Abstract: Apparatus and methods to reduce granule disruption during manufacture of electrochemical cells, such as a metal halide electrochemical cell, are provided. In one embodiment, a current collector can include a diffuser strip extending beneath an aperture configured to receive an injection stream of molten electrolyte. The diffuser strip can be configured to dissipate an injection stream of molten electrolyte when the molten electrolyte is injected into an electrochemical cell. In this way, disruption of a granule bed by the injection of the molten electrolyte during manufacture of the electrochemical cell can be reduced.

Abstract: A method of assembling a rechargeable battery is disclosed. The method includes inserting rechargeable energy storage cells into a battery housing, the battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portion, wherein the rechargeable energy storage cells are inserted into the battery housing through the aperture; installing an insulator on the rechargeable energy storage cells; and securing a housing cover to the battery housing such that the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion. Also disclosed is a rechargeable battery including a battery housing, a housing cover, a plurality of rechargeable energy storage cells disposed within the battery housing, and an insulator disposed between the rechargeable energy storage cells and the housing cover and maintained in compression.

Abstract: Apparatus and methods to reduce granule disruption during manufacture of electrochemical cells, such as a metal halide electrochemical cell, are provided. In one embodiment, a current collector can include a diffuser strip extending beneath an aperture configured to receive an injection stream of molten electrolyte. The diffuser strip can be configured to dissipate an injection stream of molten electrolyte when the molten electrolyte is injected into an electrochemical cell. In this way, disruption of a granule bed by the injection of the molten electrolyte during manufacture of the electrochemical cell can be reduced.

Abstract: Apparatus and methods to reduce granule disruption during manufacture of electrochemical cells, such as a metal halide electrochemical cell, are provided. In one embodiment, a current collector can include a diffuser strip extending beneath an aperture configured to receive an injection stream of molten electrolyte. The diffuser strip can be configured to dissipate an injection stream of molten electrolyte when the molten electrolyte is injected into an electrochemical cell. In this way, disruption of a granule bed by the injection of the molten electrolyte during manufacture of the electrochemical cell can be reduced.

Abstract: Apparatus and methods to reduce granule disruption during manufacture of electrochemical cells, such as a metal halide electrochemical cell, are provided. In one embodiment, a current collector can include a diffuser strip extending beneath an aperture configured to receive an injection stream of molten electrolyte. The diffuser strip can be configured to dissipate an injection stream of molten electrolyte when the molten electrolyte is injected into an electrochemical cell. In this way, disruption of a granule bed by the injection of the molten electrolyte during manufacture of the electrochemical cell can be reduced.

Abstract: A method of assembling a rechargeable battery is disclosed. The method includes inserting rechargeable energy storage cells into a battery housing, the battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portion, wherein the rechargeable energy storage cells are inserted into the battery housing through the aperture; installing an insulator on the rechargeable energy storage cells; and securing a housing cover to the battery housing such that the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion. Also disclosed is a rechargeable battery including a battery housing, a housing cover, a plurality of rechargeable energy storage cells disposed within the battery housing, and an insulator disposed between the rechargeable energy storage cells and the housing cover and maintained in compression.

Abstract: Fin-based current collectors provide high performance and cost savings in electrochemical cells. Embodiments of the invention provide a current collector for a sodium-metal halide electrochemical cell having at least one substantially flat and elongated metal fin being electrically conductive and having at least one bend with respect to a dominant longitudinal axis of the current collector. The at least one substantially flat and elongated metal fin is configured to be joined to a metal ring of the electrochemical cell via one of welding or brazing.

Abstract: A thermal management device is presently disclosed. The thermal management device includes an insulator with a maximum use temperature of at least 200 degrees Celsius, and a heating element having at least one heater leg, where the heater leg contacts the insulator and is configured to supply thermal energy. The heating element also has lead wires configured to provide a parallel electrical connection between the heater leg and a current source.

Abstract: A method of assembling a rechargeable battery is disclosed. The method includes inserting rechargeable energy storage cells into a battery housing, the battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portion, wherein the rechargeable energy storage cells are inserted into the battery housing through the aperture; installing an insulator on the rechargeable energy storage cells; and securing a housing cover to the battery housing such that the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion. Also disclosed is a rechargeable battery including a battery housing, a housing cover, a plurality of rechargeable energy storage cells disposed within the battery housing, and an insulator disposed between the rechargeable energy storage cells and the housing cover and maintained in compression.

Abstract: A terminal apparatus for an energy storage cell is presently disclosed. The terminal apparatus includes a terminal body with a peripheral edge extending substantially around a perimeter of the terminal body such that the terminal body is configured to be secured to a cell housing to retain an electrochemical cell in the cell housing, a terminal connector extending from the peripheral edge forming a first terminal for an energy storage cell, a sealable vacuum port extending through the terminal body, and an aperture in the terminal body configured to receive a second terminal of the energy storage cell. A method of manufacturing an energy storage cell is also disclosed.

Abstract: A thermal management device is presently disclosed. The device includes a plurality of insulator panels with a maximum use temperature of at least 500 degrees Celsius, and a heating element having at least two heater legs electrically connected in parallel, each heater leg contacting at least one of the insulator panels, and lead wires configured to provide a parallel electrical connection between the heater legs and a current source. Also disclosed is a thermal management device having an insulator and a heating element, where each of the electrically parallel heater legs is configured to provide substantially uniform heat flux over at least one surface of the device. Also disclosed is an energy storage device that includes a plurality of energy storage cells, and a thermal management device configured to supply thermal energy to the cells.

Abstract: A thermal management device is presently disclosed. The thermal management device includes an insulator with a maximum use temperature of at least 200 degrees Celsius, and a heating element having at least one heater leg, where the heater leg contacts the insulator and is configured to supply thermal energy. The heating element also has lead wires configured to provide a parallel electrical connection between the heater leg and a current source.

Abstract: A thermal management system for an energy storage system that controls the temperature of an array of electrochemical cells of the energy storage system. Fluid channels or pathways are provided around outer side regions of an array of electrochemical cells. Fluid flow is directed along one pathway to a next subsequent pathway, absorbing thermal energy generated by the array of electrochemical cells along the way. The fluid flow is eventually discharged from the energy storage system by the thermal management system, thereby removing thermal energy from the energy storage system.