material; v) a separator at least partially submerged in the electrolyte provided between the positive electrode and the negative electrode; vi) an auxiliary oxygen gas recombination electrode electrically connected to the iron negative electrode by a first electronic component, ionically connected to the electrolyte by a first ionic pathway, and exposed to a gas headspace above the electrolyte level by a first gas pathway.
    Type: Grant
    Filed: March 13, 2023
    Date of Patent: November 26, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Ai Quoc Pham, Sandeep Nijhawan, Aswin K. Manohar, Kevin Van Galloway, Chenguang Yang, Eric E. Benson, Lang McHardy, Tim Rackers
  • Patent number: 12136713
    Abstract: Various embodiments relate to several processes that may recover commodity chemicals from an alkaline metal-air battery. In various embodiments, while the cell is operating, various side products and waste streams may be collected and processed to regain use or additional value. Various embodiments also include processes to be performed after the cell has been disassembled, and each of its electrodes have been separated such as not to be an electrical hazard. The alkaline metal battery recycling processes described herein may provide multiple forms of commodity iron, high purity transition metal ores, fluoropolymer dispersions, various carbons, commodity chemicals, and catalyst dispersions.
    Type: Grant
    Filed: May 6, 2021
    Date of Patent: November 5, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Nicholas Reed Perkins, Isabella Caruso, Rachel Elizabeth Mumma, Anthony Tran, Rupak Chakraborty, Matthew Edward Via, Jocelyn Marie Newhouse, Jarrod David Milshtein, Liang Su, Michael Andrew Gibson, Danielle Cassidy Smith, William Henry Woodford, Amelie Nina Kharey
  • Patent number: 12136723
    Abstract: An electrochemical cell includes a mist elimination system that prevents mist from escaping from the cell chamber and conserves moisture within the cell. An exemplary mist elimination system includes a spill prevention device that reduces or prevents an electrolyte from escaping from the cell chamber in the event of an upset, wherein the electrochemical cell is tipped over. A mist elimination system includes a recombination portion that reacts with hydrogen to produce water, that may be reintroduced into the cell chamber. A mist elimination system includes a neutralizer portion that reacts with an electrolyte to bring the pH closer to neutral, as acid/base reaction. A mist elimination system includes a filter that captures mist that may be reintroduced into the cell chamber. A mist elimination system includes a hydrophobic filter on the outer surface to prevent water and other liquids from entering into the mist elimination system.
    Type: Grant
    Filed: January 10, 2022
    Date of Patent: November 5, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Ramkumar Krishnan, Joel Hayes, Scott Klug, Patrick Samuleson, Craig Trzebny
  • Patent number: 12061454
    Abstract: Physical and/or financial instruments may optimally hedge the cash flow of one or more renewable energy generators based on a desired risk and return profile of renewable infrastructure investors. Baseline revenues may be determined based on forward-looking electricity market price scenarios corresponding to qualified market products intended for sale from the renewable energy generators. Risk and return metrics of cash flows of the renewable energy generators may be determined. At least one physical hedge and/or financial hedge may be added. The size and operation of the renewable energy generators along with any physical hedges, or financial hedges, or both physical and financial hedges, may be optimized across multiple market price scenarios of qualified market products to optimize investor-tailored risk and return utility functions.
    Type: Grant
    Filed: April 10, 2023
    Date of Patent: August 13, 2024
    Assignee: Form Energy, Inc.
    Inventors: Aly Eldeen O. Eltayeb, Benjamin Michael Jenkins, Marco Ferrara
  • Patent number: 12046736
    Abstract: An electrochemical cell utilizes an air flow device that draws air through the cell from a scrubber that may be removed while the system is operating. The negative pressure generated by the air flow device allows ambient air to enter the cell housing when the scrubber is removed, thereby enabling continued operation without the scrubber. A moisture management system passes outflow air from the cell through a humidity exchange module that transfers moisture to the air inflow, thereby increasing the humidity of the air inflow. A recirculation feature comprising a valve allow a controller to recirculate at least a portion of the outflow air back into the inflow air. The system may comprise an inflow bypass conduit and valve that allows the humidified inflow air to pass into the cell inlet without passing through the scrubber. The scrubber may contain reversible or irreversible scrubber media.
    Type: Grant
    Filed: April 10, 2023
    Date of Patent: July 23, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Ramkumar Krishnan, Joel Hayes, Shawn Fink, Scott Klug, Patrick Samuelson
  • Patent number: 12009553
    Abstract: Systems and methods of the various embodiments may provide a refuelable battery for the power grid to provide a sustainable, cost-effective, and/or operationally efficient solution to energy source variability and/or energy demand variability. In particular, the systems and methods of the various embodiments may provide a refuelable primary battery solution that addresses bulk seasonal energy storage needs, variable demand needs, and other challenges.
    Type: Grant
    Filed: July 18, 2022
    Date of Patent: June 11, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Mateo Cristian Jaramillo, Ian Salmon McKay, William Henry Woodford
  • Patent number: 11973254
    Abstract: An electrochemical cell and battery system including cells, each cell including a catholyte, an anolyte, and a separator disposed between the catholyte and anolyte and that is permeable to the at least one ionic species (for example, a metal cation or the hydroxide ion). The catholyte solution includes a ferricyanide, permanganate, manganate, sulfur, and/or polysulfide compound, and the anolyte includes a sulfide and/or polysulfide compound. These electrochemical couples may be embodied in various physical architectures, including static (non-flowing) architectures or in flow battery (flowing) architectures.
    Type: Grant
    Filed: June 28, 2019
    Date of Patent: April 30, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Liang Su, Wei Xie, Yet-Ming Chiang, William Henry Woodford, Lucas Cohen, Jessa Silver, Katelyn Ripley, Eric Weber, Marco Ferrara, Mateo Cristian Jaramillo, Theodore Alan Wiley
  • Patent number: 11949129
    Abstract: Systems and methods of the various embodiments may provide a refuelable battery for the power grid to provide a sustainable, cost-effective, and/or operationally efficient solution to energy source variability and/or energy demand variability. In particular, the systems and methods of the various embodiments may provide a refuelable primary battery solution that addresses bulk seasonal energy storage needs, variable demand needs, and other challenges.
    Type: Grant
    Filed: July 18, 2022
    Date of Patent: April 2, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Mateo Cristian Jaramillo, Ian Salmon McKay, William Henry Woodford
  • Patent number: 11923568
    Abstract: A fuel electrode incorporates a first and second corrugated portion that are attached to each other at offset angles respect to their corrugation axis and therefore reinforce each other. A first corrugated portion may extend orthogonally with respect to a second corrugated portion. The first and second corrugated portions may be formed from metal wire and may therefore have a very high volumetric void fraction and a high surface area to volume ratio (sa/vol). In addition, the strands of the wire may be selected to enable high conductivity to the current collectors while maximizing the sa/vol. In addition, the shape of the corrugation, including the period distance, amplitude and geometry may be selected with respect to the stiffness requirements and electrochemical cell application factors. The first and second corrugated portions may be calendared or crushed to reduce thickness of the fuel electrode.
    Type: Grant
    Filed: May 13, 2022
    Date of Patent: March 5, 2024
    Assignee: FORM ENERGY, INC.
    Inventors: Joel Ryan Hayes, Ramkumar Krishnan, Todd Trimble, Clifford Anderson
  • Patent number: 11670954
    Abstract: A stationary hybrid battery back-up system incorporates two different battery units that differ in terms of recharging efficiency, cycle life, power capability, depth of discharge threshold, temperature threshold, internal impedance threshold, charger rate efficiency and/or stand-by efficiency. The battery back-up system of the present invention comprises an auxiliary power supply that can be used to charge the first and second batteries and/or provide power to a load. When the operating voltage of the system drops, due to a power failure of a power source, the control system may couple the first and/or second battery unit to a load. The control system may have voltage threshold limits wherein it engages the first and second battery units to support the load demand. The first and second battery units may be charge by the auxiliary power supply when the operating voltage is above a threshold level.
    Type: Grant
    Filed: September 13, 2017
    Date of Patent: June 6, 2023
    Assignee: FORM ENERGY, INC.
    Inventors: Ramkumar Krishnan, Shawn Fink
  • Patent number: 11664547
    Abstract: An electrochemical cell utilizes an air flow device that draws air through the cell from a scrubber that may be removed while the system is operating. The negative pressure generated by the air flow device allows ambient air to enter the cell housing when the scrubber is removed, thereby enabling continued operation without the scrubber. A moisture management system passes outflow air from the cell through a humidity exchange module that transfers moisture to the air inflow, thereby increasing the humidity of the air inflow. A recirculation feature comprising a valve allow a controller to recirculate at least a portion of the outflow air back into the inflow air. The system may comprise an inflow bypass conduit and valve that allows the humidified inflow air to pass into the cell inlet without passing through the scrubber. The scrubber may contain reversible or irreversible scrubber media.
    Type: Grant
    Filed: April 30, 2021
    Date of Patent: May 30, 2023
    Assignee: FORM ENERGY, INC.
    Inventors: Ramkumar Krishnan, Joel Hayes, Shawn Fink, Scott Klug, Patrick Samuelson
  • Patent number: 11625017
    Abstract: Physical and/or financial instruments may optimally hedge the cash flow of one or more renewable energy generators based on a desired risk and return profile of renewable infrastructure investors. Baseline revenues may be determined based on forward-looking electricity market price scenarios corresponding to qualified market products intended for sale from the renewable energy generators. Risk and return metrics of cash flows of the renewable energy generators may be determined. At least one physical hedge and/or financial hedge may be added. The size and operation of the renewable energy generators along with any physical hedges, or financial hedges, or both physical and financial hedges, may be optimized across multiple market price scenarios of qualified market products to optimize investor-tailored risk and return utility functions.
    Type: Grant
    Filed: March 25, 2022
    Date of Patent: April 11, 2023
    Assignee: Form Energy, Inc.
    Inventors: Aly Eldeen O. Eltayeb, Benjamin Michael Jenkins, Marco Ferrara
  • Patent number: 11611115
    Abstract: In an aspect, provided is an alkaline rechargeable battery comprising: i) a battery container sealed against the release of gas up to at least a threshold gas pressure, ii) a volume of an aqueous alkaline electrolyte at least partially filling the container to an electrolyte level; iii) a positive electrode containing positive active material and at least partially submerged in the electrolyte; iv) an iron negative electrode at least partially submerged in the electrolyte, the iron negative electrode comprising iron active material; v) a separator at least partially submerged in the electrolyte provided between the positive electrode and the negative electrode; vi) an auxiliary oxygen gas recombination electrode electrically connected to the iron negative electrode by a first electronic component, ionically connected to the electrolyte by a first ionic pathway, and exposed to a gas headspace above the electrolyte level by a first gas pathway.
    Type: Grant
    Filed: December 27, 2018
    Date of Patent: March 21, 2023
    Assignee: FORM ENERGY, INC.
    Inventors: Ai Quoc Pham, Sandeep Nijhawan, Aswin K. Manohar, Kevin Van Galloway, Chenguang Yang, Eric E. Benson, Lang McHardy, Tim Rackers
  • Patent number: 11587170
    Abstract: Systems, methods, and devices may enable management of a renewable power asset. A control device may generate a Day-Ahead (DA) pricing model, a Real-Time (RT) pricing model and a renewable generation model for the renewable power asset. Optimal DA commitments may be determined, and an optimal RT schedule estimated. A DA power delivery strategy and an RT power delivery strategy may be determined. The determined DA and RT power delivery strategies may be evaluated based on obtained real power prices. The DA and RT power delivery strategies may be redetermined, and the renewable power asset may be controlled to deliver power the DA and RT power delivery strategies. The value of the renewable power asset may be maximized while bounding financial risks and returns associated with scheduling the renewable power asset as tailored to risk preferences of the renewable power asset owner or operator.
    Type: Grant
    Filed: June 13, 2022
    Date of Patent: February 21, 2023
    Assignee: Form Energy, Inc.
    Inventors: Benjamin Michael Jenkins, Aly Eldeen O. Eltayeb, Marco Ferrara
  • Patent number: 11552290
    Abstract: Various embodiments provide a battery, a bulk energy storage system including the battery, and/or a method of operating the bulk energy storage system including the battery. In various embodiment, the battery may include a first electrode, an electrolyte, and a second electrode, wherein one or both of the first electrode and the second electrode comprises direct reduced iron (“DRI”). In various embodiments, the DRI may be in the form of pellets. In various embodiments, the pellets may comprise at least about 60 wt % iron by elemental mass, based on the total mass of the pellets. In various embodiments, one or both of the first electrode and the second electrode comprises from about 60% to about 90% iron and from about 1% to about 40% of a component comprising one or more of the materials selected from the group of SiO2, Al2O3, MgO, CaO, and TiO2.
    Type: Grant
    Filed: July 26, 2019
    Date of Patent: January 10, 2023
    Assignee: FORM ENERGY, INC.
    Inventors: Rupak Chakraborty, Jarrod David Milshtein, Eric Weber, William Henry Woodford, Yet-Ming Chiang, Ian Salmon McKay, Liang Su, Jay Whitacre, Theodore Alan Wiley, Kristen Carlisle, Mitchell Terrance Westwood, Rachel Elizabeth Mumma, Max Rae Chu, Amelie Nina Kharey, Benjamin Thomas Hultman, Marco Ferrara, Mateo Cristian Jaramillo, Isabella Caruso, Jocelyn Newhouse
  • Patent number: 11416936
    Abstract: Systems, methods, and devices may enable management of a renewable power asset. A control device may generate a Day-Ahead (DA) pricing model, a Real-Time (RT) pricing model and a renewable generation model for the renewable power asset. Optimal DA commitments may be determined, and an optimal RT schedule estimated. A DA power delivery strategy and an RT power delivery strategy may be determined. The determined DA and RT power delivery strategies may be evaluated based on obtained real power prices. The DA and RT power delivery strategies may be redetermined, and the renewable power asset may be controlled to deliver power the DA and RT power delivery strategies. The value of the renewable power asset may be maximized while bounding financial risks and returns associated with scheduling the renewable power asset as tailored to risk preferences of the renewable power asset owner or operator.
    Type: Grant
    Filed: June 4, 2020
    Date of Patent: August 16, 2022
    Assignee: Form Energy, Inc.
    Inventors: Benjamin Michael Jenkins, Aly Eldeen O. Eltayeb, Marco Ferrara