Variable volume containment for energy storage devices

Abstract

A stacked energy storage device (ESD) has at least two cell segments arranged in a stack. Each cell segment may have a first electrode unit having a first active material electrode, a second electrode unit having a second active material electrode, and an electrolyte layer between the active material electrodes. Variable volume containment may be used to control the inter-electrode spacing within each cell segment. In some embodiments, one or more dynamic flexible gaskets may be included in each cell segment to seal the electrolyte within the cell segment and to deform in preferred directions. In some embodiments, hard stops may set the inter-electrode spacing of the ESD.

1 . (canceled) 
     
     
         2 . An energy storage device comprising:
 a cell segment comprising:
 a first conductive substrate having a first active material electrode layer; 
 a second conductive substrate having a second active material electrode layer on a second surface of the conductive substrate, wherein the first and the second conductive substrates are provided in a stacking direction; and 
 an electrolyte layer provided between the first and second active material electrode layers; 
   a flexible gasket positioned about the electrolyte layer; and   a hard stop positioned adjacent to the flexible gasket, wherein the hard stop and the flexible gasket are separated by a gap, and wherein the flexible gasket is configured to mechanically deform into the gap.   
     
     
         3 . The energy storage device of  claim 2 , wherein the first active material electrode layer is a positive active material electrode layer, and wherein the second active material electrode layer is a negative active material electrode layer. 
     
     
         4 . The energy storage device of  claim 3  wherein the flexible gasket maintains the inter-electrode spacing of the first active material electrode layer and the second active material electrode layer during operation of the energy storage device. 
     
     
         5 . The energy storage device of  claim 3  wherein the flexible gasket minimizes the movement of the first active material electrode layer and the second active material electrode layer relative to one another. 
     
     
         6 . The energy storage device of  claim 2 , wherein the flexible gasket is mechanically deformable in at least one predetermined direction. 
     
     
         7 . The energy storage device of  claim 2 , wherein the at least one predetermined direction is at least one of: the stacking direction, an axis normal to the stacking direction, radially outwardly from a stacking direction, and an off-axes direction. 
     
     
         8 . The energy storage device of  claim 2  further comprising:
 a plurality of springs, the springs configured to deflect in response to an increase in the pressure within the energy storage device. 
 
     
     
         9 . The energy storage device of  claim 2  further comprising a separator within the electrolyte layer, the separator electrically isolating the first active material electrode layer from the second active material electrode layer. 
     
     
         10 . The energy storage device of  claim 2  wherein the hard stop comprises an inner rim with a shelf on which a respective outer edge of the first and the second conductive substrate is aligned. 
     
     
         11 . The energy storage device of  claim 10  wherein the shelf on the inner rim sets the spacing between the first and the second conductive substrates. 
     
     
         12 . The energy storage device of  claim 2  wherein the hard stop further comprises:
 a plurality of studs; and 
 a plurality of stud holes, the plurality of stud holes adapted to engage a respective stud on an adjacent hard stop. 
 
     
     
         13 . The energy storage device of  claim 12  wherein the studs are adapted to engage the stud holes to align adjacent hard stops without the use of tools. 
     
     
         14 . The energy storage device of  claim 12  wherein the plurality of studs align a substrate flange of the substrate to the hard stop by keeping the substrate centered on an axis colinear with the stacking direction. 
     
     
         15 . The energy storage device of  claim 2  wherein the hard stop comprises an outer rim having a set of holes for a plurality of compression bolts, the holes aligning the first and the second conductive substrates during assembly. 
     
     
         16 . The energy storage device of  claim 2  wherein the deformation of the flexible gasket reduces internal stresses within each cell of the energy storage device by equalizing pressure within the energy storage device while maintaining optimal spacing between the first and the second conductive substrates. 
     
     
         17 . The energy storage device of  claim 2  wherein the electrolyte layer is sealed by first and the second conductive substrates and the flexible gasket positioned about the electrolyte layer. 
     
     
         18 . The energy storage device of  claim 2  wherein the hard stop is one of a containment vessel or wrapper. 
     
     
         19 . The energy storage device of  claim 2 , wherein the hard stop and the flexible gasket are aligned in the stacking direction.