Aluminum housing with a hermetic seal
A housing for an energy storage cell includes an interior which provides beneficial properties to fabricators of the cell. The cell may be hermetically sealed by conventional laser welding techniques.
1. A housing for an energy storage cell, the housing comprising:
a body comprising a first material and a cap formed of a multi-layer material, the cap comprising a hermetically sealed electrode assembly disposed therein;
wherein a first layer of the multi-layer material is compatible with the first material, and a second layer of the multi-layer material is compatible with hermitically sealing the assembly to the cap, and
wherein the hermetically sealed electrode assembly is configured to maintain a leak rate of less than 5.0×10 −6 standard He-cc/sec at temperatures throughout an operational temperature range of about −40 degrees Celsius to about 210 degrees Celsius.
2. The housing of claim 1 , wherein the first layer comprises one of aluminum and an aluminum alloy.
3. The housing of claim 1 , wherein the second layer comprises stainless steel.
4. The housing of claim 1 , wherein the hermetic seal comprises a weld.
5. The housing of claim 1 , wherein the multi-layer material comprises aluminum clad with stainless steel.
6. The housing of claim 1 , wherein the electrolyte of the energy storage cell substantially does not react with at least one of the first material and the first layer.
7. The housing of claim 6 , wherein, the hermetically sealed electrode assembly is rated for operation at temperatures up to about 250 degrees Celsius.
8. A method for housing an energy storage cell, the method comprising:
selecting a body comprising a first material that exhibits low chemical reactivity with an electrolyte;
selecting a cap formed of a multi-layer material, the cap comprising a hermetically sealed electrode assembly disposed therein, wherein a first layer of the multi-layer material is compatible with the first material, and a second layer of the multi-layer material is compatible with hermitically sealing the assembly to the cap; and
placing the storage cell within the body,
wherein the hermetically sealed electrode assembly is configured to maintain a leak rate of less than 5.0×10 −6 standard He-cc/sec at temperatures throughout an operational temperature range of −40 degrees Celsius to 210 degrees Celsius.
9. The method as in claim 8 , further comprising filling the body with an electrolyte.
10. The method as in claim 9 , further comprising hermetically sealing the body and the cap together.
11. An energy storage comprising:
an energy storage cell disposed within a housing comprising a cap hermetically sealed to a body, the body formed of a first material that exhibits low chemical reactivity with an electrolyte; the cap formed of a multi-layer material and comprising a hermetically sealed electrode assembly disposed therein;
wherein the hermetically sealed electrode assembly is configured to maintain a leak rate of less than 5.0×10 −6 standard He-cc/sec at temperatures throughout an operational temperature range of −40 degrees Celsius to 210 degrees Celsius.
12. The energy storage of claim 11 , wherein a first layer of the multi-layer material is compatible with the first material and a second layer is compatible with hermetically sealing the assembly to the cap.
13. The energy storage of claim 11 , wherein the cell comprises one of a battery and a ultracapacitor.
14. The energy storage of claim 11 , wherein the cell comprises a carbonaceous energy storage media.
15. The energy storage of claim 11 , further comprising an electrolyte disposed within the housing.
16. The energy storage of claim 11 , further comprising at least one lead that is electrically coupled to one of the electrode and the housing.
17. The energy storage of claim 16 , wherein the lead comprises a multi-layer material.
18. The energy storage of claim 17 , wherein a portion of the multi-layer material of the lead has been removed for the electrical coupling.
19. The energy storage of claim 11 , wherein the hermetically sealed electrode is retained with an insert.
20. The energy storage of claim 19 , wherein the insert comprises a glass insulator surrounded by a metallic sleeve.
21. An energy storage comprising:
a housing comprising:
a cap; and
a body comprising a multilayer material;
wherein the multilayer material comprises:
a first layer of material that is substantially compatible with an electrolyte of an energy storage cell disposed within the housing; and
at least a second layer at least partially disposed over the first layer, wherein the second layer provides structural integrity for the housing;
wherein at least a portion of the first layer faces an interior of the housing and is exposed to the electrolyte; and
wherein the portion of the first layer that faces the interior of the housing is configured to conduct electricity to or from the energy storage,
wherein the cap comprises a cap formed of a multi-layer cap material, the cap comprising a hermetically sealed electrode assembly disposed therein;
wherein a first layer of the multi-layer cap material is compatible with a material of the body, and a second layer of the multi-layer cap material is compatible with hermetically sealing the assembly to the cap, and
wherein the hermetically sealed electrode assembly is configured to maintain a leak rate of less than 5.0×10 -6 standard He-cc/sec at temperatures throughout an operational temperature range of −40 degrees Celsius to 210 degrees Celsius.
22. The energy storage of claim 21 , wherein the second layer is clad to the first layer.
23. The energy storage of claim 21 , wherein the second layer comprises steel.
24. The energy storage of claim 21 , wherein the first layer comprises at least one of aluminum and an aluminum alloy.
25. The energy storage of claim 21 , wherein the housing comprises a glass-to-metal seal.
26. The energy storage of claim 21 , wherein the energy storage cell comprises carbonaceous energy storage media.
27. The energy storage of claim 21 , wherein the first layer of material is substantially electrochemically compatible with the electrolyte.
28. The energy storage of claim 21 , wherein the energy storage cell is coupled to a first electrical contact of the housing and a second electrical contact of the housing.
29. The energy storage of claim 21 , wherein the coupling comprises an ultrasonic weld.
30. The energy storage of claim 21 , wherein the housing is hermetically sealed.
31. The energy storage of claim 30 , wherein a leak rate of the housing is no greater than about 5.0×10 −6 standard He-cc/sec at temperatures throughout an operational temperature range.
32. The energy storage of claim 31 , wherein a glass-to-metal seal disposed in the housing provides a first electrical contact with a first electrode of the energy storage cell.
33. The energy storage of claim 32 , wherein a body of the housing provides a second electrical contact with a second electrode of the energy storage cell.
34. The energy storage of claim 21 , wherein the housing is adapted for interconnection with another energy storage.
35. The energy storage of claim 31 , wherein the energy storage exhibits a volumetric leakage current that is less than 1,000 mAmp per Liter throughout the operational temperature range and an operational voltage range.
36. The energy storage of claim 35 , wherein the temperature range is from about 60 degrees Celsius to about 250 degrees Celsius and the voltage range is from about 100 mV to about 5V.