Module for an Electrical Charge Storage Apparatus Including a Seal Layer and a Method of Making the Same

1 . A module for an electrical charge storage apparatus that circulates an anolyte fluid and a catholyte fluid to charge and discharge the apparatus, the module comprising:

an anode plate assembly including a first anode plate and a first separator membrane defining the anolyte fluid passage on an outer side of the anode plate;

a cathode plate assembly including a first cathode plate and a second separator membrane defining a catholyte fluid passage on an outer side of the cathode plate,

at least one pole piece hub conductively connecting an inner side of the anode plate assembly to an inner side of the cathode plate assembly; and

a seal layer disposed between the anode plate and the cathode plate, the seal layer defines an opening for each pole piece hub, wherein the seal layer precludes the flow of the anolyte fluid and the catholyte fluid between the anode plate and the cathode plate around each pole piece hub.

2 . The module of claim 1 further comprising a first flow screen disposed in the anolyte fluid passage and a second flow screen disposed in the catholyte fluid passage.

3 . The module of claim 1 further comprising a nickel foam member disposed in the catholyte fluid passage, wherein the cathode plate assembly is plated with a nickel plating.

4 . The module of claim 1 wherein the seal includes four openings, two pole piece hubs are provided on the anode plate and two pole piece hubs are provided on the cathode plate, wherein the anode plate and pole piece hubs that are provided on the anode hub are structurally identical to the cathode plate and two pole piece hubs are provided on the cathode plate, and wherein the anode plate and cathode plate are assembled to each other in an opposite orientation with the hubs spaced from each other.

5 . The module of claim 1 further comprising a housing that receives the anode plate, the cathode plate and the seal, the housing defining anolyte inlet passages and anolyte outlet passages that are in fluid flow communication with the anolyte fluid passage, and the housing defining catholyte inlet passages and catholyte outlet passages that are in fluid flow communication with the catholyte fluid passage.

6 . The module of claim 5 further comprising a peripheral seal provided between the housing, and the anode plate, the cathode plate and the seal that separates the anolyte from the catholyte.

7 . An energy storage cell that is provided with an anolyte and a catholyte, the cell comprising:

a housing that defines a first set of flow passages for the anolyte and a second set of flow passages for the catholyte;

a plurality of anode plates having an inner surface and an outer surface;

a plurality of cathode plates having an inner surface and an outer surface;

a plurality of conductors assembled between the inner surface of the anode plates and the inner surface of the cathode plates to electrically connect one of the anode plates to one of the cathode plates to maintain each paired anode plate and cathode plate at the same electrical potential;

a plurality of separator membranes disposed between the outer surface of one of the anode plates and the outer surface of one of the cathode plates that defines an anolyte fluid passage and a catholyte fluid passage on opposite sides of each of the separator membranes; and

a seal layer provided between the inner surface of the anode plates and the inner surface of the cathode plates, the seal defining an opening for each of the conductors, wherein the seal layer prevents the anolyte and the catholyte from mixing between the inner surfaces of the anode plates and the inner surfaces of the cathode plates.

8 . The energy storage cell of claim 7 further comprising a first flow screen disposed in the anolyte fluid passage and a second flow screen disposed in the catholyte fluid passage.

9 . The energy storage cell of claim 7 further comprising a nickel foam member disposed in the catholyte fluid passage, wherein the cathode plate assembly is plated with a nickel plating.

10 . The energy storage cell of claim 7 wherein the seal includes four openings, two conductors are provided on the anode plate and two conductors are provided on the cathode plate, wherein the anode plate and conductors that are provided on the anode hub are structurally identical to the cathode plate and two conductors are provided on the cathode plate, and wherein the anode plate and cathode plate are assembled to each other in an opposing orientation with the conductors spaced from each other.

11 . The energy storage cell of claim 7 wherein the first set of flow passages is in fluid flow communication with the anolyte fluid passage, and the second set of fluid passages is in fluid flow communication with the catholyte fluid passage.

12 . The energy storage cell of claim 11 further comprising a peripheral seal provided between the housing, and the anode plates, the cathode plates and the seals that separates the anolyte from the catholyte.

13 . A method of making an energy storage cell comprising:

selecting a plurality of anode plates having an inner side and an outer side;

selecting a plurality of cathode plates having an inner side and an outer side;

attaching at least one conductor between each of the inner sides of the anode plates and cathode plates;

selecting a plurality of seal layers that each define at least one opening;

assembling each of the seals between the inner side of one of the anode plates and the inner side of one of the cathode plates with the conductors each being received within one of the openings in the seals;

assembling a separator membrane between each of the spaced outer sides of the anode plates and the cathode plates to define a plurality of adjacent fluid channels on two opposite sides of the separator membranes.

14 . The method of claim 13 wherein the method further comprises:

assembling a flow screen between the separator membrane and each of the spaced outer sides of the anode plates and the cathode plates.

15 . The method of claim 13 wherein the method further comprises:

assembling a nickel foam member between the separator membrane and each of the spaced outer sides of the cathode plates disposed in the catholyte fluid passage, wherein the cathode plate assembly is plated with a nickel plating.

16 . The method of claim 13 comprising:

attaching two conductors on the anode plate and two conductors are provided on the cathode plate, wherein the anode plate and conductors that are provided on the anode hub are located in the same location on the respective anode and cathode plates; and

assembling anode plate to the cathode plate, and wherein the anode plates and cathode plate are assembled to each other in opposite orientations with the conductors spaced from each other.

17 . The method of claim 16 wherein during the step of attaching the conductors to the anode plates the conductor are aligned in an array, and during the step of attaching the conductors to the cathode plates the are aligned in the same array with the conductors facing the adjacent plate but in spaced locations relative to the conductors on the anode plates.