The present invention provides a terminal assembly, and storage batteries comprising a terminal assembly, wherein the terminal assembly comprises a conductive cup-shaped member comprising a terminal wall in electric communication with a terminal of the electrochemical cell when the terminal wall is in contact with the terminal; a sidewall; and a rim separated from the terminal wall by the sidewall; and a bipolar endplate having first and second surfaces parallel with the terminal wall and joining to the rim at the first surface, the joining enabling bi-directional uniform current flow through the cup-shaped member between the terminal and the endplate when the terminal wall is in contact with the terminal, the endplate having an electrochemically active region comprising a first surface area enclosed by the rim and a remaining second surface area outside an outer periphery of the rim, the first and second surface areas being substantially equal.

A separator for a bobbin-style electrochemical cell is inserted into an interior opening within a ring-shaped cathode in an electrochemical cell can. An expansion force is then applied to an interior surface of the separator to press the separator against the interior walls of the cathode. A tool may then remove various creases and/or wrinkles in the separator and/or may then heat seal at least a portion of the tubular walls of the separator to minimize the void space between the separator and active material (e.g., cathode and/or anode) within the electrochemical cell.

The present invention provides an aqueous electrolyte for use in rechargeable zinc-halide storage batteries that possesses improved stability and durability and improves zinc-halide battery performance. One aspect of the present invention provides an electrolyte for use in a secondary zinc bromine electrochemical cell comprising from about 30 wt % to about 40 wt % of ZnBr.sub.2 by weight of the electrolyte; from about 5 wt % to about 15 wt % of KBr; from about 5 wt % to about 15 wt % of KCl; and one or more quaternary ammonium agents, wherein the electrolyte comprises from about 0.5 wt % to about 10 wt % of the one or more quaternary ammonium agents.

The present disclosure is directed to electrochemical cells having injection molded or 3D printed components, such as cathodes, anodes, and/or electrolytes, and methods for making such electrochemical cells. The cathodes, anodes, and/or electrolytes can be formed from a binder resin and various conductive and active materials, mixtures of which are injected into a mold under heat and pressure to form the components of the electrochemical cells. The cathode can include conductive metallic powder, flakes, ribbons, fibers, wires, and/or nanotubes. Further, electrochemical arrays can be formed from multiple electrochemical cells having injection molded or 3D printed components.

An energy storage device includes an electrode made from an active material in which a plurality of channels have been etched. The channels are coated with an electrically functional substance selected from a conductor and an electrolyte.

The present disclosure is directed to electrochemical cells having injection molded or 3D printed components, such as cathodes, anodes, and/or electrolytes, and methods for making such electrochemical cells. The cathodes, anodes, and/or electrolytes can be formed from a binder resin and various conductive and active materials, mixtures of which are injected into a mold under heat and pressure to form the components of the electrochemical cells. The cathode can include conductive metallic powder, flakes, ribbons, fibers, wires, and/or nanotubes. Further, electrochemical arrays can be formed from multiple electrochemical cells having injection molded or 3D printed components.

The present invention provides a bipolar electrode that is useful in zinc-halide electrochemical cells or battery stacks. The bipolar electrode comprises a titanium bipolar electrode plate wherein a cathode assembly is disposed on a front surface of the electrode plate. The cathode assembly comprises a titanium cathode cage, a separator, and carbon material, wherein the cathode cage holds the carbon material in electrical communication with the front surface of the electrode plate.

Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that are coated on only one side of a current collector. In some embodiments, an electrochemical cell includes a semi-solid positive electrode coated on only one side of a positive current collector and a semi-solid negative electrode coated on only one side of a negative current collector. A separator is disposed between the semi-solid positive electrode and the semi-solid negative electrode. At least one of the semi-solid positive electrode and the semi-solid negative electrode can have a thickness of at least about 250 m.

Methods and apparatus to form biocompatible energization elements are described. In some examples, the methods and apparatus to form the biocompatible energization elements involve forming pellets comprising active cathode chemistry. The active elements of the cathode and anode are sealed with a biocompatible material. In some examples, a field of use for the methods and apparatus may include any biocompatible device or product that requires energization elements.

The present invention provides a terminal assembly, and storage batteries comprising a terminal assembly, wherein the terminal assembly comprises a conductive cup-shaped member comprising a terminal wall in electric communication with a terminal of the electrochemical cell when the terminal wall is in contact with the terminal; a sidewall; and a rim separated from the terminal wall by the sidewall; and a bipolar endplate having first and second surfaces coplanar with the terminal wall and joining to the rim at the first surface, the joining enabling bi-directional uniform current flow through the cup-shaped member between the terminal and the endplate when the terminal wall is in contact with the terminal, the endplate having an electrochemically active region comprising a first surface area enclosed by the rim and a remaining second surface area outside an outer periphery of the rim, the first and second surface areas being substantially equal.