Abstract: A braze alloy composition is disclosed, containing nickel, about 5% to about 40% of at least one refractory metal selected from niobium, tantalum, or molybdenum; about 2% to about 32% chromium; and about 0.5% to about 10% of at least one active metal element. An electrochemical cell that includes two components joined to each other by such a braze composition is also described. A method for joining components such as those within an electrochemical cell is also described. The method includes the step of introducing a braze alloy composition between a first component and a second component to be joined, to form a brazing structure. In many instances, one component is formed of a ceramic, while the other is formed of a metal or metal alloy.

Abstract: A braze alloy composition for sealing a ceramic component to a metal component in an electrochemical cell is presented. The braze alloy composition includes copper, nickel, and an active metal element. The braze alloy includes nickel in an amount less than about 30 weight percent, and the active metal element in an amount less than about 10 weight percent. An electrochemical cell using the braze alloy for sealing a ceramic component to a metal component in the cell is also provided.

Abstract: A braze alloy composition for sealing a ceramic component to a metal component in an electrochemical cell is presented. The braze alloy composition includes nickel, silicon, boron, and an active metal element. The braze alloy includes nickel in an amount greater than about 50 weight percent, and the active metal element in an amount less than about 10 weight percent. An electrochemical cell using the braze alloy for sealing a ceramic component to a metal component in the cell is also provided.

Abstract: An electrochemical cell is presented. The cell includes a housing having an interior surface defining a volume, and an elongated, ion-conducting separator disposed in the volume. The separator usually extends in a vertical direction relative to a base of the housing, so as to define a height dimension of the cell. The separator has a first circumferential surface defining a portion of a first compartment. The cell further includes a shim structure disposed generally parallel to the first circumferential surface of the separator between the interior surface and the first circumferential surface of the separator. The structure includes at least two shims, a first shim and a second shim, that substantially overlap each other. An energy storage device including such an electrochemical cell is also provided.

Abstract: A braze alloy composition for sealing a ceramic component to a metal component in an electrochemical cell is presented. The braze alloy composition includes nickel, germanium, and an active metal element. The braze alloy includes germanium in an amount greater than about 5 weight percent, and the active metal element in an amount less than about 10 weight percent. A method for sealing a ceramic component to a metal component in an electrochemical cell and, an electrochemical cell sealed thereby, are also provided.

Abstract: An electrochemical cell includes an outer housing, a separator for separating an anode material from a cathode material, wherein the separator is disposed in the outer housing. The electrochemical cell also includes a conductive thin sheet disposed around an outer circumference of the separator, wherein the conductive thin sheet is disposed such that it allows passage of the anode material between the separator and the conductive thin sheet. The electrochemical cell further includes a conductive matrix disposed between, and in contact with, the conductive thin sheet and the outer housing.

Abstract: An electrochemical cell is presented. The cell includes a housing having an interior surface defining a volume, and an elongated, ion-conducting separator disposed in the volume. The separator usually extends in a vertical direction relative to a base of the housing, so as to define a height dimension of the cell. The separator has a first circumferential surface defining a portion of a first compartment. The cell further includes a shim structure disposed between the interior surface and the first circumferential surface of the separator. The structure includes at least two shims. Each shim has a circumferential surface generally parallel to the other, and generally parallel to the first circumferential surface of the separator. An energy storage device including such an electrochemical cell is also provided.

Abstract: The battery cell design includes a battery cell component comprises a current conducting element, that includes at least a portion that is hollow, further component is configured to be located within a battery cell. Another embodiment of the component comprises a first element that defines a first fluid path therein; and a second element that defines a second fluid path, wherein the two fluid paths are in communication with each other, further wherein the battery cell component is configured to conduct electric current. A battery cell and battery cell assembly that uses the component, and a method of cooling a battery assembly is also disclosed. The present invention has been described in terms of specific embodiment(s), and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.

Abstract: A lamp is provided with an axially and radially graded structure to reduce the possibility of thermal stresses, cracks, and other defects in the lamp. In one embodiment, a system includes a ceramic lamp having a ceramic arc envelope and an end structure coupled to the ceramic arc envelope, wherein the end structure is graded both axially and radially into a plurality of regions. In another embodiment, a system includes a lamp having a layered end structure with a plurality of layers disposed one over another and that extend in both axial and radial directions relative to an axis of the lamp, wherein the plurality of layers include different materials having different coefficients of thermal expansion, Poisson's ratios, or elastic moduli, or a combination thereof.

Abstract: Methods for making a reinforced refractory crucible for melting titanium alloys including providing a form, applying a facecoat to the form, the facecoat having at least one facecoat layer, applying a backing about the facecoat, the backing having at least one backing layer, applying at least one reinforcing element to at least a portion of the facecoat layer, the backing layer, or a combination thereof where the reinforcing element includes at least one composition selected from ceramic compositions, metallic compositions, and combinations thereof.

Abstract: Refractory crucibles capable of managing thermal stress and suitable for melting highly reactive alloys having a facecoat, a backing, and at least one retaining ring applied about at least a portion of the backing of the crucible, the retaining ring comprising a composition selected from the group consisting of conductive materials, non-conductive materials, and combinations thereof.

Abstract: A system, in certain embodiments, includes a high intensity discharge lamp having a composite leg. The composite leg includes a plurality of leg sections coupled together in series. The plurality of leg sections includes different materials, coefficients of thermal expansion, Poisson's ratios, or elastic moduli, or a combination thereof. A method, in certain embodiments, includes enclosing a high intensity discharge within a ceramic arc envelope. The method also includes reducing thermal stresses associated with the high intensity discharge via a composite leg extending outwardly from the ceramic arc envelope. The composite leg includes a plurality of leg sections coupled together in series. The plurality of leg sections includes different materials, coefficients of thermal expansion, Poisson's ratios, or elastic moduli, or a combination thereof.

Abstract: Crucibles for melting titanium alloys having a facecoat including at least one facecoat layer containing an oxide selected from scandium oxide, yttrium oxide, hafnium oxide, a lanthanide series oxide, and combinations thereof, and a backing including at least one backing layer where the crucible has a backing to facecoat thickness ratio of from about 6.5:1 to about 20:1.

Abstract: A high intensity discharge lamp, in certain embodiments, includes a uniquely shaped shoulder and dimensions selected to reduce stress and associated cracking. The uniquely shaped shoulder has a variable diameter, such as, e.g., a cup-shaped geometry, a curved funnel-shaped geometry, or a conical-shaped geometry. The selected or optimized dimensions may include a tip-to-neck distance, a tip-to-wall distance, and an internal diameter of the lamp. The selected or optimized dimensions also may include a uniform wall thickness, an arc gap distance, and an electrode thickness. These dimensions and shapes are selected to reduce undesirably high maximum stresses and temperatures in the lamp. As a result, the lamp is able to provide higher performance with a longer life due to a decreased risk of stress cracking during rapid start up and steady state operation.

Abstract: A metalized ceramic comprising a ceramic substrate comprising a first ceramic and a ceramic metallization layer disposed on the ceramic substrate. The ceramic metallization layer comprises a mixture of (i) a second ceramic and (ii) a metal comprising nickel or a refractory metal. The refractory metal may consist one or more of molybdenum, tungsten, niobium and tantalum. The first ceramic and the second ceramic have a purity of greater than about 95 percent. A method of making the metalized ceramic is provided. An electrochemical cell including the metalized ceramic is also provided.

Abstract: An electrolyte separator structure is provided. The electrolyte separator structure comprises a graded integral structure, wherein the structure comprises an ion-conducting first ceramic at a first end and an electrically insulating second ceramic at a second end, wherein the difference in the coefficient of thermal expansion of the ion-conducting first ceramic and the electrically insulating second ceramic is less than or equal to about 5 parts per million per degrees Centigrade, and wherein at least one of the first ceramic or the second ceramic comprises a strengthening agent. Method of making the ion-separator structure is provided. Electrochemical cells comprising the ion-separator structure and method of making the electrochemical cell using the ion-separator structure are also provided.

Abstract: Reinforced crucibles for melting titanium alloys having a facecoat including at least one facecoat layer, a backing including at least one backing layer, and at least one reinforcing element applied to at least a portion of one or more of the facecoat layer, the backing layer, or a combination thereof where the reinforcing element includes at least one composition selected from ceramic compositions, metallic compositions, and combinations thereof.

Abstract: A pre-sealed anode tube assembly for a sodium-metal-halide energy storage device includes an anode tube and a feed-through current collector assembly at least partially sealed within the anode tube. The pre-sealed anode tube assembly can be independently transported prior to being integrated with a desired sodium-metal-halide energy storage device.

Abstract: An energy storage device includes a housing having an interior surface defining a volume and a plurality of solid electrolyte elements disposed in the volume. Each solid electrolyte element has a first surface that defines at least a portion of a first, cathodic chamber, and a second surface that defines a second, anodic chamber. A plurality of individual anodic chambers are thus provided, at least one of which is evacuated below atmospheric pressure. A majority of anodic chambers can be spaced from one another in a manner that provides a substantially uniform reaction rate throughout the cathodic chamber.

Abstract: In certain embodiments, a lamp is provided with an arc envelope including a ceramic, an end member including a material different from the ceramic, and a compliant seal disposed between the end member and the arc envelope. The compliant seal includes a plurality of layers having different thermal expansion characteristics in an order of gradual change between the arc envelope and the end member.