Construction of planar rechargeable oxide-ion battery cells and stacks using stainless steel housing structures

1. A process for constructing a rechargeable oxide-ion battery cell comprising the steps:

a) forming a membrane assembly of a top air electrode, a bottom negative metal electrode and a middle contacting ceramic electrolyte which extends beyond either the top air electrode, the bottom air electrode or both the top and bottom air electrodes;

b) sealing extending sides of the middle contacting ceramic electrolyte to a surface of a metallic frame which surrounds the membrane assembly to form a framed membrane assembly;

c) incorporating active material into hollow portions of a metal housing structure to form an active housing structure;

d) forming electrically conductive contact between the framed membrane assembly and the active housing structure; and

e) joining the framed membrane assembly and the active housing structure to form a rechargeable oxide-ion battery cell.

2. A process for constructing a rechargeable oxide-ion battery multiple-cell stack comprising the additional steps of:

f) after step e), forming electrical contact between two cells by installing a cell-to-cell current collector between an air electrode of a first rechargeable oxide-ion battery cell made according to claim 1 and a central section of a bottom surface of the active housing structure of a second rechargeable oxide-ion battery cell; and then

g) forming an insulation seal between a top surface of a frame of the first rechargeable oxide-ion battery cell and a bottom peripheral section of the second rechargeable oxide-ion battery cell.

3. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the top air electrode in step 1a) comprises electronically conductive materials selected from the group consisting of doped LaMnO 3-z , LaCoO 3-z , LaCo x Fe 1-x O 3-z , Sm y Sr 1-y CoO 3-z , doped cerin, stabilized zirconia, doped/updoped La a Sr 1-a Ga b Mg 1-b O 3-z , doped Bi 2 O 3 and their mixture, where x=0 to 1, y 0.2 to 0.7, z=0.001 to 0.1, a=0.5 to 1, and b=0.6 to 1.

4. The process fore constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the middle contacting ceramic electrolyte in step 1a) comprises oxide-ion, conductive materials selected from the group consisting of doped CeO 2 , stabilized zirconia, doped/updoped La a Sr 1-a Ga b Mg 1-b O 3-z , and their mixture, where z=0.001 to 0.1, a=0.5 to 1, and b=0.6 to 1.

5. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the bottom negative metal electrode in step 1a) comprises electronically conductive materials.

6. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the metallic frame in step 1b) comprises oxidation-resistant alloy.

7. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the sealing in step 1b) comprises a sealing process that includes use of a material selected from the group consisting of: glass, ceramic, braze, or combination thereof.

8. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the sealing in step 1b) comprises a brazing process performed at a temperature between 850° C. and 1100° C. to provide a braze seal of from 0.001 millimeter to 1 millimeter thickness.

9. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the metal housing structure in step 1c) comprises stainless steel.

10. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the percentage of hollow space of the metal housing structure in step 1c) is from 10% to 90%, and the thickness of the metal housing structure is from 0.1 millimeter to 20 millimeter.

11. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the active material in step 1c) comprise mixture of metal and metal oxide, and additives.

12. The process for constructing the rechargeable oxide-ion battery cell of claim 1 , wherein the electrically conductive contact in step 1d) comprises a material selected from the group consisting of silver, gold, platinum, palladium, nickel, copper, or electrically-conductive ceramics, or metal-ceramic composites.

13. The process for constructing the rechargeable oxide-ion battery cell of claim 2 , wherein the cell-to-cell current collector in step 2f) includes a metal/alloy screen or a contact paste made of metal or electrically conductive ceramic.

14. The process for constructing the rechargeable oxide-ion battery cell of claim 2 , wherein the insulation seal in step 2g) comprises at least one of glass, cement, welding, ceramics or brazing.

15. The process for constructing the rechargeable oxide-ion battery cell of claim 5 , wherein the bottom negative metal electrode is selected from the group of electrically conductive materials consisting of: silver, gold, platinum, palladium, nickel, copper, stainless steel, and any of their mixtures and combinations thereof.

16. The process for constructing the rechargeable oxide-ion battery cell of claim 13 , wherein the metal/alloy screen or a contact paste is made of a metal or electrically conductive ceramic selected from the group consisting of: doped/undoped CeO 2 , stabilized zirconia, doped/undoped La x Sr 1-x Ga y Mg 1-y O 3-z , doped LaCrO 3-z , doped SrTiO 3-z , doped LaVO 3-z , Gd 2 Ti x Mo 1-x O 7 , Sr 2 Mg 1-x Mn x MoO 6-z , and any of their mixtures, where x=0.5 to 1, y=0.6 to 1 and z=0.001 to 0.1.