Electrochemical stack and method of assembly thereof

Abstract

An electrochemical stack assembly includes a laminated pouch surrounding a frame which encloses solid-state electrochemical cells and electrochemical stacks. In some embodiments, an electrochemical stack assembly includes one or more electrochemical cells, each electrochemical cell comprising a solid-state electrolyte to form at least one electrochemical stack with two major surfaces and four minor surfaces; a frame surrounding the at least one electrochemical stack with space between the frame and each of the four minor surfaces; and a laminated pouch surrounding the frame and the at least one electrochemical stack, the laminated pouch in contact with one or both of the major surfaces. In some embodiments, the frame comprises a tray. In some embodiments, the electrochemical stack assembly comprises two trays, each with an electrochemical stack comprising an electrochemical cell, the cell comprising a solid-state electrolyte.

1 . An electrochemical stack assembly comprising:
 one or more electrochemical cells, each electrochemical cell comprising a solid-state electrolyte to form at least one electrochemical stack with two major surfaces and four minor surfaces;   a frame surrounding the at least one electrochemical stack with space between the frame and each of the four minor surfaces;   a flat plate, comprising a thermally conductive material, attached to or integral with the frame, and   a laminated pouch surrounding the frame and the at least one electrochemical stack, the laminated pouch in contact with one or both of the two major surfaces.   
     
     
         2 . The electrochemical stack assembly of  claim 1 , further comprising an adhesive to adhere the flat plate to one of the two major surfaces, wherein the laminated pouch is in contact with the other of the two major surfaces. 
     
     
         3 . The electrochemical stack assembly of  claim 2 , wherein the one or more electrochemical cells form at least two electrochemical stacks, each having two major surfaces and four minor surfaces, each of the at least two electrochemical stacks having one of the two major surfaces attached to respective sides of the flat plate. 
     
     
         4 . The electrochemical stack assembly of  claim 3 , wherein the frame comprises a first frame portion and a second frame portion, and the flat plate attached to both the first frame portion and the second frame portion, and to which one of the two major surfaces of the at least one electrochemical stack or one of the two major surfaces of each of the at least two electrochemical stacks is attached. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . The electrochemical stack assembly of  claim 1 , wherein the frame comprises material selected from the group consisting of metal, plastic, plastic with thermal additives, rubber, silicone, ceramic, clay, glass, tempered glass, thermoplastics, carbon fiber, metal-plastic composites, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy, or combinations thereof. 
     
     
         9 . (canceled) 
     
     
         10 . The electrochemical stack assembly of  claim 1 , wherein the space between the frame and the four minor surfaces of the at least one electrochemical stack prevents the application of force by the laminated pouch to the four minor surfaces of the at least one electrochemical stack during charge and discharge cycles of the at least one electrochemical stack without deforming, cracking, or otherwise damaging the solid-state electrolyte in each of the one or more electrochemical cells. 
     
     
         11 . (canceled) 
     
     
         12 . The electrochemical stack assembly of  claim 1 , wherein the space between the frame and the four minor surfaces of the at least one electrochemical stack provides space for the at least one electrochemical stack to expand or contract during charge or discharge without deforming, cracking, or otherwise damaging the solid-state electrolyte in each of the one or more electrochemical cells. 
     
     
         13 . The electrochemical stack assembly of  claim 1 , wherein the laminated pouch provides about 20% of expansion and contraction in a direction normal to at least one of the two major surfaces of the at least one electrochemical stack. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The electrochemical stack assembly of  claim 1 , wherein the laminated pouch comprises a pair of laminate forms with facing surfaces forming a seam, the facing surfaces being bonded with a seal at the seam. 
     
     
         17 . The electrochemical stack assembly of  claim 1 , wherein the laminated pouch has a formed shape with two major surfaces, wherein the ratio of the surface area of each of the two major surfaces of the formed shape on the laminated pouch to the surface area of each of the two major surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than 1. 
     
     
         18 . The electrochemical stack assembly of  claim 1 , wherein a thickness of the formed shape of the laminated pouch is about 20% of the thickness of the at least one electrochemical stack. 
     
     
         19 . The electrochemical stack assembly of any preceding claim, further comprising at least one positive electrode terminal and at least one negative electrode terminal, which extend through the frame and the laminated pouch. 
     
     
         20 . The electrochemical stack assembly of  claim 19 , wherein the at least one positive electrode terminal and at least one negative electrode terminal are flat, bent, folded, or have a Z-bend. 
     
     
         21 . The electrochemical stack assembly of  claim 1  wherein each electrochemical cell comprises a solid-state electrolyte separator. 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . electrochemical stack assembly of  claim 3 , wherein the frame comprises a first frame portion including a first flat plate to which one of the major surfaces of each of the at least two electrochemical stacks is attached, and a second frame portion including a second flat plate to which the other of the major surfaces of the other of the at least two electrochemical stacks is attached, wherein the first and second frame portions are positioned with respect to each other such that the first and second flat plates contact each other. 
     
     
         25 . The electrochemical stack assembly of  claim 24 , wherein the first frame portion is rectangular, and comprises four edges protruding from the first flat plate so as to form a first tray which surrounds one of the at least two electrochemical stacks, and wherein the second frame portion is rectangular, and comprises four edges protruding from the second flat plate so as to form a second tray which surrounds a second of the at least two electrochemical stacks. 
     
     
         26 . The electrochemical stack assembly of  claim 25 , wherein one of the four edges of the first tray contains a first elongate opening, and one of the four edges of the second tray contains a second elongate opening. 
     
     
         27 . The electrochemical stack assembly of  claim 26 , further comprising a first piece extending over the first elongate opening, and a second piece extending over the second elongate opening. 
     
     
         28 . (canceled) 
     
     
         29 . The electrochemical stack assembly of  claim 27 , wherein each of said at least two electrochemical stacks comprises an anode and a cathode which extend through a respective one of said first and second elongate openings. 
     
     
         30 . (canceled) 
     
     
         31 . The electrochemical stack assembly of  claim 29 , wherein a cathode of a first one of the at least two electrochemical stacks has a higher energy density or greater power output or greater capacity than a cathode of a second one of the at least two electrochemical stacks. 
     
     
         32 . (canceled) 
     
     
         33 . (canceled) 
     
     
         34 . (canceled) 
     
     
         35 . (canceled) 
     
     
         36 . (canceled)