Planar high density sodium battery

1. A method of making a molten sodium battery comprising:

a. providing a first metallic interconnect frame having a first interconnect vent hole, anode chamber and cathode chamber;

b. providing a second metallic interconnect frame having a second interconnect vent hole, anode chamber and cathode chamber;

c. interposing an electrolyte plate having a cathode vent hole and an anode vent hole between the metallic interconnect frames; and

d. sealing the metallic interconnect frames and the electrolyte plate thereby forming gaseous communication between the anode chamber of the first interconnect frame through the anode vent holes and gaseous communication between the cathode chamber of the second interconnect frame through the cathode vent holes, wherein the vent holes minimize a pressure differential within the battery during a charge/discharge cycle.

2. The method of claim 1 further comprising stacking a plurality of electrolyte plates and metallic interconnect frames, wherein each interconnect frame is disposed on opposite sides of each electrolyte plate, each electrolyte plate having a cathode vent hole and an anode vent hole, and each interconnect frame having an interconnect vent hole, and wherein the plurality of plates and interconnect frames are sealed.

3. The method of claim 2 further comprising a pressure accumulator in gaseous communication with the cathode vent holes and the anode vent holes to simultaneously provide pressure relief to the stack while containing the gasses.

4. The method of claim 1 further comprising providing a cathode composition containing a transition metal and sodium chloride in the cathode chambers.

5. The method of claim 1 further comprising adding a secondary electrolyte into the cathode chambers through the cathode vent holes.

6. The method of claim 4 further comprising providing a cathode composition containing a transition metal, sodium chloride, and a secondary electrolyte in the cathode chambers.

7. The method of claim 4 wherein the transition metal is nickel.

8. The method of claim 1 wherein the electrolyte plate is formed of β″ alumina solid electrolyte (BASE).

9. A molten sodium battery comprising:

a. a first metallic interconnect frame having a first interconnect vent hole, anode chamber and cathode chamber;

b. a second metallic interconnect frame having a second interconnect vent hole, anode chamber and cathode chamber; and

c. an electrolyte plate having a cathode vent hole and an anode vent hole interposed between the metallic interconnect frames, wherein the interconnect frames and the electrolyte plate are sealed thereby forming gaseous communication between the anode chamber of the first interconnect frame through the anode vent holes and gaseous communication between the cathode chamber of the second interconnect frame through the cathode vent holes, wherein the vent holes minimize a pressure differential within the battery during a charge/discharge cycle.

10. The molten sodium battery of claim 9 further comprising a plurality of electrolyte plates and metallic interconnect frames, wherein each interconnect frame is disposed on opposite sides of each electrolyte plate, each electrolyte plate having a cathode vent hole and an anode vent hole, and each interconnect frame having an interconnect vent hole, and wherein the plurality of plates and interconnect frames are sealed, thus forming a stack.

11. The molten sodium battery of claim 10 further comprising a pressure accumulator in gaseous communication with the cathode vent holes to simultaneously provide pressure relief to the stack while containing the gasses.

12. The molten sodium battery of claim 9 further comprising a cathode composition containing a transition metal and sodium chloride in the cathode chambers.

13. The molten sodium battery of claim 12 wherein the transition metal is nickel.

14. The molten sodium battery of claim 9 further comprising a secondary electrolyte added into the cathode chambers through the cathode vent holes.

15. The molten sodium battery of claim 9 further comprising a cathode composition containing a transition metal, sodium chloride, and a secondary electrolyte in the cathode chambers.

16. The molten sodium battery of claim 9 wherein the electrolyte plate is formed of β″ alumina solid electrolyte (BASE).

17. A molten sodium battery comprising a plurality of electrolyte plates and metallic interconnect frames, wherein each interconnect frame is disposed on opposite sides of each electrolyte plate, each plate having a cathode vent hole and an anode vent hole, and each interconnect frame having an interconnect vent hole, an anode chamber and a cathode chamber, and wherein the plurality of plates and interconnect frames are sealed, wherein the vent holes minimize a pressure differential within the battery during a charge/discharge cycle.

18. The molten sodium battery of claim 17 wherein gaseous communication between anode chambers through the anode vent holes and gaseous communication between cathode chambers through the cathode vent holes are formed.

19. The molten sodium battery of claim 18 further comprising a cathode composition containing a transition metal and sodium chloride in the cathode chambers.

20. The molten sodium battery of claim 19 wherein the transition metal is nickel.

21. The molten sodium battery of claim 17 further comprising a secondary electrolyte added into the cathode chambers through the cathode vent holes.

22. The molten sodium battery of claim 17 wherein the electrolyte plates are formed of β″ alumina solid electrolyte (BASE).

23. The molten sodium battery of claim 17 further comprising a pressure accumulator in gaseous communication with the cathode vent holes and the anode vent holes to simultaneously provide pressure relief to the stack while containing the gasses.

24. A molten sodium battery comprising:

a. a first metallic interconnect frame having a first interconnect vent hole, anode chamber and cathode chamber;

b. a second metallic interconnect frame having a second interconnect vent hole, anode chamber and cathode chamber;

c. an electrolyte plate formed of β″ alumina solid electrolyte (BASE) having a cathode vent hole and an anode vent hole interposed between the metallic interconnect frames, wherein the interconnect frames and the electrolyte plate are sealed thereby forming gaseous communication between the anode chamber of the first interconnect frame through the anode vent holes and gaseous communication between the cathode chamber of the second interconnect frame through the cathode vent holes;

d. a cathode composition containing nickel and sodium chloride in the cathode chambers; and

e. a pressure accumulator in gaseous communication with the cathode vent holes and the anode vent holes to simultaneously provide pressure relief to the stack while containing the gasses.

25. A molten sodium battery comprising:

a. a plurality of electrolyte plates formed of β″ alumina solid electrolyte (BASE);

b. a plurality of metallic interconnect frames, wherein each interconnect frame is disposed on opposite sides of each electrolyte plate, each plate having a cathode vent hole and an anode vent hole, and each interconnect frame having an interconnect vent hole, anode chamber and cathode chamber, and wherein the plurality of plates and interconnect frames are sealed and wherein gaseous communication between anode chambers through the anode vent holes and gaseous communication between cathode chambers through the cathode vent holes are formed; and

c. a cathode composition containing nickel and sodium chloride in the cathode chambers; and

d. a pressure accumulator in gaseous communication with the cathode vent holes and the anode vent holes to simultaneously provide pressure relief to the stack while containing the gasses.