Form Energy, Inc.

United States of America

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H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type 92
H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode 57
H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys 27
H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells 27
H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells 26
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1.

CARBON DIOXIDE REMOVAL FOR ELECTROCHEMICAL POWER STORAGE

      
Application Number 18815751
Status Pending
Filing Date 2024-08-26
First Publication Date 2026-02-26
Owner FORM ENERGY, INC. (USA)
Inventor
  • Bunten, Aurora Hope
  • Smith, Danielle Cassidy
  • Friesen, Grant Harrison
  • Vasavada, Jhalak Joshipura

Abstract

According to one aspect, a system for electrochemical power storage may include a plurality of instances of a metal-air battery, each instance of the metal-air battery including an air electrode, a metal electrode, and a liquid electrolyte separating the air electrode from the metal electrode with the air electrode and the metal electrode ionically coupled to one another via the liquid electrolyte; and a carbon dioxide removal system into which ambient air is directable, carbon dioxide from the ambient air removable in the carbon dioxide removal system to generate purified air, and the carbon dioxide removal system in fluid communication with the plurality of instances of the metal-air batteries such that the purified air is movable from the carbon dioxide removal system to the plurality of instances of the metal-air battery.

IPC Classes  ?

  • B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode

2.

NEGATIVE ELECTRODES FOR ELECTROCHEMICAL CELLS

      
Application Number 19263139
Status Pending
Filing Date 2025-07-08
First Publication Date 2026-02-12
Owner FORM ENERGY, INC. (USA)
Inventor
  • Chakraborty, Rupak
  • Milshtein, Jarrod David
  • Weber, Eric
  • Woodford, William Henry
  • Chiang, Yet-Ming
  • Mckay, Ian Salmon
  • Su, Liang
  • Whitacre, Jay
  • Wiley, Theodore Alan
  • Carlisle, Kristen
  • Westwood, Mitchell Terrance
  • Mumma, Rachel Elizabeth
  • Chu, Max Rae
  • Kharey, Amelie Nina
  • Hultman, Benjamin Thomas
  • Ferrara, Marco
  • Jaramillo, Mateo Cristian
  • Caruso, Isabella
  • Newhouse, Jocelyn

Abstract

Various embodiments provide a battery, a bulk energy storage system including the battery, and/or a method of operating the bulk energy storage system including the battery. In various embodiment, the battery may include a first electrode, an electrolyte, and a second electrode, wherein one or both of the first electrode and the second electrode comprises direct reduced iron (“DRI”). In various embodiments, the DRI may be in the form of pellets. In various embodiments, the pellets may comprise at least about 60 wt % iron by elemental mass, based on the total mass of the pellets. In various embodiments, one or both of the first electrode and the second electrode comprises from about 60% to about 90% iron and from about 1% to about 40% of a component comprising one or more of the materials selected from the group of SiO2, Al2O3, MgO, CaO, and TiO2.

IPC Classes  ?

  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/36 - Selection of substances as active materials, active masses, active liquids
  • H01M 4/58 - Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFySelection of substances as active materials, active masses, active liquids of polyanionic structures, e.g. phosphates, silicates or borates
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

3.

METHODS, SYSTEMS, AND DEVICES FOR PURIFYING METAL-CONTAINING MATERIAL

      
Application Number US2025035673
Publication Number 2026/006716
Status In Force
Filing Date 2025-06-27
Publication Date 2026-01-02
Owner FORM ENERGY, INC. (USA)
Inventor
  • Perkins, Nicholas Reed
  • Manser, Joseph Stephen
  • Morgan, Robert
  • Newhouse, Jocelyn
  • Norman, Zachariah
  • Blummer, Laine
  • Nation, Leah
  • Reynolds, Christopher
  • Thompson, Annelise

Abstract

Methods and systems of the present disclosure are generally directed to purification of metal-containing material. For example, soft oxidation may be used to generate an oxygen-free product from a low-quality alloy of a base metal. The oxygen-free product may be electrolyzed directly to generate a higher-quality alloy of the base metal – namely, an alloy with higher weight percentage of the base metal and, thus, lower weight percentage of tramp elements. As compared to recycling the base metal with a metal-air electrochemical cell, the methods and systems of the present disclosure may facilitate forming high-quality recycled metal (e.g., aluminum) using significantly less energy.

IPC Classes  ?

  • C25C 3/24 - Refining
  • C25C 3/04 - Electrolytic production, recovery or refining of metals by electrolysis of melts of magnesium
  • C25C 3/28 - Electrolytic production, recovery or refining of metals by electrolysis of melts of titanium, zirconium, hafnium, tantalum or vanadium of titanium
  • H01M 4/46 - Alloys based on magnesium or aluminium
  • H01M 10/39 - Accumulators not provided for in groups working at high temperature
  • C25C 7/06 - Operating or servicing

4.

METHODS, SYSTEMS, AND DEVICES FOR PURIFYING METAL-CONTAINING MATERIAL

      
Application Number 19253324
Status Pending
Filing Date 2025-06-27
First Publication Date 2026-01-01
Owner FORM ENERGY, INC. (USA)
Inventor
  • Perkins, Nicholas Reed
  • Manser, Joseph Stephen
  • Morgan, Robert
  • Newhouse, Jocelyn
  • Norman, Zachariah
  • Blummer, Laine
  • Nation, Leah
  • Reynolds, Christopher
  • Thompson, Annelise

Abstract

Methods and systems of the present disclosure are generally directed to purification of metal-containing material. For example, soft oxidation may be used to generate an oxygen-free product from a low-quality alloy of a base metal. The oxygen-free product may be electrolyzed directly to generate a higher-quality alloy of the base metal—namely, an alloy with higher weight percentage of the base metal and, thus, lower weight percentage of tramp elements. As compared to recycling the base metal with a metal-air electrochemical cell, the methods and systems of the present disclosure may facilitate forming high-quality recycled metal (e.g., aluminum) using significantly less energy.

IPC Classes  ?

  • C25C 3/24 - Refining
  • C25C 3/04 - Electrolytic production, recovery or refining of metals by electrolysis of melts of magnesium
  • C25C 3/18 - Electrolytes
  • C25C 3/28 - Electrolytic production, recovery or refining of metals by electrolysis of melts of titanium, zirconium, hafnium, tantalum or vanadium of titanium
  • C25C 7/06 - Operating or servicing

5.

System and method for large volume design, build, and test

      
Application Number 18360440
Grant Number 12450151
Status In Force
Filing Date 2023-07-27
First Publication Date 2025-10-21
Grant Date 2025-10-21
Owner Form Energy, Inc. (USA)
Inventor
  • Wong, Frank
  • Schneider, Anna
  • Mackenzie, Scott
  • Makhija, Anushka
  • Vliet, Peter
  • Capili, Jason
  • Tareque, Henry
  • Chakraborty, Rupak
  • Wehner, Florian
  • Mako, Natalie
  • Giusti, Adam
  • Feder, Seth
  • Carlisle, Kristen
  • Challis, John
  • Solnushkin, Konstantin S.

Abstract

Detailed herein are systems and methods for large volume design, building, and testing, particularly suited for rechargeable batteries intended for long duration energy storage. A specific item, such as a battery cell, may be designed through input and selection of various components and configurations, along with desired test protocols and configurations. A build team is notified of the new item, and confirms material and resources are ready to build the item. A specific channel is reserved or committed for the test. Test data, along with specifics and any errors or conditions encountered from specification through teardown, is tracked.

IPC Classes  ?

  • G06F 11/3668 - Testing of software
  • G06F 8/71 - Version control Configuration management
  • G06F 11/34 - Recording or statistical evaluation of computer activity, e.g. of down time, of input/output operation

6.

METAL-OXYGEN BATTERY AND METHOD OF USE THEREOF

      
Application Number 19175169
Status Pending
Filing Date 2025-04-10
First Publication Date 2025-10-16
Owner Form Energy, Inc. (USA)
Inventor
  • Manser, Joseph S.
  • Reynolds, Christopher Thomas
  • Su, Liang
  • Perkins, Nicholas

Abstract

A metal-oxygen battery system, including: an electrochemical cell including a positive electrode, a negative electrode, and an electrolyte between the positive electrode and the negative electrode; and an energy storage reactor in fluid communication with the negative electrode; a gas store in fluid communication with the positive electrode, the gas store configured to store oxygen; and a fuel gauge configured to determine a state of charge, wherein the gas store and the positive electrode form a closed system.

IPC Classes  ?

  • H01M 8/04089 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
  • H01M 8/0438 - PressureAmbient pressureFlow
  • H01M 8/04537 - Electric variables
  • H01M 8/04746 - PressureFlow
  • H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

7.

METHANE-OXYGEN BATTERY SYSTEM AND METHOD OF USE THEREOF

      
Application Number 19175341
Status Pending
Filing Date 2025-04-10
First Publication Date 2025-10-16
Owner Form Energy, Inc. (USA)
Inventor
  • Manser, Joseph S.
  • Reynolds, Christopher Thomas
  • Su, Liang
  • Perkins, Nicholas

Abstract

A methane-oxygen battery system including an electrochemical cell including a positive electrode, a negative electrode, and an electrolyte; a reactor in fluid communication with the negative electrode; a fuel gauge; and a gas store including a first compartment in fluid communication with the positive electrode and configured to store oxygen, a second compartment in fluid communication with the negative electrode and configured to store carbon dioxide and water, a third compartment in fluid communication with the negative electrode or the reactor and configured to store methane, a first barrier between the first compartment and the second compartment, and a second barrier between the second compartment and the third compartment. The gas store and the electrochemical cell form a closed system. The fuel gauge is configured to determine a state of charge based on a position of at least one of the first barrier or the second barrier.

IPC Classes  ?

  • H01M 8/0612 - Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants from carbon-containing material
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/04089 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
  • H01M 8/0444 - ConcentrationDensity
  • H01M 8/2457 - Grouping of fuel cells, e.g. stacking of fuel cells with both reactants being gaseous or vaporised

8.

HIGH SURFACE AREA PLATING FOR OXYGEN EVOLUTION ELECTRODES

      
Application Number 19177086
Status Pending
Filing Date 2025-04-11
First Publication Date 2025-10-16
Owner FORM ENERGY, INC. (USA)
Inventor
  • Sullivan, Anthony Edwards
  • Hitt, Jeremy
  • Nasir, Muhammad
  • Hickey, Anne Katherine
  • Becerra, Daniel Louis
  • Kaufman, Zachary Dean

Abstract

Oxygen evolution electrodes having high surface area plating and methods of forming such oxygen evolution electrodes are described. According to one aspect, an electrode for an oxygen evolution reaction (OER) may include a substrate including at least one surface and a layer of nickel coated on the at least one surface of the substrate. The at least one surface of the substrate has a first surface area, the layer of nickel has a second surface area, and a ratio of the second surface area to the first surface area is greater than about 10:1 and less than about 50:1.

IPC Classes  ?

  • H01M 4/88 - Processes of manufacture
  • H01M 4/90 - Selection of catalytic material
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode

9.

METAL-OXYGEN BATTERY AND METHOD OF USE THEREOF

      
Application Number US2025024119
Publication Number 2025/217431
Status In Force
Filing Date 2025-04-10
Publication Date 2025-10-16
Owner FORM ENERGY, INC. (USA)
Inventor
  • Manser, Joseph S.
  • Reynolds, Christopher Thomas
  • Su, Liang
  • Perkins, Nicholas

Abstract

A metal-oxygen battery system, including: an electrochemical cell including a positive electrode, a negative electrode, and an electrolyte between the positive electrode and the negative electrode; and an energy storage reactor in fluid communication with the negative electrode; a gas store in fluid communication with the positive electrode, the gas store configured to store oxygen; and a fuel gauge configured to determine a state of charge, wherein the gas store and the positive electrode form a closed system.

IPC Classes  ?

  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/02 - Details
  • H01M 4/52 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
  • H01M 10/0561 - Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of inorganic materials only
  • H01M 10/0562 - Solid materials
  • H01M 4/90 - Selection of catalytic material
  • H01M 4/92 - Metals of platinum group

10.

PASSIVE CARBON-OXYGEN BATTERY SYSTEM AND METHOD OF USE THEREOF

      
Application Number 19175148
Status Pending
Filing Date 2025-04-10
First Publication Date 2025-10-16
Owner Form Energy, Inc. (USA)
Inventor
  • Manser, Joseph S.
  • Reynolds, Christopher Thomas
  • Su, Liang
  • Perkins, Nicholas

Abstract

A carbon-oxygen battery system, including a Boudouard reactor in fluid communication with an electrochemical cell; a carbon store configured to store carbon; a gas store in fluid communication with the electrochemical cell, and a fuel gauge. The gas store is configured to separately store oxygen and a carbon-containing gas, wherein the gas store comprises a movable barrier separating the oxygen from the carbon-containing gas. The fuel gauge configured to determine a state of charge based on a position of the movable barrier, a mass of the oxygen in the gas store, a mass of the carbon-containing gas in the gas store, a mass of carbon in the carbon store, a volume of carbon in the carbon store, or a combination thereof. The gas store and the electrochemical cell form a closed system.

IPC Classes  ?

  • H01M 8/04082 - Arrangements for control of reactant parameters, e.g. pressure or concentration
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/0668 - Removal of carbon monoxide or carbon dioxide
  • H01M 8/1246 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides
  • H01M 8/14 - Fuel cells with fused electrolytes
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

11.

PASSIVE CARBON-OXYGEN BATTERY SYSTEM AND METHOD OF USE THEREOF

      
Application Number US2025024088
Publication Number 2025/217410
Status In Force
Filing Date 2025-04-10
Publication Date 2025-10-16
Owner FORM ENERGY, INC. (USA)
Inventor
  • Manser, Joseph S.
  • Reynolds, Christopher Thomas
  • Su, Liang
  • Perkins, Nicholas

Abstract

A carbon-oxygen battery system, including a Boudouard reactor in fluid communication with an electrochemical cell; a carbon store configured to store carbon; a gas store in fluid communication with the electrochemical cell, and a fuel gauge. The gas store is configured to separately store oxygen and a carbon-containing gas, wherein the gas store comprises a movable barrier separating the oxygen from the carbon-containing gas. The fuel gauge configured to determine a state of charge based on a position of the movable barrier, a mass of the oxygen in the gas store, a mass of the carbon-containing gas in the gas store, a mass of carbon in the carbon store, a volume of carbon in the carbon store, or a combination thereof. The gas store and the electrochemical cell form a closed system.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 8/04082 - Arrangements for control of reactant parameters, e.g. pressure or concentration
  • H01M 8/0444 - ConcentrationDensity
  • H01M 8/04089 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/1233 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte with one of the reactants being liquid, solid or liquid-charged
  • H01M 8/04746 - PressureFlow

12.

METHANE-OXYGEN BATTERY SYSTEM AND METHOD OF USE THEREOF

      
Application Number US2025024123
Publication Number 2025/217434
Status In Force
Filing Date 2025-04-10
Publication Date 2025-10-16
Owner FORM ENERGY, INC. (USA)
Inventor
  • Manser, Joseph S.
  • Reynolds, Christopher Thomas
  • Su, Liang
  • Perkins, Nicholas

Abstract

A methane-oxygen battery system including an electrochemical cell including a positive electrode, a negative electrode, and an electrolyte; a reactor in fluid communication with the negative electrode; a fuel gauge; and a gas store including a first compartment in fluid communication with the positive electrode and configured to store oxygen, a second compartment in fluid communication with the negative electrode and configured to store carbon dioxide and water, a third compartment in fluid communication with the negative electrode or the reactor and configured to store methane, a first barrier between the first compartment and the second compartment, and a second barrier between the second compartment and the third compartment. The gas store and the electrochemical cell form a closed system. The fuel gauge is configured to determine a state of charge based on a position of at least one of the first barrier or the second barrier.

IPC Classes  ?

  • H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
  • H01M 8/1213 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the electrode/electrolyte combination or the supporting material
  • H01M 8/04082 - Arrangements for control of reactant parameters, e.g. pressure or concentration
  • H01M 8/04111 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants using a compressor turbine assembly
  • H01M 8/04119 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants with simultaneous supply or evacuation of electrolyteHumidifying or dehumidifying
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/04791 - ConcentrationDensity

13.

HIGH SURFACE AREA PLATING FOR OXYGEN EVOLUTION ELECTRODES

      
Application Number US2025024318
Publication Number 2025/217546
Status In Force
Filing Date 2025-04-11
Publication Date 2025-10-16
Owner FORM ENERGY, INC. (USA)
Inventor
  • Sullivan, Anthony Edwards
  • Hitt, Jeremy
  • Nasir, Muhammad
  • Hickey, Anne Katherine
  • Becerra, Daniel Louis
  • Kaufman, Zachary Dean

Abstract

Oxygen evolution electrodes having high surface area plating and methods of forming such oxygen evolution electrodes are described. According to one aspect, an electrode for an oxygen evolution reaction (OER) may include a substrate including at least one surface and a layer of nickel coated on the at least one surface of the substrate. The at least one surface of the substrate has a first surface area, the layer of nickel has a second surface area, and a ratio of the second surface area to the first surface area is greater than about 10:1 and less than about 50:1.

IPC Classes  ?

  • C25D 3/12 - ElectroplatingBaths therefor from solutions of nickel or cobalt
  • C25D 5/00 - Electroplating characterised by the processPretreatment or after-treatment of workpieces
  • C25D 7/06 - WiresStripsFoils
  • H01M 4/04 - Processes of manufacture in general
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 4/02 - Electrodes composed of, or comprising, active material

14.

SEPARATOR ATTACHMENT IN METAL-AIR BATTERIES

      
Application Number 19061774
Status Pending
Filing Date 2025-02-24
First Publication Date 2025-08-28
Owner Form Energy, Inc. (USA)
Inventor
  • Pitt, Emily C.
  • Paxson, Derek

Abstract

An electrochemical cell may include an anode, a gas diffusion electrode (GDE), an oxygen evolution electrode (OEE); a vessel, a separator, and at least one standoff. The vessel may define a volume in which the OEE, the GDE, and the anode are each at least partially disposed with the OEE between the anode and the GDE. The separator may be ionically conductive and electrically insulative and disposed between the anode and the OEE. The at least one standoff may space the OEE from the anode, the at least one standoff penetrating the separator at discontinuities and forming at least a portion of respective liquid tight seals with the separator at the discontinuities.

IPC Classes  ?

  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells
  • H01M 12/02 - Details
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

15.

GAS DIFFUSION ELECTRODES FOR METAL-AIR BATTERIES

      
Application Number US2025016975
Publication Number 2025/179252
Status In Force
Filing Date 2025-02-24
Publication Date 2025-08-28
Owner FORM ENERGY, INC. (USA)
Inventor
  • Brandt, Riley
  • Cummings, Malcolm
  • Wood, Christopher Evan

Abstract

The present disclosure is generally directed to a discharge cathode of a metal-air battery. A method of fabricating the discharge cathode includes forming a frame of electrically insulating material onto a terminal with a first end portion of the terminal exposed in a window defined by the frame and a second end portion of the terminal outside of the frame. The method includes positioning a gas diffusion electrode (GDE) on the frame with a busbar supported on the GDE and a bus tab extending from the busbar to the window. The method includes connecting the bus tab and the first end portion of the terminal to one another through the window. The method includes, with the bus tab and the terminal connected to one another, hermetically sealing the window.

IPC Classes  ?

  • H01M 8/0273 - Sealing or supporting means around electrodes, matrices or membranes with sealing or supporting means in the form of a frame
  • H01M 10/38 - Construction or manufacture
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/138 - Primary casingsJackets or wrappings adapted for specific cells, e.g. electrochemical cells operating at high temperature
  • H01M 50/545 - Terminals formed by the casing of the cells

16.

CURRENT COLLECTING IN METAL-AIR BATTERIES

      
Application Number US2025016979
Publication Number 2025/179256
Status In Force
Filing Date 2025-02-24
Publication Date 2025-08-28
Owner FORM ENERGY, INC. (USA)
Inventor Paxson, Derek

Abstract

The present disclosure is generally directed to current collectors for electrochemical cells and methods of fabricating current collectors. In some implementations, a current collector includes a terminal electrically connectable to an external electric circuit. The current collector includes a substrate including an electrically conductive material and having a first end portion and a second end portion. The terminal is disposed on the first end portion. The substrate has a length from the first end portion to the second end portion. The electrically conductive material has a cross-sectional area decreasing along at least a portion of the length in a longitudinal direction from the terminal to the second end portion of the substrate.

IPC Classes  ?

  • H01M 4/70 - Carriers or collectors characterised by shape or form
  • H01M 4/66 - Selection of materials
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

17.

GAS SENSOR ADAPTER FOR A HIGH FLOW VENTILATION SYSTEM

      
Application Number 19060103
Status Pending
Filing Date 2025-02-21
First Publication Date 2025-08-28
Owner FORM ENERGY, INC. (USA)
Inventor Rodriguez, David

Abstract

The present disclosure is generally directed to ventilation systems and an assembly for sensing gas concentration in a ventilation system. The assembly includes a body defining an opening and a passage. The assembly includes a first tube supported on the body, the first tube defining a first channel and one or more first apertures, the one or more first apertures in fluid communication with the passage via the first channel. The assembly includes a second tube supported on the body, the second tube defining a second channel and one or more second apertures, the one or more second apertures in fluid communication with the passage via the second channel and, collectively, the one or more first apertures, the first channel, the passage, the second channel, and the one or more second apertures defining at least a portion of a flow path.

IPC Classes  ?

  • G01N 33/00 - Investigating or analysing materials by specific methods not covered by groups
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 50/358 - External gas exhaust passages located on the battery cover or case

18.

GAS DIFFUSION ELECTRODES FOR METAL-AIR BATTERIES

      
Application Number 19060909
Status Pending
Filing Date 2025-02-24
First Publication Date 2025-08-28
Owner Form Energy, Inc. (USA)
Inventor
  • Brandt, Riley
  • Cummings, Malcolm
  • Wood, Christopher Evan

Abstract

The present disclosure is generally directed to a discharge cathode of a metal-air battery. A method of fabricating the discharge cathode includes forming a frame of electrically insulating material onto a terminal with a first end portion of the terminal exposed in a window defined by the frame and a second end portion of the terminal outside of the frame. The method includes positioning a gas diffusion electrode (GDE) on the frame with a busbar supported on the GDE and a bus tab extending from the busbar to the window. The method includes connecting the bus tab and the first end portion of the terminal to one another through the window. The method includes, with the bus tab and the terminal connected to one another, hermetically sealing the window.

IPC Classes  ?

  • H01M 4/88 - Processes of manufacture
  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells
  • H01M 12/02 - Details
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

19.

CURRENT COLLECTING IN METAL-AIR BATTERIES

      
Application Number 19060931
Status Pending
Filing Date 2025-02-24
First Publication Date 2025-08-28
Owner Form Energy, Inc. (USA)
Inventor Paxson, Derek

Abstract

The present disclosure is generally directed to current collectors for electrochemical cells and methods of fabricating current collectors. In some implementations, a current collector includes a terminal electrically connectable to an external electric circuit. The current collector includes a substrate including an electrically conductive material and having a first end portion and a second end portion. The terminal is disposed on the first end portion. The substrate has a length from the first end portion to the second end portion. The electrically conductive material has a cross-sectional area decreasing along at least a portion of the length in a longitudinal direction from the terminal to the second end portion of the substrate.

IPC Classes  ?

  • H01M 4/74 - Meshes or woven materialExpanded metal
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

20.

ELECTROCHEMICAL CELLS INCLUDING ELECTRODE STACKS FOR METAL-AIR BATTERIES

      
Application Number 19061979
Status Pending
Filing Date 2025-02-24
First Publication Date 2025-08-28
Owner Form Energy, Inc. (USA)
Inventor
  • Pitt, Emily C.
  • Brandt, Riley
  • Wynn, Nathaniel C.
  • Rivera, Angel Ruben
  • Paxson, Derek
  • Cummings, Malcolm
  • Sledd, Alan
  • Syvertsen, Marc Louis
  • Zhang, Mei

Abstract

An electrochemical cell may include a vessel, a first module, a second module, and a gas diffusion electrode (GDE). The vessel has a thickness dimension. The first module includes a first anode sandwiched between two first oxygen evolution electrodes along the thickness dimension of the vessel. The second module includes a second anode sandwiched between two second oxygen evolution electrodes along the thickness dimension of the vessel. A gas diffusion electrode (GDE) is disposed between the first module and the second module in the vessel along the thickness dimension of the vessel.

IPC Classes  ?

  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells
  • H01M 50/172 - Arrangements of electric connectors penetrating the casing
  • H01M 50/193 - Organic material
  • H01M 50/55 - Terminals characterised by the disposition of the terminals on the cells on the same side of the cell
  • H01M 50/562 - Terminals characterised by the material

21.

GAS SENSOR ADAPTER FOR A HIGH FLOW VENTILATION SYSTEM

      
Application Number US2025016882
Publication Number 2025/179201
Status In Force
Filing Date 2025-02-21
Publication Date 2025-08-28
Owner FORM ENERGY, INC. (USA)
Inventor Rodriguez, David

Abstract

The present disclosure is generally directed to ventilation systems and an assembly for sensing gas concentration in a ventilation system. The assembly includes a body defining an opening and a passage. The assembly includes a first tube supported on the body, the first tube defining a first channel and one or more first apertures, the one or more first apertures in fluid communication with the passage via the first channel. The assembly includes a second tube supported on the body, the second tube defining a second channel and one or more second apertures, the one or more second apertures in fluid communication with the passage via the second channel and, collectively, the one or more first apertures, the first channel, the passage, the second channel, and the one or more second apertures defining at least a portion of a flow path.

IPC Classes  ?

  • G01N 33/00 - Investigating or analysing materials by specific methods not covered by groups
  • G01N 1/22 - Devices for withdrawing samples in the gaseous state
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte

22.

SEPARATOR ATTACHMENT IN METAL-AIR BATTERIES

      
Application Number US2025017065
Publication Number 2025/179283
Status In Force
Filing Date 2025-02-24
Publication Date 2025-08-28
Owner FORM ENERGY, INC. (USA)
Inventor
  • Pitt, Emily C.
  • Paxson, Derek

Abstract

An electrochemical cell may include an anode, a gas diffusion electrode (GDE), an oxygen evolution electrode (OEE); a vessel, a separator, and at least one standoff. The vessel may define a volume in which the OEE, the GDE, and the anode are each at least partially disposed with the OEE between the anode and the GDE. The separator may be ionically conductive and electrically insulative and disposed between the anode and the OEE. The at least one standoff may space the OEE from the anode, the at least one standoff penetrating the separator at discontinuities and forming at least a portion of respective liquid tight seals with the separator at the discontinuities.

IPC Classes  ?

  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells
  • H01M 50/46 - Separators, membranes or diaphragms characterised by their combination with electrodes
  • H01M 50/463 - Separators, membranes or diaphragms characterised by their shape
  • H01M 50/497 - Ionic conductivity
  • H01M 50/411 - Organic material
  • H01M 50/417 - Polyolefins
  • H01M 4/52 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron

23.

ELECTROCHEMICAL CELLS INCLUDING ELECTRODE STACKS FOR METAL-AIR BATTERIES

      
Application Number US2025017098
Publication Number 2025/179298
Status In Force
Filing Date 2025-02-24
Publication Date 2025-08-28
Owner FORM ENERGY, INC. (USA)
Inventor
  • Pitt, Emily C.
  • Brandt, Riley
  • Wynn, Nathaniel C.
  • Rivera, Angel Ruben
  • Paxson, Derek
  • Cummings, Malcolm
  • Sledd, Alan

Abstract

An electrochemical cell may include a vessel, a first module, a second module, and a gas diffusion electrode (GDE). The vessel has a thickness dimension. The first module includes a first anode sandwiched between two first oxygen evolution electrodes along the thickness dimension of the vessel. The second module includes a second anode sandwiched between two second oxygen evolution electrodes along the thickness dimension of the vessel. A gas diffusion electrode (GDE) is disposed between the first module and the second module in the vessel along the thickness dimension of the vessel.

IPC Classes  ?

  • H01M 10/04 - Construction or manufacture in general
  • H01M 10/38 - Construction or manufacture
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/138 - Primary casingsJackets or wrappings adapted for specific cells, e.g. electrochemical cells operating at high temperature

24.

BATTERY RECYCLING

      
Application Number 18886523
Status Pending
Filing Date 2024-09-16
First Publication Date 2025-08-07
Owner FORM ENERGY, INC. (USA)
Inventor
  • Perkins, Nicholas Reed
  • Caruso, Isabella
  • Mumma, Rachel Elizabeth
  • Tran, Anthony
  • Chakraborty, Rupak
  • Via, Matthew Edward
  • Newhouse, Jocelyn Marie
  • Milshtein, Jarrod David
  • Su, Liang
  • Gibson, Michael Andrew
  • Smith, Danielle Cassidy
  • Woodford, William Henry
  • Kharey, Amelie Nina

Abstract

Various embodiments relate to several processes that may recover commodity chemicals from an alkaline metal-air battery. In various embodiments, while the cell is operating, various side products and waste streams may be collected and processed to regain use or additional value. Various embodiments also include processes to be performed after the cell has been disassembled, and each of its electrodes have been separated such as not to be an electrical hazard. The alkaline metal battery recycling processes described herein may provide multiple forms of commodity iron, high purity transition metal ores, fluoropolymer dispersions, various carbons, commodity chemicals, and catalyst dispersions.

IPC Classes  ?

  • H01M 10/54 - Reclaiming serviceable parts of waste accumulators
  • C21B 13/00 - Making spongy iron or liquid steel, by direct processes
  • C22B 1/02 - Roasting processes
  • C22B 3/04 - Extraction of metal compounds from ores or concentrates by wet processes by leaching
  • C22B 3/12 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic alkaline solutions
  • C22B 3/16 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in organic solutions
  • C22B 7/00 - Working-up raw materials other than ores, e.g. scrap, to produce non-ferrous metals or compounds thereof

25.

IRON POWDER, IRON ELECTRODE, IRON BATTERY, AND METHOD OF MANUFACTURE THEREOF

      
Application Number 19002307
Status Pending
Filing Date 2024-12-26
First Publication Date 2025-07-10
Owner Form Energy, Inc. (USA)
Inventor
  • Nation, Leah
  • Eisenach, Rebecca Marie
  • Conry, Thomas
  • Devlin, Kasey
  • Ickes, Michael
  • Sacha, Valerie Christine
  • Gibson, Michael
  • Perkins, Nicholas

Abstract

An electrode, including a first iron material and a second iron material. The first iron material is a first reduced iron and the second iron material is different from the first iron material. Also provided is an electrochemical cell comprising an electrode including a first iron material and a second iron material. Further provided is a method of making an electrode.

IPC Classes  ?

  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/48 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides

26.

IRON POWDER, IRON ELECTRODE, IRON BATTERY, AND METHOD OF MANUFACTURE THEREOF

      
Application Number US2024061957
Publication Number 2025/147423
Status In Force
Filing Date 2024-12-26
Publication Date 2025-07-10
Owner FORM ENERGY, INC. (USA)
Inventor
  • Nation, Leah
  • Eisenach, Rebecca Marie
  • Conry, Thomas
  • Devlin, Kasey
  • Ickes, Michael
  • Sacha, Valerie Christine
  • Gibson, Michael
  • Perkins, Nicholas

Abstract

An electrode, including a first iron material and a second iron material. The first iron material is a first reduced iron and the second iron material is different from the first iron material. Also provided is an electrochemical cell comprising an electrode including a first iron material and a second iron material. Further provided is a method of making an electrode.

IPC Classes  ?

  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/36 - Selection of substances as active materials, active masses, active liquids
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode

27.

ELECTROCHEMICAL CELL INCLUDING AN ADDITIVE AND METHOD OF OPERATING THE ELECTROCHEMICAL CELL

      
Application Number 19001934
Status Pending
Filing Date 2024-12-26
First Publication Date 2025-07-03
Owner Form Energy, Inc. (USA)
Inventor
  • Norman, Zachariah
  • Gibson, Michael
  • Thompson, Annelise
  • Nation, Leah
  • Eisenach, Rebecca
  • Douair, Iskander

Abstract

An electrochemical cell including: a first electrode including iron, wherein a density (D) of the iron in the first electrode is greater than 2.11 g/cm3 and less than 7.87 g/cm3, based on a total weight of the iron and a total volume of the first electrode; an alkaline electrolyte; a second electrode; and an additive comprising a metal M, wherein the additive is effective to facilitate oxidation of the iron to Fe3-xMxO4, wherein 0≤x<1, and wherein a specific discharge capacity (Q) of the first electrode in the first discharge plateau is represented by Formula 1: An electrochemical cell including: a first electrode including iron, wherein a density (D) of the iron in the first electrode is greater than 2.11 g/cm3 and less than 7.87 g/cm3, based on a total weight of the iron and a total volume of the first electrode; an alkaline electrolyte; a second electrode; and an additive comprising a metal M, wherein the additive is effective to facilitate oxidation of the iron to Fe3-xMxO4, wherein 0≤x<1, and wherein a specific discharge capacity (Q) of the first electrode in the first discharge plateau is represented by Formula 1: Q>((7.87/D)−1)*352 mAh/gram of iron, based on a total weight of iron in the first electrode  (1).

IPC Classes  ?

  • H01M 10/26 - Selection of materials as electrolytes
  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/52 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
  • H01M 10/44 - Methods for charging or discharging

28.

ELECTROCHEMICAL CELL INCLUDING AN ADDITIVE AND METHOD OF OPERATING THE ELECTROCHEMICAL CELL

      
Application Number US2024061895
Publication Number 2025/144881
Status In Force
Filing Date 2024-12-26
Publication Date 2025-07-03
Owner FORM ENERGY, INC. (USA)
Inventor
  • Norman, Zachariah
  • Gibson, Michael
  • Thompson, Annelise
  • Nation, Leah
  • Eisenach, Rebecca
  • Douair, Iskander

Abstract

An electrochemical cell including: a first electrode including iron, wherein a density (D) of the iron in the first electrode is greater than 2.11 g/cm3and less than 7.87 g/cm33-xx44, wherein 0≤x<1, and wherein a specific discharge capacity (Q) of the first electrode in the first discharge plateau is represented by Formula 1: Q > ((7.87/D)-1)∗352 mAh/gram of iron, based on a total weight of iron in the first electrode (1).

IPC Classes  ?

  • H01M 10/24 - Alkaline accumulators
  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers

29.

MIST ELIMINATION SYSTEM FOR ELECTROCHEMICAL CELLS

      
Application Number 18826974
Status Pending
Filing Date 2024-09-06
First Publication Date 2025-06-26
Owner FORM ENERGY, INC. (USA)
Inventor
  • Krishnan, Ramkumar
  • Hayes, Joel
  • Klug, Scott
  • Samuleson, Patrick
  • Trzebny, Craig

Abstract

An electrochemical cell includes a mist elimination system that prevents mist from escaping from the cell chamber and conserves moisture within the cell. An exemplary mist elimination system includes a spill prevention device that reduces or prevents an electrolyte from escaping from the cell chamber in the event of an upset, wherein the electrochemical cell is tipped over. A mist elimination system includes a recombination portion that reacts with hydrogen to produce water, that may be reintroduced into the cell chamber. A mist elimination system includes a neutralizer portion that reacts with an electrolyte to bring the pH closer to neutral, as acid/base reaction. A mist elimination system includes a filter that captures mist that may be reintroduced into the cell chamber. A mist elimination system includes a hydrophobic filter on the outer surface to prevent water and other liquids from entering into the mist elimination system.

IPC Classes  ?

  • H01M 12/02 - Details
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/30 - Arrangements for facilitating escape of gases
  • H01M 50/35 - Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages
  • H01M 50/367 - Internal gas exhaust passages forming part of the battery cover or caseDouble cover vent systems
  • H01M 50/392 - Arrangements for facilitating escape of gases with means for neutralising or absorbing electrolyteArrangements for facilitating escape of gases with means for preventing leakage of electrolyte through vent holes

30.

DECOUPLED ELECTRODE ELECTROCHEMICAL ENERGY STORAGE SYSTEM

      
Application Number 18971608
Status Pending
Filing Date 2024-12-06
First Publication Date 2025-06-05
Owner FORM ENERGY, INC. (USA)
Inventor
  • Smith, Danielle Cassidy
  • Woodford, William Henry
  • Milshtein, Jarrod David
  • Thompson, Annelise Christine
  • Rousseau, Alexandra
  • Silver, Jessa

Abstract

Systems and methods of the various embodiments may provide decoupled electrode electrochemical energy storage systems.

IPC Classes  ?

  • H01M 8/1027 - Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having carbon, oxygen and other atoms, e.g. sulfonated polyethersulfones [S-PES]
  • H01M 4/52 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
  • H01M 8/14 - Fuel cells with fused electrolytes

31.

DEVICE ARCHITECTURES FOR METAL-AIR BATTERIES

      
Application Number 18966998
Status Pending
Filing Date 2024-12-03
First Publication Date 2025-05-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Weber, Eric
  • Westwood, Mitchell Terrance
  • Mumma, Rachel Elizabeth
  • Slocum, Alexander H.
  • Su, Liang
  • Milshtein, Jarrod David
  • Woodford, William Henry
  • Chiang, Yet-Ming
  • Jaramillo, Mateo Cristian
  • Mckay, Ian Salmon
  • Brushett, Fikile
  • Van Benchoten, Helen
  • Gilbert, Tristan
  • Perkins, Nicholas Reed
  • Pantano, Joseph Anthony
  • Smith, Weston
  • Carlisle, Kristen
  • Caruso, Isabella
  • Hultman, Benjamin Thomas
  • Thompson, Annelise Christine
  • Smith, Danielle
  • Tarasov, Vladimir
  • Hartman, Katherine
  • Liotta, Andrew Haynes
  • Talu, Onur
  • Goulet, Marc-Antoni
  • Chakraborty, Rupak
  • Wehner, Florian
  • Mileson, Bradley
  • Rousseau, Alexandra

Abstract

Systems and methods of the various embodiments may provide device architectures for batteries. In various embodiments, these may be primary or secondary batteries. In various embodiments these devices may be useful for energy storage. Various embodiments may provide a battery including an Oxygen Reduction Reaction (ORR) electrode, an Oxygen Evolution Reaction (OER) electrode, a metal electrode; and an electrolyte separating the ORR electrode and the OER electrode from the metal electrode.

IPC Classes  ?

  • H01M 12/02 - Details
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

32.

PURIFICATION OF ALKALINE ELECTROLYTES

      
Application Number 18793146
Status Pending
Filing Date 2024-08-02
First Publication Date 2025-05-22
Owner Form Energy, Inc. (USA)
Inventor
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

A method of purifying an alkaline electrolyte includes contacting the alkaline electrolyte with an aluminum compound to provide a purified alkaline electrolyte. The alkaline electrolyte includes a metal hydroxide, a compound comprising aluminum, silicon, or a combination thereof, and a solvent. The method can be particularly advantageous when used with a method of processing an iron-containing feedstock.

IPC Classes  ?

  • B01D 15/36 - Selective adsorption, e.g. chromatography characterised by the separation mechanism involving ionic interaction, e.g. ion-exchange, ion-pair, ion-suppression or ion-exclusion
  • B01D 21/01 - Separation of suspended solid particles from liquids by sedimentation using flocculating agents
  • C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
  • C25C 7/06 - Operating or servicing

33.

GENERATING AND CONTROLLING MAGNETIC FIELDS FOR ELECTROLYZER STACKS

      
Application Number US2024055036
Publication Number 2025/101833
Status In Force
Filing Date 2024-11-08
Publication Date 2025-05-15
Owner FORM ENERGY, INC. (USA)
Inventor
  • Agarwal, Kostubh
  • Rathert, Janna
  • Manser, Joseph Stephen
  • Sokol, Julia

Abstract

An electrochemical reactor, including: a first magnetic field source; a second magnetic field source; and an electrochemical cell between the first magnetic field source and the second magnetic field source, the electrochemical cell comprising an anode and a cathode, wherein the anode and the cathode are in a channel configured to contain an electrolyte stream comprising an iron-containing feedstock, and wherein the anode and the cathode are configured to contact the electrolyte stream, and wherein the electrochemical reactor is configured to electrochemically reduce at least a portion of the iron-containing feedstock to iron metal at the cathode and in a magnetic field provided by the first magnetic field source, the second magnetic field source, or a combination thereof.

IPC Classes  ?

  • C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells
  • C25C 1/24 - Alloys obtained by cathodic reduction of all their ions

34.

REMOVAL OF IMPURITIES CONTAINED IN IRON ORES

      
Application Number US2024055042
Publication Number 2025/101838
Status In Force
Filing Date 2024-11-08
Publication Date 2025-05-15
Owner FORM ENERGY, INC. (USA)
Inventor
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

A method of removing one or more impurities from an iron-containing feedstock includes grinding the iron-containing feedstock in the presence of a grinding aid to form a pretreated iron-containing feedstock, the grinding aid including an alkali metal chloride, a fluoride salt, or a combination thereof; contacting the pretreated iron-containing feedstock with a flux comprising a metal borate; fusing the pretreated iron-containing feedstock and the flux to form a fused mixture; treating the fused mixture with a leaching solution to form a purified iron-containing feedstock and a used leaching solution; and solid-liquid separating the purified iron-containing feedstock from the used leaching solution, wherein an amount of aluminum, silicon, or a combination thereof is less in the purified iron-containing feedstock than in the iron-containing feedstock. Methods of removing one or more impurities from an iron-containing feedstock also include leaching the pretreated iron-containing feedstock with acid or base without fusion.

IPC Classes  ?

  • C21C 1/04 - Removing impurities other than carbon, phosphorus, or sulfur
  • C21C 7/00 - Treating molten ferrous alloys, e.g. steel, not covered by groups
  • C21C 7/04 - Removing impurities by adding a treating agent

35.

SYSTEM AND METHODS FOR SEPARATION OF ELECTROLYTIC IRON FROM IRON-CONTAINING FEEDSTOCK

      
Application Number US2024055076
Publication Number 2025/101866
Status In Force
Filing Date 2024-11-08
Publication Date 2025-05-15
Owner FORM ENERGY, INC. (USA)
Inventor
  • Rathert, Janna
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

An electrochemical reactor system includes: an electrochemical cell, having: an anode; a cathode; an electrolyte stream including an electrolyte and an iron-containing feedstock containing feedstock particles; and a channel that contains the electrolyte stream; and a magnetic field source positioned to provide a magnetic field at the surface of the cathode. The electrochemical cell electrochemically reduces the iron-containing feedstock to form iron particles at a surface of the cathode and in the magnetic field. The feedstock particles have an average particle size in at least one dimension of 10 micrometers or less, and the iron particles have an average particle size in at least one dimension of 50 to 1,000 micrometers, or the feedstock particles have an average particle size in at least one dimension of 25 micrometers or greater, and the iron particles have an average particle size in at least one dimension of 0.1 to 20 micrometers.

IPC Classes  ?

  • C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells
  • C25C 7/02 - ElectrodesConnections thereof
  • C25C 5/04 - Electrolytic production, recovery or refining of metal powders or porous metal masses from melts
  • C25C 3/36 - Alloys obtained by cathodic reduction of all their ions

36.

GENERATING AND CONTROLLING MAGNETIC FIELDS FOR ELECTROLYZER STACKS

      
Application Number 18941919
Status Pending
Filing Date 2024-11-08
First Publication Date 2025-05-08
Owner Form Energy, Inc. (USA)
Inventor
  • Agarwal, Kostubh
  • Rathert, Janna
  • Manser, Joseph Stephen
  • Sokol, Julia

Abstract

An electrochemical reactor, including: a first magnetic field source; a second magnetic field source; and an electrochemical cell between the first magnetic field source and the second magnetic field source, the electrochemical cell comprising an anode and a cathode, wherein the anode and the cathode are in a channel configured to contain an electrolyte stream comprising an iron-containing feedstock, and wherein the anode and the cathode are configured to contact the electrolyte stream, and wherein the electrochemical reactor is configured to electrochemically reduce at least a portion of the iron-containing feedstock to iron metal at the cathode and in a magnetic field provided by the first magnetic field source, the second magnetic field source, or a combination thereof.

IPC Classes  ?

  • C25C 7/06 - Operating or servicing
  • C25C 5/02 - Electrolytic production, recovery or refining of metal powders or porous metal masses from solutions
  • C25C 7/04 - DiaphragmsSpacing elements

37.

REMOVAL OF IMPURITIES CONTAINED IN IRON ORES

      
Application Number 18941806
Status Pending
Filing Date 2024-11-08
First Publication Date 2025-05-08
Owner Form Energy, Inc. (USA)
Inventor
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

A method of removing one or more impurities from an iron-containing feedstock includes grinding the iron-containing feedstock in the presence of a grinding aid to form a pretreated iron-containing feedstock, the grinding aid including an alkali metal chloride, a fluoride salt, or a combination thereof; contacting the pretreated iron-containing feedstock with a flux comprising a metal borate; fusing the pretreated iron-containing feedstock and the flux to form a fused mixture; treating the fused mixture with a leaching solution to form a purified iron-containing feedstock and a used leaching solution; and solid-liquid separating the purified iron-containing feedstock from the used leaching solution, wherein an amount of aluminum, silicon, or a combination thereof is less in the purified iron-containing feedstock than in the iron-containing feedstock. Methods of removing one or more impurities from an iron-containing feedstock also include leaching the pretreated iron-containing feedstock with acid or base without fusion.

IPC Classes  ?

  • C22B 1/24 - BindingBriquetting
  • C21B 15/00 - Other processes for the manufacture of iron from iron compounds
  • C22B 3/10 - Hydrochloric acid
  • C22B 3/12 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic alkaline solutions
  • C22B 3/22 - Treatment or purification of solutions, e.g. obtained by leaching by physical processes, e.g. by filtration, by magnetic means
  • C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese

38.

SYSTEM AND METHODS FOR SEPARATION OF ELECTROLYTIC IRON FROM IRON-CONTAINING FEEDSTOCK

      
Application Number 18942097
Status Pending
Filing Date 2024-11-08
First Publication Date 2025-05-08
Owner Form Energy, Inc. (USA)
Inventor
  • Rathert, Janna
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

An electrochemical reactor system includes: an electrochemical cell, having: an anode; a cathode; an electrolyte stream including an electrolyte and an iron-containing feedstock containing feedstock particles; and a channel that contains the electrolyte stream; and a magnetic field source positioned to provide a magnetic field at the surface of the cathode. The electrochemical cell electrochemically reduces the iron-containing feedstock to form iron particles at a surface of the cathode and in the magnetic field. The feedstock particles have an average particle size in at least one dimension of 10 micrometers or less, and the iron particles have an average particle size in at least one dimension of 50 to 1,000 micrometers, or the feedstock particles have an average particle size in at least one dimension of 25 micrometers or greater, and the iron particles have an average particle size in at least one dimension of 0.1 to 20 micrometers.

IPC Classes  ?

  • C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
  • B22F 9/24 - Making metallic powder or suspensions thereofApparatus or devices specially adapted therefor using chemical processes with reduction of metal compounds starting from liquid metal compounds, e.g. solutions
  • C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells

39.

PROCESSING IRON-CONTAINING FEEDSTOCKS USING OXALATE

      
Application Number 18906722
Status Pending
Filing Date 2024-10-04
First Publication Date 2025-05-01
Owner FORM ENERGY, INC. (USA)
Inventor
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

The present disclosure is directed to processing iron-containing feedstocks using oxalic acid to cost-effectively and cleanly transform low-cost iron feedstocks into iron-containing products (e.g., metallic iron and/or iron oxide) of high purity. In general, the methods of production using the systems described herein may include leaching low-purity iron feedstocks using a lixiviant including oxalic acid and an iron-complexing additive. The iron-complexing additive may suppress formation of iron (II) oxalate crystals and iron (III) oxalate crystals as leaching of a low-purity iron feedstock is carried out using oxalic acid, thus improving process kinetics and increasing the amount of iron that goes into solution during the leaching operation and ultimately recovered as a high-purity iron-containing product (e.g., metallic iron and/or iron oxide).

IPC Classes  ?

  • C21B 13/00 - Making spongy iron or liquid steel, by direct processes
  • C01G 49/02 - OxidesHydroxides

40.

ADDITIVE FOR IRON-AIR BATTERIES

      
Application Number 18926383
Status Pending
Filing Date 2024-10-25
First Publication Date 2025-05-01
Owner Form Energy, Inc. (USA)
Inventor
  • Bentley, Caitlin
  • Taylor, Olivia
  • Thompson, Annelise
  • Norman, Zachariah
  • Kyriakides, Cleo
  • Gray, Sydney
  • Schroder, Kjell William
  • Gibson, Michael
  • Taussig, Abigail

Abstract

An alkaline electrolyte including: an alkaline solution having a total hydroxide concentration of greater than 1 molar, based on a total volume of the alkaline electrolyte; and an additive including a trivalent element, wherein a concentration of the trivalent element is 1 millimolar to 5 molar, based on a total volume of the alkaline electrolyte, sulfur, and tin.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers

41.

ADDITIVE FOR IRON-AIR BATTERIES

      
Application Number US2024052897
Publication Number 2025/090823
Status In Force
Filing Date 2024-10-25
Publication Date 2025-05-01
Owner FORM ENERGY, INC. (USA)
Inventor
  • Bentley, Caitlin
  • Taylor, Olivia
  • Thompson, Annelise
  • Norman, Zachariah
  • Kyriakides, Cleo
  • Gray, Sydney
  • Schroder, Kjell William
  • Gibson, Michael
  • Taussig, Abigail

Abstract

An alkaline electrolyte including: an alkaline solution having a total hydroxide concentration of greater than 1 molar, based on a total volume of the alkaline electrolyte; and an additive including a trivalent element, wherein a concentration of the trivalent element is 1 millimolar to 5 molar, based on a total volume of the alkaline electrolyte, sulfur, and tin.

IPC Classes  ?

  • H01M 10/056 - Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 10/26 - Selection of materials as electrolytes

42.

PROCESSING IRON-CONTAINING FEEDSTOCKS USING OXALATE

      
Application Number US2024049883
Publication Number 2025/090274
Status In Force
Filing Date 2024-10-04
Publication Date 2025-05-01
Owner FORM ENERGY, INC. (USA)
Inventor
  • Luyima, Alex
  • Manser, Joseph Stephen

Abstract

The present disclosure is directed to processing iron-containing feedstocks using oxalic acid to cost-effectively and cleanly transform low-cost iron feedstocks into iron-containing products (e.g., metallic iron and/or iron oxide) of high purity. In general, the methods of production using the systems described herein may include leaching low-purity iron feedstocks using a lixiviant including oxalic acid and an iron-complexing additive. The iron-complexing additive may suppress formation of iron (II) oxalate crystals and iron (III) oxalate crystals as leaching of a low-purity iron feedstock is carried out using oxalic acid, thus improving process kinetics and increasing the amount of iron that goes into solution during the leaching operation and ultimately recovered as a high-purity iron-containing product (e.g., metallic iron and/or iron oxide).

IPC Classes  ?

  • C21B 15/00 - Other processes for the manufacture of iron from iron compounds
  • C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
  • C22B 3/08 - Sulfuric acid
  • C22B 3/10 - Hydrochloric acid
  • C22B 3/44 - Treatment or purification of solutions, e.g. obtained by leaching by chemical processes
  • C22B 7/00 - Working-up raw materials other than ores, e.g. scrap, to produce non-ferrous metals or compounds thereof

43.

LOW CONCENTRATION ADDITIVES FOR IRON NEGATIVE ELECTRODES

      
Application Number 18922247
Status Pending
Filing Date 2024-10-21
First Publication Date 2025-04-24
Owner FORM ENERGY, INC. (USA)
Inventor
  • Norman, Zachariah
  • Thompson, Annelise Christine
  • Kyriakides, Cleo
  • Gibson, Michael Andrew
  • Frisco, Sarah
  • Hooke, David
  • Choudhury, Rishav
  • Groschner, Catherine Kingston
  • Stringer, Craig

Abstract

According to an aspect, an electrochemical cell may include an electrolyte and an anode in the electrolyte, the anode including an iron-containing active material, at least one of the anode and the electrolyte including an additive reactive to inhibit hydrogen evolution in a charge state and in a resting state of the electrochemical cell, and the additive in a concentration greater than about 10 and less than about 10,000 atoms of additive per million atoms iron of the iron-containing active material.

IPC Classes  ?

  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/36 - Selection of substances as active materials, active masses, active liquids
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers

44.

LOW CONCENTRATION ADDITIVES FOR IRON NEGATIVE ELECTRODES

      
Application Number US2024052275
Publication Number 2025/085926
Status In Force
Filing Date 2024-10-21
Publication Date 2025-04-24
Owner FORM ENERGY, INC. (USA)
Inventor
  • Norman, Zachariah
  • Thompson, Annelise Christine
  • Kyriakides, Cleo
  • Gibson, Michael Andrew
  • Frisco, Sarah
  • Hooke, David
  • Choudhury, Rishav
  • Groschner, Catherine Kingston
  • Stringer, Craig

Abstract

According to an aspect, an electrochemical cell may include an electrolyte and an anode in the electrolyte, the anode including an iron-containing active material, at least one of the anode and the electrolyte including an additive reactive to inhibit hydrogen evolution in a charge state and in a resting state of the electrochemical cell, and the additive in a concentration greater than about 10 and less than about 10,000 atoms of additive per million atoms iron of the iron-containing active material.

IPC Classes  ?

  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 10/26 - Selection of materials as electrolytes
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 4/04 - Processes of manufacture in general

45.

MITIGATING PASSIVATION OF METAL ELECTRODES

      
Application Number 18922381
Status Pending
Filing Date 2024-10-21
First Publication Date 2025-04-24
Owner FORM ENERGY, INC. (USA)
Inventor
  • Bates, Hannah
  • Poirier, Jeffrey
  • Syvertsen, Marc
  • Thompson, Annelise Christine
  • Newhouse, Jocelyn Marie
  • Huang, Ke
  • Norman, Zachariah
  • Bentley, Caitlin
  • Barbour, Johanna

Abstract

According to one aspect, an electrochemical cell may include a first electrode including a metal-containing active material, a second electrode, and an electrolyte in ionic communication between the first electrode and the second electrode, the electrolyte including a gel and an additive, the gel including a polymer network and a liquid medium, the polymer network carried in the liquid medium, the additive suspended in the gel and accumulable at the metal-containing active material of the first electrode.

IPC Classes  ?

  • H01M 10/0565 - Polymeric materials, e.g. gel-type or solid-type

46.

MITIGATING PASSIVATION OF METAL ELECTRODES

      
Application Number US2024052295
Publication Number 2025/085934
Status In Force
Filing Date 2024-10-21
Publication Date 2025-04-24
Owner FORM ENERGY, INC. (USA)
Inventor
  • Bates, Hannah
  • Poirier, Jeffrey
  • Syvertsen, Marc
  • Thompson, Annelise Christine
  • Newhouse, Jocelyn Marie
  • Huang, Ke
  • Norman, Zachariah
  • Bentley, Caitlin
  • Barbour, Johanna

Abstract

According to one aspect, an electrochemical cell may include a first electrode including a metal-containing active material, a second electrode, and an electrolyte in ionic communication between the first electrode and the second electrode, the electrolyte including a gel and an additive, the gel including a polymer network and a liquid medium, the polymer network carried in the liquid medium, the additive suspended in the gel and accumulable at the metal-containing active material of the first electrode.

IPC Classes  ?

  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 10/26 - Selection of materials as electrolytes
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode

47.

METAL AIR ELECTROCHEMICAL CELL ARCHITECTURE

      
Application Number 18988337
Status Pending
Filing Date 2024-12-19
First Publication Date 2025-04-17
Owner FORM ENERGY, INC. (USA)
Inventor
  • Milshtein, Jarrod David
  • Westwood, Mitchell Terrance
  • Woodford, William Henry
  • Chiang, Yet-Ming
  • Jaramillo, Mateo Cristian
  • Mckay, Ian Salmon
  • Mumma, Rachel Elizabeth
  • Weber, Eric
  • Su, Liang
  • Kharey, Amelie Nina
  • Ferrara, Marco
  • Wiley, Theodore Alan

Abstract

Systems and methods of the various embodiments may provide metal air electrochemical cell architectures. Various embodiments may provide a battery, such as an unsealed battery or sealed battery, with an open cell arrangement configured such that a liquid electrolyte layer separates a metal electrode from an air electrode. In various embodiments, the electrolyte may be disposed within one or more vessel of the battery such that electrolyte serves as a barrier between a metal electrode and gaseous oxygen. Systems and methods of the various embodiments may provide for removing a metal electrode from electrolyte to prevent self-discharge of the metal electrode. Systems and methods of the various embodiments may provide a three electrode battery configured to operate each in a discharge mode, but with two distinct electrochemical reactions occurring at each electrode.

IPC Classes  ?

  • H01M 12/02 - Details
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/609 - Arrangements or processes for filling with liquid, e.g. electrolytes

48.

REFUELABLE BATTERY FOR THE ELECTRIC GRID AND METHOD OF USING THEREOF

      
Application Number 18658437
Status Pending
Filing Date 2024-05-08
First Publication Date 2025-04-10
Owner FORM ENERGY, INC. (USA)
Inventor
  • Jaramillo, Mateo Cristian
  • Mckay, Ian Salmon
  • Woodford, William Henry

Abstract

Systems and methods of the various embodiments may provide a refuelable battery for the power grid to provide a sustainable, cost-effective, and/or operationally efficient solution to energy source variability and/or energy demand variability. In particular, the systems and methods of the various embodiments may provide a refuelable primary battery solution that addresses bulk seasonal energy storage needs, variable demand needs, and other challenges.

IPC Classes  ?

  • H01M 6/50 - Methods or arrangements for servicing or maintenance, e.g. for maintaining operating temperature
  • H01M 6/52 - Reclaiming serviceable parts of waste cells or batteries
  • H01M 50/70 - Arrangements for stirring or circulating the electrolyte

49.

FLAME ARRESTING IN ELECTROCHEMICAL ENERGY STORAGE MODULES

      
Application Number US2024049641
Publication Number 2025/076121
Status In Force
Filing Date 2024-10-02
Publication Date 2025-04-10
Owner FORM ENERGY, INC. (USA)
Inventor
  • Ocampo, Jaime Andres
  • Milshtein, Jarrod David
  • Friesen, Grant Harrison
  • Nansel, Alli

Abstract

According to one aspect, a method of flame arresting in an electrochemical energy storage module may include receiving one or more signals indicative of operation of a plurality of electrochemical cells; based on the one or more signals, determining an operating state of the plurality of electrochemical cells; and, according to a predetermined relationship between the operating state of the plurality of electrochemical cells and a flame risk in a shared vent in fluid communication with the plurality of electrochemical cells, controlling power to at least one fan to control movement of gas along the shared vent and toward an outlet region in fluid communication with the shared vent.

IPC Classes  ?

  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 10/63 - Control systems
  • H01M 10/633 - Control systems characterised by algorithms, flow charts, software details or the like
  • H01M 50/383 - Flame arresting or ignition-preventing means

50.

FLAME ARRESTING IN ELECTROCHEMICAL ENERGY STORAGE MODULES

      
Application Number 18904966
Status Pending
Filing Date 2024-10-02
First Publication Date 2025-04-03
Owner FORM ENERGY, INC. (USA)
Inventor
  • Ocampo, Jaime Andres
  • Milshtein, Jarrod David
  • Friesen, Grant Harrison
  • Nansel, Alli

Abstract

According to one aspect, a method of flame arresting in an electrochemical energy storage module may include receiving one or more signals indicative of operation of a plurality of electrochemical cells; based on the one or more signals, determining an operating state of the plurality of electrochemical cells; and, according to a predetermined relationship between the operating state of the plurality of electrochemical cells and a flame risk in a shared vent in fluid communication with the plurality of electrochemical cells, controlling power to at least one fan to control movement of gas along the shared vent and toward an outlet region in fluid communication with the shared vent.

IPC Classes  ?

  • H01M 50/383 - Flame arresting or ignition-preventing means
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte

51.

LOW COST METAL ELECTRODES

      
Application Number 18968032
Status Pending
Filing Date 2024-12-04
First Publication Date 2025-03-20
Owner FORM ENERGY, INC. (USA)
Inventor
  • Newhouse, Jocelyn Marie
  • Milshtein, Jarrod David
  • Chakraborty, Rupak
  • Kharey, Amelie Nina
  • Woodford, William Henry
  • Chiang, Yet-Ming
  • Gibson, Michael
  • Thompson, Annelise Christine
  • Smith, Weston
  • Pantano, Joseph Anthony
  • Caruso, Isabella
  • Hultman, Benjamin Thomas
  • Chu, Max Rae
  • Su, Liang
  • Perkins, Nicholas Reed
  • Wehner, Florian
  • Eisenach, Rebecca
  • Westwood, Mitchell Terrance
  • Gilbert, Tristan
  • Liotta, Andrew Haynes
  • Conry, Thomas
  • Mumma, Rachel Elizabeth
  • Uber, Brandon
  • Weber, Eric
  • Smith, Danielle Cassidy
  • Wojeski, Brooke

Abstract

Systems and methods of the various embodiments may provide metal electrodes for electrochemical cells. In various embodiments, the electrodes may comprise iron. Various methods may enable achieving high surface area with low cost for production of metal electrodes, such as iron electrodes.

IPC Classes  ?

  • H01M 4/58 - Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFySelection of substances as active materials, active masses, active liquids of polyanionic structures, e.g. phosphates, silicates or borates
  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 4/66 - Selection of materials
  • H01M 10/26 - Selection of materials as electrolytes

52.

OXYGEN REDUCTION REACTION CATALYST AND METHODS OF SYNTHESIZING THE SAME

      
Application Number US2024044720
Publication Number 2025/054096
Status In Force
Filing Date 2024-08-30
Publication Date 2025-03-13
Owner FORM ENERGY, INC. (USA)
Inventor
  • Paz, Mauricio
  • Butts, Danielle Marie
  • Su, Liang
  • Tarasov, Vlad
  • Donahey, Glenn

Abstract

xyzz, wherein A is an A-site element and includes Ba, Ca, Cu, Dy, Er, Gd, La, Nd, Pr, Sm, Sr, Y, or Yb, or a combination thereof, M is an M-site element and includes Co, Cu, Fe, Mn, Ni, Ti, Sc, or P, or a combination thereof, and 0

IPC Classes  ?

  • B01J 23/889 - Manganese, technetium or rhenium
  • B01J 23/34 - Manganese
  • B01J 23/10 - Catalysts comprising metals or metal oxides or hydroxides, not provided for in group of rare earths
  • B01J 23/02 - Catalysts comprising metals or metal oxides or hydroxides, not provided for in group of the alkali- or alkaline earth metals or beryllium
  • B01J 35/61 - Surface area
  • B01J 37/08 - Heat treatment
  • B01J 35/70 - Catalysts, in general, characterised by their form or physical properties characterised by their crystalline properties, e.g. semi-crystalline
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 4/90 - Selection of catalytic material
  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells

53.

OXYGEN REDUCTION REACTION CATALYST AND METHODS OF SYNTHESIZING THE SAME

      
Application Number 18821451
Status Pending
Filing Date 2024-08-30
First Publication Date 2025-03-06
Owner Form Energy, Inc. (USA)
Inventor
  • Paz, Mauricio
  • Butts, Danielle Marie
  • Su, Liang
  • Tarasov, Vlad
  • Donahey, Glenn

Abstract

A composition includes a compound of the formula AxMyOz, wherein A is an A-site element and includes Ba, Ca, Cu, Dy, Er, Gd, La, Nd, Pr, Sm, Sr, Y, or Yb, or a combination thereof, M is an M-site element and includes Co, Cu, Fe, Mn, Ni, Ti, Sc, or P, or a combination thereof, and 0

IPC Classes  ?

54.

ELECTROLYTE MANAGEMENT FOR ELECTROCHEMICAL POWER STORAGE

      
Application Number 18815825
Status Pending
Filing Date 2024-08-26
First Publication Date 2025-02-27
Owner FORM ENERGY, INC. (USA)
Inventor
  • Smith, Danielle Cassidy
  • Friesen, Grant Harrison
  • Mckibben, Nicholas
  • Riveria, Angel Ruben
  • Vasavada, Jhalak Joshipura

Abstract

According to one aspect, a system for electrochemical power storage may include at least one instance of a battery module, each instance of the battery module including a battery enclosure and a metal-air battery, the metal-air battery disposed in the battery enclosure; a reservoir including a volume of a liquid electrolyte; a supply conduit in fluid communication between the reservoir and the battery enclosure; a pump actuatable to move the liquid electrolyte from the reservoir into the battery enclosure via the supply conduit; and a return conduit in fluid communication between the battery enclosure and the reservoir, the liquid electrolyte movable from the battery enclosure to the reservoir, via the return conduit, with the metal-air battery immersed in the liquid electrolyte in the battery enclosure.

IPC Classes  ?

  • H01M 50/609 - Arrangements or processes for filling with liquid, e.g. electrolytes
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/673 - Containers for storing liquidsDelivery conduits therefor
  • H01M 50/691 - Arrangements or processes for draining liquids from casingsCleaning battery or cell casings

55.

CARBON DIOXIDE REMOVAL FOR ELECTROCHEMICAL POWER STORAGE

      
Application Number US2024043920
Publication Number 2025/043256
Status In Force
Filing Date 2024-08-26
Publication Date 2025-02-27
Owner FORM ENERGY, INC. (USA)
Inventor
  • Bunten, Aurora Hope
  • Smith, Danielle Cassidy
  • Friesen, Grant Harrison
  • Vasavada, Jhalak Joshipura

Abstract

According to one aspect, a system for electrochemical power storage may include a plurality of instances of a metal-air battery, each instance of the metal-air battery including an air electrode, a metal electrode, and a liquid electrolyte separating the air electrode from the metal electrode with the air electrode and the metal electrode ionically coupled to one another via the liquid electrolyte; and a carbon dioxide removal system into which ambient air is directable, carbon dioxide from the ambient air removable in the carbon dioxide removal system to generate purified air, and the carbon dioxide removal system in fluid communication with the plurality of instances of the metal-air batteries such that the purified air is movable from the carbon dioxide removal system to the plurality of instances of the metal-air battery.

IPC Classes  ?

56.

ELECTROLYTE MANAGEMENT FOR ELECTROCHEMICAL POWER STORAGE

      
Application Number US2024043931
Publication Number 2025/043261
Status In Force
Filing Date 2024-08-26
Publication Date 2025-02-27
Owner FORM ENERGY, INC. (USA)
Inventor
  • Smith, Danielle Cassidy
  • Friesen, Grant Harrison
  • Mckibben, Nicholas
  • Rivera, Angel Ruben
  • Vasavada, Jhalak Joshipura

Abstract

According to one aspect, a system for electrochemical power storage may include at least one instance of a battery module, each instance of the battery module including a battery enclosure and a metal-air battery, the metal-air battery disposed in the battery enclosure; a reservoir including a volume of a liquid electrolyte; a supply conduit in fluid communication between the reservoir and the battery enclosure; a pump actuatable to move the liquid electrolyte from the reservoir into the battery enclosure via the supply conduit; and a return conduit in fluid communication between the battery enclosure and the reservoir, the liquid electrolyte movable from the battery enclosure to the reservoir, via the return conduit, with the metal-air battery immersed in the liquid electrolyte in the battery enclosure.

IPC Classes  ?

  • H01M 10/42 - Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 16/00 - Structural combinations of different types of electrochemical generators
  • H01M 50/609 - Arrangements or processes for filling with liquid, e.g. electrolytes
  • H01M 50/673 - Containers for storing liquidsDelivery conduits therefor
  • H01M 50/77 - Arrangements for stirring or circulating the electrolyte with external circulating path

57.

ELECTROCHEMICAL REACTOR AND METHOD FOR REDUCING IRON FROM AN IRON-CONTAINING FEEDSTOCK

      
Application Number 18795566
Status Pending
Filing Date 2024-08-06
First Publication Date 2025-02-13
Owner Form Energy, Inc. (USA)
Inventor
  • Rathert, Janna
  • Manser, Joseph S.
  • Sokol, Julia

Abstract

An electrochemical reactor, including a channel for containing and directing flow of an electrolyte stream, wherein the electrolyte stream includes an electrolyte and an iron-containing feedstock; an anode and a cathode positioned in contact with the channel; and a source of a magnetic field positioned in proximity to the cathode, wherein the electrochemical reactor is configured to electrochemically reduce at least a portion of the iron-containing feedstock to iron metal at a surface of the cathode and in a magnetic field of the source, and wherein the at least a portion of the iron-containing feedstock is electrochemically reduced to the iron metal at a current efficiency of at least 0.75, wherein the current efficiency is a ratio of charge used for the reduction of the iron-containing feedstock to a total charge provided to the cathode.

IPC Classes  ?

  • C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
  • C25C 7/04 - DiaphragmsSpacing elements
  • C25C 7/06 - Operating or servicing
  • C25D 3/20 - ElectroplatingBaths therefor from solutions of iron

58.

ELECTROCHEMICAL COGENERATION OF IRON AND COMMODITY CHEMICALS

      
Application Number US2024041108
Publication Number 2025/034747
Status In Force
Filing Date 2024-08-06
Publication Date 2025-02-13
Owner FORM ENERGY, INC. (USA)
Inventor
  • Manser, Joseph S.
  • Rathert, Janna
  • Luyima, Alex
  • Sokol, Julia

Abstract

An electrochemical reactor comprising a source of a magnetic field positioned in proximity to a cathode and configured to generate a magnetic field; and an electrochemical cell comprising an anode and the cathode, and further comprising a catholyte channel configured to direct a catholyte stream comprising an iron-containing feedstock to the cathode; an anolyte channel configured to direct an anolyte stream comprising a metal chloride to the anode, wherein the catholyte channel and the anolyte channel are disposed between the cathode and the anode; and a separator disposed between the catholyte channel and the anolyte channel, wherein the electrochemical reactor is configured to electrochemically oxidize chloride anions to chlorine gas at a surface of the anode, and wherein the electrochemical reactor is further configured to electrochemically reduce the iron-containing feedstock to an iron particle comprising iron metal at the surface of the cathode and in the magnetic field.

IPC Classes  ?

  • C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells
  • C25C 7/04 - DiaphragmsSpacing elements
  • C25C 3/36 - Alloys obtained by cathodic reduction of all their ions
  • C25C 7/06 - Operating or servicing

59.

AQUEOUS POLYSULFIDE-BASED ELECTROCHEMICAL CELL

      
Application Number 18621659
Status Pending
Filing Date 2024-03-29
First Publication Date 2025-02-13
Owner FORM ENERGY, INC. (USA)
Inventor
  • Su, Liang
  • Xie, Wei
  • Chiang, Yet-Ming
  • Woodford, William Henry
  • Cohen, Lucas
  • Silver, Jessa
  • Ripley, Katelyn
  • Weber, Eric
  • Ferrara, Marco
  • Jaramillo, Mateo Cristian
  • Wiley, Theodore Alan

Abstract

An electrochemical cell and battery system including cells, each cell including a catholyte, an anolyte, and a separator disposed between the catholyte and anolyte and that is permeable to the at least one ionic species (for example, a metal cation or the hydroxide ion). The catholyte solution includes a ferricyanide, permanganate, manganate, sulfur, and/or polysulfide compound, and the anolyte includes a sulfide and/or polysulfide compound. These electrochemical couples may be embodied in various physical architectures, including static (non-flowing) architectures or in flow battery (flowing) architectures.

IPC Classes  ?

  • H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
  • H01M 4/50 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese
  • H01M 4/58 - Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFySelection of substances as active materials, active masses, active liquids of polyanionic structures, e.g. phosphates, silicates or borates
  • H01M 8/1025 - Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having only carbon and oxygen, e.g. polyethers, sulfonated polyetheretherketones [S-PEEK], sulfonated polysaccharides, sulfonated celluloses or sulfonated polyesters
  • H01M 8/1246 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides
  • H01M 50/429 - Natural polymers
  • H01M 50/44 - Fibrous material
  • H01M 50/451 - Separators, membranes or diaphragms characterised by the material having a layered structure comprising layers of only organic material and layers containing inorganic material
  • H01M 50/489 - Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
  • H01M 50/491 - Porosity

60.

ELECTROCHEMICAL COGENERATION OF IRON AND COMMODITY CHEMICALS

      
Application Number 18795905
Status Pending
Filing Date 2024-08-06
First Publication Date 2025-02-13
Owner FORM ENERGY, INC. (USA)
Inventor
  • Manser, Joseph S.
  • Rathert, Janna
  • Luyima, Alex
  • Sokol, Julia

Abstract

An electrochemical reactor comprising a source of a magnetic field positioned in proximity to a cathode and configured to generate a magnetic field; and an electrochemical cell comprising an anode and the cathode, and further comprising a catholyte channel configured to direct a catholyte stream comprising an iron-containing feedstock to the cathode; an anolyte channel configured to direct an anolyte stream comprising a metal chloride to the anode, wherein the catholyte channel and the anolyte channel are disposed between the cathode and the anode; and a separator disposed between the catholyte channel and the anolyte channel, wherein the electrochemical reactor is configured to electrochemically oxidize chloride anions to chlorine gas at a surface of the anode, and wherein the electrochemical reactor is further configured to electrochemically reduce the iron-containing feedstock to an iron particle comprising iron metal at the surface of the cathode and in the magnetic field.

IPC Classes  ?

  • C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
  • C25C 7/02 - ElectrodesConnections thereof
  • C25C 7/04 - DiaphragmsSpacing elements
  • C25C 7/06 - Operating or servicing

61.

PURIFICATION OF ALKALINE ELECTROLYTES

      
Application Number US2024040903
Publication Number 2025/034623
Status In Force
Filing Date 2024-08-05
Publication Date 2025-02-13
Owner FORM ENERGY, INC. (USA)
Inventor
  • Luyima, Alex
  • Manser, Joseph, S.

Abstract

A method of purifying an alkaline electrolyte includes contacting the alkaline electrolyte with an aluminum compound to provide a purified alkaline electrolyte. The alkaline electrolyte includes a metal hydroxide, a compound comprising aluminum, silicon, or a combination thereof, and a solvent. The method can be particularly advantageous when used with a method of processing an iron-containing feedstock.

IPC Classes  ?

62.

ELECTROCHEMICAL REACTOR AND METHOD FOR REDUCING IRON FROM AN IRON-CONTAINING FEEDSTOCK

      
Application Number US2024041082
Publication Number 2025/034735
Status In Force
Filing Date 2024-08-06
Publication Date 2025-02-13
Owner FORM ENERGY, INC. (USA)
Inventor
  • Rathert, Janna
  • Manser, Joseph S.
  • Sokol, Julia

Abstract

An electrochemical reactor, including a channel for containing and directing flow of an electrolyte stream, wherein the electrolyte stream includes an electrolyte and an iron-containing feedstock; an anode and a cathode positioned in contact with the channel; and a source of a magnetic field positioned in proximity to the cathode, wherein the electrochemical reactor is configured to electrochemically reduce at least a portion of the iron-containing feedstock to iron metal at a surface of the cathode and in a magnetic field of the source, and wherein the at least a portion of the iron-containing feedstock is electrochemically reduced to the iron metal at a current efficiency of at least 0.75, wherein the current efficiency is a ratio of charge used for the reduction of the iron-containing feedstock to a total charge provided to the cathode.

IPC Classes  ?

  • C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells
  • C25C 7/02 - ElectrodesConnections thereof
  • C25C 7/06 - Operating or servicing
  • C25C 3/36 - Alloys obtained by cathodic reduction of all their ions

63.

IN RUST WE TRUST

      
Serial Number 99028902
Status Pending
Filing Date 2025-02-04
Owner Form Energy, Inc. ()
NICE Classes  ? 09 - Scientific and electric apparatus and instruments

Goods & Services

Batteries; Supercapacitors for energy storage

64.

RUST IS A MUST

      
Serial Number 99028905
Status Pending
Filing Date 2025-02-04
Owner Form Energy, Inc. ()
NICE Classes  ? 09 - Scientific and electric apparatus and instruments

Goods & Services

Batteries; Supercapacitors for energy storage

65.

Long life sealed alkaline secondary batteries

      
Application Number 18755136
Grant Number 12355042
Status In Force
Filing Date 2024-06-26
First Publication Date 2025-01-23
Grant Date 2025-07-08
Owner FORM ENERGY, INC. (USA)
Inventor
  • Pham, Ai Quoc
  • Nijhawan, Sandeep
  • Manohar, Aswin K.
  • Van Galloway, Kevin
  • Yang, Chenguang
  • Benson, Eric E.
  • Mchardy, Lang
  • Rackers, Tim

Abstract

In an aspect, provided is an alkaline rechargeable battery comprising: i) a battery container sealed against the release of gas up to at least a threshold gas pressure, ii) a volume of an aqueous alkaline electrolyte at least partially filling the container to au electrolyte level; iii) a positive electrode containing positive active material and at least partially submerged in the electrolyte, iv) an iron negative electrode at least partially submerged in the electrolyte, the iron negative electrode comprising iron active material; v) a separator at least partially submerged in the electrolyte provided between the positive electrode and the negative electrode; vi) an auxiliary oxygen gas recombination electrode electrically connected to the iron negative electrode by a first electronic component, ionically connected to the electrolyte by a first some pathway, and exposed to a gas headspace above the electrolyte level by a first gas pathway.

IPC Classes  ?

  • H01M 10/00 - Secondary cellsManufacture thereof
  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 4/58 - Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFySelection of substances as active materials, active masses, active liquids of polyanionic structures, e.g. phosphates, silicates or borates
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 10/24 - Alkaline accumulators
  • H01M 10/42 - Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
  • H01M 10/52 - Removing gases inside the secondary cell, e.g. by absorption
  • H01M 50/116 - Primary casingsJackets or wrappings characterised by the material
  • H01M 4/02 - Electrodes composed of, or comprising, active material

66.

METHODS AND SYSTEMS OF CONTROLLING BIDIRECTIONAL OPERATION OF AN ELECTROWINNING PLANT

      
Application Number 18763736
Status Pending
Filing Date 2024-07-03
First Publication Date 2025-01-09
Owner FORM ENERGY, INC. (USA)
Inventor
  • Su, Liang
  • Thomas-Alyea, Karen
  • Rathert, Janna
  • Poirier, Jeffrey
  • Manser, Joseph Stephen

Abstract

Methods and systems of the present disclosure are generally directed to switching operation of one or more electrochemical cells of an electrowinning plant between a charge mode and a discharge mode. In the charge mode, the one or more electrochemical cells may reduce metal from an oxidized state to a zero valence state with a first electric current applied across the one or more electrochemical cells. In the discharge mode, the one or more electrochemical cells may oxidize at least some of the metal from the zero valence state to the oxidized state to generate a second electric current, oppositely charged relative to the first electric current, to generate electricity (e.g., for delivery to the grid). Operation of the one or more electrochemical cells of the electrowinning plant may be selectively changed between the charge mode and the discharge mode based on, for example, availability/cost of electricity from the grid.

IPC Classes  ?

  • C25C 7/06 - Operating or servicing
  • C25C 7/02 - ElectrodesConnections thereof
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

67.

METHODS AND SYSTEMS OF CONTROLLING BIDIRECTIONAL OPERATION OF AN ELECTROWINNING PLANT

      
Application Number US2024036765
Publication Number 2025/010352
Status In Force
Filing Date 2024-07-03
Publication Date 2025-01-09
Owner FORM ENERGY, INC. (USA)
Inventor
  • Su, Liang
  • Thomas-Alyea, Karen
  • Rathert, Janna
  • Poirier, Jeffrey
  • Manser, Joseph Stephen

Abstract

Methods and systems of the present disclosure are generally directed to switching operation of one or more electrochemical cells of an electrowinning plant between a charge mode and a discharge mode. In the charge mode, the one or more electrochemical cells may reduce metal from an oxidized state to a zero valence state with a first electric current applied across the one or more electrochemical cells. In the discharge mode, the one or more electrochemical cells may oxidize at least some of the metal from the zero valence state to the oxidized state to generate a second electric current, oppositely charged relative to the first electric current, to generate electricity (e.g., for delivery to the grid). Operation of the one or more electrochemical cells of the electrowinning plant may be selectively changed between the charge mode and the discharge mode based on, for example, availability/cost of electricity from the grid.

IPC Classes  ?

  • C25C 1/02 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of light metals
  • C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
  • C25C 1/08 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese of nickel or cobalt
  • C25C 1/10 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese of chromium or manganese
  • C25C 1/12 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of copper
  • C25C 1/18 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of lead
  • C25C 7/00 - Constructional parts, or assemblies thereof, of cellsServicing or operating of cells
  • C25C 7/02 - ElectrodesConnections thereof
  • C25C 7/06 - Operating or servicing
  • H01M 8/22 - Fuel cells in which the fuel is based on materials comprising carbon or oxygen or hydrogen and other elementsFuel cells in which the fuel is based on materials comprising only elements other than carbon, oxygen or hydrogen
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

68.

Hybrid battery system

      
Application Number 18535643
Grant Number 12476479
Status In Force
Filing Date 2023-12-11
First Publication Date 2024-11-28
Grant Date 2025-11-18
Owner FORM ENERGY, INC. (USA)
Inventor
  • Krishnan, Ramkumar
  • Fink, Shawn

Abstract

A stationary hybrid battery back-up system incorporates two different battery units that differ in terms of recharging efficiency, cycle life, power capability, depth of discharge threshold, temperature threshold, internal impedance threshold, charger rate efficiency and/or stand-by efficiency. The battery back-up system of the present invention comprises an auxiliary power supply that can be used to charge the first and second batteries and/or provide power to a load. When the operating voltage of the system drops, due to a power failure of a power source, the control system may couple the first and/or second battery unit to a load. The control system may have voltage threshold limits wherein it engages the first and second battery units to support the load demand. The first and second battery units may be charge by the auxiliary power supply when the operating voltage is above a threshold level.

IPC Classes  ?

  • H01M 10/46 - Accumulators structurally combined with charging apparatus
  • H02J 7/00 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
  • H02J 7/34 - Parallel operation in networks using both storage and other DC sources, e.g. providing buffering
  • H02J 7/35 - Parallel operation in networks using both storage and other DC sources, e.g. providing buffering with light sensitive cells
  • H02J 9/06 - Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over

69.

Corrugated fuel electrode

      
Application Number 18436647
Grant Number 12444755
Status In Force
Filing Date 2024-02-08
First Publication Date 2024-11-21
Grant Date 2025-10-14
Owner FORM ENERGY, INC. (USA)
Inventor
  • Hayes, Joel Ryan
  • Krishnan, Ramkumar
  • Trimble, Todd
  • Anderson, Clifford

Abstract

A fuel electrode incorporates a first and second corrugated portion that are attached to each other at offset angles respect to their corrugation axis and therefore reinforce each other. A first corrugated portion may extend orthogonally with respect to a second corrugated portion. The first and second corrugated portions may be formed from metal wire and may therefore have a very high volumetric void fraction and a high surface area to volume ratio (sa/vol). In addition, the strands of the wire may be selected to enable high conductivity to the current collectors while maximizing the sa/vol. In addition, the shape of the corrugation, including the period distance, amplitude and geometry may be selected with respect to the stiffness requirements and electrochemical cell application factors. The first and second corrugated portions may be calendared or crushed to reduce thickness of the fuel electrode.

IPC Classes  ?

  • H01M 8/0254 - CollectorsSeparators, e.g. bipolar separatorsInterconnectors characterised by the form corrugated or undulated
  • H01M 4/66 - Selection of materials
  • H01M 4/74 - Meshes or woven materialExpanded metal
  • H01M 4/78 - Shapes other than plane or cylindrical, e.g. helical
  • H01M 8/0232 - Metals or alloys
  • H01M 8/0245 - Composites in the form of layered or coated products
  • H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

70.

FEEDSTOCKS AND METHODS FOR FABRICATION OF IRON ELECTRODES USING SULFIDE-CONTAINING PARTICLES

      
Application Number 18435597
Status Pending
Filing Date 2024-02-07
First Publication Date 2024-11-07
Owner FORM ENERGY, INC. (USA)
Inventor
  • Gibson, Michael Andrew
  • Perkins, Nicholas Reed
  • Nation, Leah Nicole
  • Manser, Joseph Stephen
  • Norman, Zachariah
  • Thompson, Annelise Christine

Abstract

According to one aspect, a feedstock for fabricating an iron electrode of an electrochemical cell may include iron-containing particles of a first material, sulfide-containing particles of a second material different from the first material, and a barrier material different from each of the first material and the second material, the barrier material at least partially physically separating the sulfide-containing particles from the iron particles, the at least partial physical separation of the iron-containing particles from the sulfide-containing particles maintainable by the barrier material at temperatures at which iron in the iron-containing particles bonds in the solid state.

IPC Classes  ?

  • H01M 4/36 - Selection of substances as active materials, active masses, active liquids
  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys

71.

MOISTURE AND CARBON DIOXIDE MANAGEMENT SYSTEM IN ELECTROCHEMICAL CELLS

      
Application Number 18733231
Status Pending
Filing Date 2024-06-04
First Publication Date 2024-09-26
Owner FORM ENERGY, INC. (USA)
Inventor
  • Krishnan, Ramkumar
  • Hayes, Joel
  • Fink, Shawn
  • Klug, Scott
  • Samuelson, Patrick

Abstract

An electrochemical cell utilizes an air flow device that draws air through the cell from a scrubber that may be removed while the system is operating. The negative pressure generated by the air flow device allows ambient air to enter the cell housing when the scrubber is removed, thereby enabling continued operation without the scrubber. A moisture management system passes outflow air from the cell through a humidity exchange module that transfers moisture to the air inflow, thereby increasing the humidity of the air inflow. A recirculation feature comprising a valve allow a controller to recirculate at least a portion of the outflow air back into the inflow air. The system may comprise an inflow bypass conduit and valve that allows the humidified inflow air to pass into the cell inlet without passing through the scrubber. The scrubber may contain reversible or irreversible scrubber media.

IPC Classes  ?

  • H01M 12/02 - Details
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/04014 - Heat exchange using gaseous fluidsHeat exchange by combustion of reactants
  • H01M 8/04089 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
  • H01M 8/04119 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants with simultaneous supply or evacuation of electrolyteHumidifying or dehumidifying
  • H01M 8/0668 - Removal of carbon monoxide or carbon dioxide
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

72.

CARBON-OXYGEN BATTERY AND METHOD OF USE THEREOF

      
Application Number 18631919
Status Pending
Filing Date 2024-04-10
First Publication Date 2024-08-15
Owner FORM ENERGY, INC. (USA)
Inventor
  • Woodford, William Henry
  • Grandahl, Tyler
  • Moon, Hwan

Abstract

A carbon-oxygen battery system, including: a Boudouard reactor in fluid communication with an electrochemical cell, wherein the electrochemical cell has a CO/CO2 inlet, a CO/CO2 outlet, and an oxygen outlet, and wherein the CO/CO2 outlet is fluidly connected by a first stream to an inlet of the Boudouard reactor, and wherein the CO/CO2 inlet is fluidly connected by a second stream to an outlet of the Boudouard reactor, and a CO/CO2 tank fluidly connected to at least one of the first stream or the second stream.

IPC Classes  ?

  • H01M 8/0612 - Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants from carbon-containing material
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/04746 - PressureFlow
  • H01M 8/0668 - Removal of carbon monoxide or carbon dioxide
  • H01M 8/12 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
  • H01M 8/1246 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

73.

FEEDSTOCKS AND METHODS FOR FABRICATION OF IRON ELECTRODES USING SULFIDE-CONTAINING PARTICLES

      
Application Number US2024014834
Publication Number 2024/168058
Status In Force
Filing Date 2024-02-07
Publication Date 2024-08-15
Owner FORM ENERGY, INC. (USA)
Inventor
  • Gibson, Michael Andrew
  • Perkins, Nicholas Reed
  • Nation, Leah Nicole
  • Manser, Joseph
  • Norman, Zachariah
  • Thompson, Annelise Christine

Abstract

According to one aspect, a feedstock for fabricating an iron electrode of an electrochemical cell may include iron-containing particles of a first material, sulfide-containing particles of a second material different from the first material, and a barrier material different from each of the first material and the second material, the barrier material at least partially physically separating the sulfide-containing particles from the iron particles, the at least partial physical separation of the iron-containing particles from the sulfide-containing particles maintainable by the barrier material at temperatures at which iron in the iron-containing particles bonds in the solid state.

IPC Classes  ?

  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 4/26 - Processes of manufacture
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 4/02 - Electrodes composed of, or comprising, active material

74.

Renewable energy system controls

      
Application Number 18297907
Grant Number 12061454
Status In Force
Filing Date 2023-04-10
First Publication Date 2024-08-13
Grant Date 2024-08-13
Owner Form Energy, Inc. (USA)
Inventor
  • Eltayeb, Aly Eldeen O.
  • Jenkins, Benjamin Michael
  • Ferrara, Marco

Abstract

Physical and/or financial instruments may optimally hedge the cash flow of one or more renewable energy generators based on a desired risk and return profile of renewable infrastructure investors. Baseline revenues may be determined based on forward-looking electricity market price scenarios corresponding to qualified market products intended for sale from the renewable energy generators. Risk and return metrics of cash flows of the renewable energy generators may be determined. At least one physical hedge and/or financial hedge may be added. The size and operation of the renewable energy generators along with any physical hedges, or financial hedges, or both physical and financial hedges, may be optimized across multiple market price scenarios of qualified market products to optimize investor-tailored risk and return utility functions.

IPC Classes  ?

  • G05B 19/04 - Programme control other than numerical control, i.e. in sequence controllers or logic controllers
  • G05B 19/042 - Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
  • G06Q 30/02 - MarketingPrice estimation or determinationFundraising
  • G06Q 30/0201 - Market modellingMarket analysisCollecting market data
  • G06Q 40/04 - Trading Exchange, e.g. stocks, commodities, derivatives or currency exchange
  • G06Q 50/06 - Energy or water supply

75.

SOLID STATE ADDITIVES FOR IRON NEGATIVE ELECTRODES

      
Application Number 18479668
Status Pending
Filing Date 2023-10-02
First Publication Date 2024-07-18
Owner Form Energy, Inc. (USA)
Inventor
  • Hooke, David
  • Gibson, Michael Andrew
  • Thompson, Annelise Christine
  • Pantano, Joseph Anthony
  • Syvertsen, Marc Louis

Abstract

According to one aspect, an additive for an iron negative electrode of an alkaline electrochemical cell may include a powder of discrete granules including agglomerated particles, the agglomerated particles including at least one metal sulfide.

IPC Classes  ?

  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/02 - Electrodes composed of, or comprising, active material
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers

76.

METHOD FOR MANUFACTURING DIRECT REDUCED IRON WITH A LOW CARBON CONTENT

      
Application Number IB2022062380
Publication Number 2024/127074
Status In Force
Filing Date 2022-12-16
Publication Date 2024-06-20
Owner
  • ARCELORMITTAL (Luxembourg)
  • FORM ENERGY, INC. (USA)
Inventor
  • Boulanov, Dmitri
  • Farahani, Mahdi
  • Andrade, Marcelo

Abstract

A direct reduction method to manufacture a direct reduced iron product 12 having a carbon content less than 1.8% by weight and a shaft furnace exit temperature lower than 65°C. A carbon-containing cooling gas 30 is introduced into the cooling zone 3 of the shaft furnace 1 with a flow rate higher than 800Nm3/ton of Direct Reduced Iron produced.

IPC Classes  ?

  • C21B 13/00 - Making spongy iron or liquid steel, by direct processes
  • C21B 13/02 - Making spongy iron or liquid steel, by direct processes in shaft furnaces

77.

METHOD FOR MANUFACTURING DIRECT REDUCED IRON WITH A LOW CARBON CONTENT

      
Application Number IB2023062805
Publication Number 2024/127360
Status In Force
Filing Date 2023-12-15
Publication Date 2024-06-20
Owner
  • ARCELORMITTAL (Luxembourg)
  • FORM ENERGY, INC. (USA)
Inventor
  • Boulanov, Dmitri
  • Farahani, Mahdi
  • Andrade, Marcelo

Abstract

A direct reduction method to manufacture a direct reduced iron product 12 having a carbon content less than 1.8% by weight and a shaft furnace exit temperature lower than 65°C. A carbon-containing cooling gas 30 is introduced into the cooling zone 3 of the shaft furnace 1 with a flow rate higher than 800Nm3/ton of Direct Reduced Iron produced.

IPC Classes  ?

  • C21B 13/00 - Making spongy iron or liquid steel, by direct processes
  • C21B 13/02 - Making spongy iron or liquid steel, by direct processes in shaft furnaces

78.

ROLLING DIAPHRAGM SEAL

      
Application Number 18331446
Status Pending
Filing Date 2023-06-08
First Publication Date 2024-05-02
Owner FORM ENERGY, INC. (USA)
Inventor
  • Westwood, Mitchell Terrance
  • Slocum, Alexander H.
  • Woodford, William Henry
  • Chiang, Yet-Ming
  • Mckay, Ian Salmon
  • Jaramillo, Mateo Cristian
  • Weber, Eric
  • Milshtein, Jarrod David
  • Su, Liang
  • Chakraborty, Rupak
  • Mumma, Rachel Elizabeth
  • Goulet, Marc-Antoni
  • Beggan, Brian
  • Ferrara, Marco
  • Wiley, Theodore Alan

Abstract

Systems and methods of the various embodiments may provide a battery including a rolling diaphragm configured to move to accommodate an internal volume change of one or more components of the battery. Systems and methods of the various embodiments may provide a battery housing including a rolling diaphragm seal disposed between an interior volume of the battery and an electrode assembly within the battery. Various embodiments may provide an air electrode assembly including an air electrode supported on a buoyant platform such that the air electrode is above a surface of a volume of electrolyte when the buoyant platform is floating in the electrolyte.

IPC Classes  ?

  • H01M 50/152 - Lids or covers characterised by their shape for cells having curved cross-section, e.g. round or elliptic
  • H01M 50/184 - Sealing members characterised by their shape or structure
  • H01M 50/191 - Inorganic material
  • H01M 50/46 - Separators, membranes or diaphragms characterised by their combination with electrodes
  • H01M 50/54 - Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges
  • H01M 50/636 - Closing or sealing filling ports, e.g. using lids

79.

CHLORINE DIOXIDE-BASED ENERGY STORAGE

      
Application Number 18495412
Status Pending
Filing Date 2023-10-26
First Publication Date 2024-05-02
Owner FORM ENERGY, INC. (USA)
Inventor
  • Su, Liang
  • Chiang, Yet-Ming
  • Chiang, Merrill K.

Abstract

According to one aspect, an electrochemical cell may include a positive electrode, a negative electrode, and an electrolyte separating the positive electrode and the negative electrode from one another. The positive electrode, the negative electrode, and the electrolyte may collectively store and discharge energy by an electrode reaction of chlorine dioxide (ClO2).

IPC Classes  ?

  • H01M 8/22 - Fuel cells in which the fuel is based on materials comprising carbon or oxygen or hydrogen and other elementsFuel cells in which the fuel is based on materials comprising only elements other than carbon, oxygen or hydrogen
  • H01M 4/96 - Carbon-based electrodes
  • H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
  • H01M 10/05 - Accumulators with non-aqueous electrolyte

80.

ELECTRODE CONFIGURATIONS FOR IRON-AIR ELECTROCHEMICAL SYSTEMS

      
Application Number 18485804
Status Pending
Filing Date 2023-10-12
First Publication Date 2024-04-18
Owner Form Energy, Inc. (USA)
Inventor
  • Manser, Joseph Stephen
  • Reynolds, Christopher Thomas
  • Thomas-Alyea, Karen
  • Chon, Michael
  • Hooke, David
  • Gibson, Michael Andrew
  • Takagi, Yuto
  • Goodman, Johanna
  • Morgan, Robert Wesley
  • Sacha, Valerie Christine
  • Rivera, Angel Ruben
  • Pantano, Joseph Anthony
  • Sokol, Julia
  • Perkins, Nicholas Reed

Abstract

An iron-air battery including an iron electrode in contact with an anode current collector, wherein the iron electrode includes a plurality of channels; an oxygen reduction reaction electrode having a first surface facing the plurality of channels and an opposing second surface in contact with air; an oxygen evolution reaction electrode interdigitated with the plurality of channels of the iron electrode, wherein at least a portion of the oxygen evolution reaction electrode is disposed within the plurality of channels in a direction perpendicular to a plane of the oxygen reduction reaction electrode; and an electrolyte in contact with the iron electrode, the first surface of the oxygen reduction reaction electrode, the plurality of channels, and the oxygen evolution reaction electrode.

IPC Classes  ?

  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 4/52 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
  • H01M 50/138 - Primary casingsJackets or wrappings adapted for specific cells, e.g. electrochemical cells operating at high temperature

81.

CARBON-OXYGEN BATTERY AND METHOD OF USE THEREOF

      
Application Number US2023076544
Publication Number 2024/081697
Status In Force
Filing Date 2023-10-11
Publication Date 2024-04-18
Owner FORM ENERGY, INC. (USA)
Inventor
  • Woodford, William Henry
  • Grandahl, Tyler
  • Moon, Hwan

Abstract

A carbon-oxygen battery system, including: a Boudouard reactor in fluid communication with an electrochemical cell, wherein the electrochemical cell has a CO/CO2 inlet, a CO/CO2 outlet, and an oxygen outlet, and wherein the CO/CO2 outlet is fluidly connected by a first stream to an inlet of the Boudouard reactor, and wherein the CO/CO2 inlet is fluidly connected by a second stream to an outlet of the Boudouard reactor; and a CO/CO2 tank fluidly connected to at least one of the first stream or the second stream.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • C25B 1/02 - Hydrogen or oxygen
  • C25B 1/135 - Carbon
  • C25B 1/23 - Carbon monoxide or syngas
  • H01M 8/04082 - Arrangements for control of reactant parameters, e.g. pressure or concentration
  • H01M 8/0438 - PressureAmbient pressureFlow
  • H01M 8/04089 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
  • H01M 8/1246 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides
  • H01M 8/14 - Fuel cells with fused electrolytes

82.

ELECTRODE CONFIGURATIONS FOR IRON-AIR ELECTROCHEMICAL SYSTEMS

      
Application Number US2023076700
Publication Number 2024/081792
Status In Force
Filing Date 2023-10-12
Publication Date 2024-04-18
Owner FORM ENERGY, INC. (USA)
Inventor
  • Manser, Joseph Stephen
  • Reynolds, Christopher Thomas
  • Thomas-Alyea, Karen
  • Chon, Michael
  • Hooke, David
  • Gibson, Michael Andrew
  • Takagi, Yuto
  • Goodman, Johanna
  • Morgan, Robert Wesley
  • Sacha, Valerie Christine
  • Rivera, Angel Ruben
  • Pantano, Joseph Anthony
  • Sokol, Julia
  • Perkins, Nicholas Reed

Abstract

An iron-air battery including an iron electrode in contact with an anode current collector, wherein the iron electrode includes a plurality of channels; an oxygen reduction reaction electrode having a first surface facing the plurality of channels and an opposing second surface in contact with air; an oxygen evolution reaction electrode interdigitated with the plurality of channels of the iron electrode, wherein at least a portion of the oxygen evolution reaction electrode is disposed within the plurality of channels in a direction perpendicular to a plane of the oxygen reduction reaction electrode; and an electrolyte in contact with the iron electrode, the first surface of the oxygen reduction reaction electrode, the plurality of channels, and the oxygen evolution reaction electrode.

IPC Classes  ?

  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells

83.

CARBON-OXYGEN BATTERY AND METHOD OF USE THEREOF

      
Application Number 18378860
Status Pending
Filing Date 2023-10-11
First Publication Date 2024-04-11
Owner Form Energy, Inc. (USA)
Inventor
  • Woodford, William Henry
  • Grandahl, Tyler
  • Moon, Hwan

Abstract

A carbon-oxygen battery system, including: a Boudouard reactor in fluid communication with an electrochemical cell, wherein the electrochemical cell has a CO/CO2 inlet, a CO/CO2 outlet, and an oxygen outlet, and wherein the CO/CO2 outlet is fluidly connected by a first stream to an inlet of the Boudouard reactor, and wherein the CO/CO2 inlet is fluidly connected by a second stream to an outlet of the Boudouard reactor; and a CO/CO2 tank fluidly connected to at least one of the first stream or the second stream.

IPC Classes  ?

  • H01M 8/0612 - Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants from carbon-containing material
  • H01M 8/0444 - ConcentrationDensity
  • H01M 8/1246 - Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides

84.

SOLID STATE ADDITIVES FOR IRON NEGATIVE ELECTRODES

      
Application Number US2023075744
Publication Number 2024/076932
Status In Force
Filing Date 2023-10-02
Publication Date 2024-04-11
Owner FORM ENERGY, INC. (USA)
Inventor
  • Hooke, David
  • Gibson, Michael Andrew
  • Thompson, Annelise Christine
  • Pantano, Joseph Anthony
  • Syvertsen, Marc Louis

Abstract

According to one aspect, an additive for an iron negative electrode of an alkaline electrochemical cell may include a powder of discrete granules including agglomerated particles, the agglomerated particles including at least one metal sulfide.

IPC Classes  ?

  • H01M 4/26 - Processes of manufacture
  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 4/30 - Pressing
  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 10/24 - Alkaline accumulators

85.

GAS MANAGEMENT FOR METAL-AIR BATTERIES

      
Application Number 18352223
Status Pending
Filing Date 2023-07-13
First Publication Date 2024-04-04
Owner FORM ENERGY, INC. (USA)
Inventor
  • Ocampo, Jaime Andres
  • Friesen, Grant
  • Nansel, Alli
  • Banerjee, Sid
  • Smith, Danielle Cassidy
  • Parker, Ellie
  • Mckibben, Nicholas
  • Mohan, Aruna

Abstract

Systems, methods, and devices for gas management of metal-air batteries. Each one of a plurality of electrochemical cells may include at least one air electrode, a metal electrode, a vessel, and a liquid electrolyte between the at least one air electrode and the metal electrode in the vessel, with each one of the plurality of electrochemical cells defining a respective headspace above the liquid electrolyte in the vessel. A manifold may include ducting defining a shared vent and an outlet region, and the respective headspace of each one of the plurality of electrochemical cells may be fluidically coupled to the shared vent and in fluid communication with the outlet region of the ducting.

IPC Classes  ?

  • H01M 50/358 - External gas exhaust passages located on the battery cover or case
  • H01M 10/42 - Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 10/6563 - Gases with forced flow, e.g. by blowers
  • H01M 10/6569 - Fluids undergoing a liquid-gas phase change or transition, e.g. evaporation or condensation
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/209 - Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells

86.

Methods for power storage in a power network

      
Application Number 18307355
Grant Number 12191702
Status In Force
Filing Date 2023-04-26
First Publication Date 2024-03-21
Grant Date 2025-01-07
Owner FORM ENERGY, INC. (USA)
Inventor
  • Krishnan, Ramkumar
  • Fink, Shawn

Abstract

A stationary hybrid battery back-up system incorporates two different battery units that differ in terms of recharging efficiency, cycle life, power capability, depth of discharge threshold, temperature threshold, internal impedance threshold, charger rate efficiency and/or stand-by efficiency. The battery back-up system of the present invention comprises an auxiliary power supply that can be used to charge the first and second batteries and/or provide power to a load. When the operating voltage of the system drops, due to a power failure of a power source, the control system may couple the first and/or second battery unit to a load. The control system may have voltage threshold limits wherein it engages the first and second battery units to support the load demand. The first and second battery units may be charge by the auxiliary power supply when the operating voltage is above a threshold level.

IPC Classes  ?

  • H01M 10/44 - Methods for charging or discharging
  • H01M 10/46 - Accumulators structurally combined with charging apparatus
  • H02J 7/00 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
  • H02J 7/34 - Parallel operation in networks using both storage and other DC sources, e.g. providing buffering
  • H02J 7/35 - Parallel operation in networks using both storage and other DC sources, e.g. providing buffering with light sensitive cells
  • H02J 9/06 - Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over

87.

Battery Management System Control Circuitry

      
Application Number 18454017
Status Pending
Filing Date 2023-08-22
First Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Truong, Tuan Minh
  • Grandahl, Tyler
  • Johnston, Keith William
  • Vasavada, Jhalak Joshipura
  • Friesen, Grant Harrison

Abstract

Systems, methods, and devices of the various embodiments may provide control and/or sensing circuit configurations for electrochemical energy storage systems, such as metal-air battery systems. Various embodiments may include systems, methods, and devices supporting terminal switching between a charge cathode and a discharge cathode of a metal-air battery, bypass switching for the metal-air battery, and/or electrolyte low level detection for the metal-air battery.

IPC Classes  ?

  • H01M 10/42 - Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H02J 7/00 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries

88.

CONSTRUCTION OF ELECTRODE AND CELL COMPONENTS FOR METAL-AIR BATTERIES

      
Application Number 18454260
Status Pending
Filing Date 2023-08-23
First Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Rivera, Angel Ruben
  • Yang, Kalina Chia-Shi
  • Spriggs, Katherine
  • Rodriquez, Adrianna
  • Parker, Madeline Elliott
  • Howe, Ryan
  • Mckibben, Nicholas
  • Friesen, Grant Harrison
  • Milshtein, Jarrod David
  • Vasavada, Jhalak Joshipura
  • Morgan, Robert Wesley
  • Traini, Erica Skye
  • Wood, Christopher Evan
  • Patrick, Meghan Marya
  • Dinitto, Matthew

Abstract

According to an aspect, an electrochemical cell may include a vessel, at least two instances of an anode assembly, at least two instances of an oxygen evolution electrode (OEE), and a gas diffusion electrode (GDE). In the vessel, the GDE may be disposed between mirrored arrangements of the at least two instances of the OEE and the at least two instances of the anode assembly.

IPC Classes  ?

  • H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/105 - Pouches or flexible bags
  • H01M 50/121 - Organic material

89.

CONSTRUCTION OF ELECTRODE AND CELL COMPONENTS FOR METAL-AIR BATTERIES

      
Application Number US2023030935
Publication Number 2024/044255
Status In Force
Filing Date 2023-08-23
Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Rivera, Angel Ruben
  • Yang, Kalina Chia-Shi
  • Spriggs, Katherine
  • Rodriquez, Adrianna
  • Parker, Madeline Elliott
  • Howe, Ryan
  • Mckibben, Nicholas
  • Friesen, Grant Harrison
  • Milshtein, Jarrod David
  • Vasavada, Jhalak Joshipura
  • Morgan, Robert Wesley
  • Traini, Erica Skye
  • Wood, Christopher Evan
  • Patrick, Meghan Marya
  • Dinitto, Matthew

Abstract

According to an aspect, an electrochemical cell may include a vessel, at least two instances of an anode assembly, at least two instances of an oxygen evolution electrode (OEE), and a gas diffusion electrode (GDE). In the vessel, the GDE may be disposed between mirrored arrangements of the at least two instances of the OEE and the at least two instances of the anode assembly.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/166 - Lids or covers characterised by the methods of assembling casings with lids
  • H01M 50/16 - Organic material

90.

CONSTRUCTION OF BATTERY MODULE AND SYSTEMS INTERFACES FOR METAL-AIR BATTERIES

      
Application Number US2023030955
Publication Number 2024/044269
Status In Force
Filing Date 2023-08-23
Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Rivera, Angel Ruben
  • Yang, Kalina Chia-Shi
  • Spriggs, Katherine
  • Rodriquez, Adrianna
  • Parker, Madeline Elliott
  • Howe, Ryan
  • Mckibben, Nicholas
  • Friesen, Grant Harrison
  • Milshtein, Jarrod David
  • Ocampo, Jaime Andres
  • Vasavada, Jhalak Joshipura
  • Sledd, Alan
  • Truong, Tuan Minh
  • Mohan, Aruna
  • Dinitto, Matthew

Abstract

According to one aspect, a power storage system may include an enclosure, and one or more modules disposed in the enclosure. Each of the one or more modules may include a plurality of electrochemical cells electrically coupled to one another, each one of the plurality of electrochemical cells including an oxygen evolution electrode (OEE), an anode, a gas diffusion electrode (GDE), an electrolyte, and a vessel and, within the vessel, the OEE, the anode, and the GDE at least partially immersed in the electrolyte.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/284 - MountingsSecondary casings or framesRacks, modules or packsSuspension devicesShock absorbersTransport or carrying devicesHolders with incorporated circuit boards, e.g. printed circuit boards [PCB]
  • H01M 50/502 - Interconnectors for connecting terminals of adjacent batteriesInterconnectors for connecting cells outside a battery casing
  • H01M 50/543 - Terminals
  • H01M 50/186 - Sealing members characterised by the disposition of the sealing members
  • H01M 10/6561 - Gases
  • H01M 10/613 - Cooling or keeping cold

91.

THERMAL MANAGEMENT SYSTEM ARCHITECTURE FOR METAL AIR BATTERIES

      
Application Number US2023072680
Publication Number 2024/044605
Status In Force
Filing Date 2023-08-22
Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Ocampo, Jaime Andres
  • Friesen, Grant Harrison
  • Vasavada, Jhalak Joshipura

Abstract

Systems, methods, and devices of the various embodiments may provide configurations for components of battery systems configured for thermal management. Systems, methods, and devices of the various embodiments may include a battery system with a plurality of metal-air batteries that each includes at least one air electrode, a metal electrode, a liquid electrolyte separating the at least one air electrode from the metal electrode, and a vessel including the liquid electrolyte. In various embodiments, the battery system may also include an air circulation system, a heating, ventilation, and air conditioning (HVAC) unit, and/or a liquid cooling system.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 10/6563 - Gases with forced flow, e.g. by blowers
  • H01M 10/6567 - Liquids
  • H01M 10/6571 - Resistive heaters

92.

BATTERY MANAGEMENT SYSTEM CONTROL CIRCUITRY

      
Application Number US2023072684
Publication Number 2024/044609
Status In Force
Filing Date 2023-08-22
Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Truong, Tuan Minh
  • Grandahl, Tyler
  • Johnston, Keith William
  • Vasavada, Jhalak Joshipura
  • Friesen, Grant Harrison

Abstract

Systems, methods, and devices of the various embodiments may provide control and/or sensing circuit configurations for electrochemical energy storage systems, such as metal-air battery systems. Various embodiments may include systems, methods, and devices supporting terminal switching between a charge cathode and a discharge cathode of a metal-air battery, bypass switching for the metal-air battery, and/or electrolyte low level detection for the metal-air battery.

IPC Classes  ?

  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H02J 3/32 - Arrangements for balancing the load in a network by storage of energy using batteries with converting means

93.

Thermal Management System Architecture for Metal Air Batteries

      
Application Number 18453899
Status Pending
Filing Date 2023-08-22
First Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Ocampo, Jaime Andres
  • Friesen, Grant Harrison
  • Vasavada, Jhalak Joshipura

Abstract

Systems, methods, and devices of the various embodiments may provide configurations for components of battery systems configured for thermal management. Systems, methods, and devices of the various embodiments may include a battery system with a plurality of metal-air batteries that each includes at least one air electrode, a metal electrode, a liquid electrolyte separating the at least one air electrode from the metal electrode, and a vessel including the liquid electrolyte. In various embodiments, the battery system may also include an air circulation system, a heating, ventilation, and air conditioning (HVAC) unit, and/or a liquid cooling system.

IPC Classes  ?

  • H01M 12/02 - Details
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/04014 - Heat exchange using gaseous fluidsHeat exchange by combustion of reactants

94.

CONSTRUCTION OF BATTERY MODULE AND SYSTEMS INTERFACES FOR METAL-AIR BATTERIES

      
Application Number 18454272
Status Pending
Filing Date 2023-08-23
First Publication Date 2024-02-29
Owner FORM ENERGY, INC. (USA)
Inventor
  • Rivera, Angel Ruben
  • Yang, Kalina Chia-Shi
  • Spriggs, Katherine
  • Rodriquez, Adrianna
  • Parker, Madeline Elliott
  • Howe, Ryan
  • Mckibben, Nicholas
  • Friesen, Grant Harrison
  • Milshtein, Jarrod David
  • Ocampo, Jaime Andres
  • Vasavada, Jhalak Joshipura
  • Sledd, Alan
  • Truong, Tuan Minh
  • Mohan, Aruna
  • Dinitto, Matthew

Abstract

According to one aspect, a power storage system may include an enclosure, and one or more modules disposed in the enclosure. Each of the one or more modules may include a plurality of electrochemical cells electrically coupled to one another, each one of the plurality of electrochemical cells including an oxygen evolution electrode (OEE), an anode, a gas diffusion electrode (GDE), an electrolyte, and a vessel and, within the vessel, the OEE, the anode, and the GDE at least partially immersed in the electrolyte.

IPC Classes  ?

  • H01M 50/507 - Interconnectors for connecting terminals of adjacent batteriesInterconnectors for connecting cells outside a battery casing comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
  • H01M 10/613 - Cooling or keeping cold
  • H01M 10/6556 - Solid parts with flow channel passages or pipes for heat exchange
  • H01M 10/6566 - Means within the gas flow to guide the flow around one or more cells, e.g. manifolds, baffles or other barriers
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 50/264 - MountingsSecondary casings or framesRacks, modules or packsSuspension devicesShock absorbersTransport or carrying devicesHolders with fastening means, e.g. locks for cells or batteries, e.g. straps, tie rods or peripheral frames
  • H01M 50/287 - Fixing of circuit boards to lids or covers
  • H01M 50/636 - Closing or sealing filling ports, e.g. using lids

95.

SOLID STATE ADDITIVES FOR IRON NEGATIVE ELECTRODES

      
Application Number US2023030484
Publication Number 2024/039790
Status In Force
Filing Date 2023-08-17
Publication Date 2024-02-22
Owner FORM ENERGY, INC. (USA)
Inventor
  • Hooke, David
  • Gibson, Michael Andrew
  • Thompson, Annelise Christine
  • Pantano, Joseph Anthony
  • Syvertsen, Marc Louis

Abstract

According to one aspect, an additive for an iron negative electrode of an alkaline electrochemical cell may include a powder of discrete granules including agglomerated particles, the agglomerated particles including at least one metal sulfide.

IPC Classes  ?

  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 4/24 - Electrodes for alkaline accumulators
  • H01M 4/26 - Processes of manufacture
  • H01M 4/04 - Processes of manufacture in general
  • H01M 4/02 - Electrodes composed of, or comprising, active material

96.

SOLID STATE ADDITIVES FOR IRON NEGATIVE ELECTRODES

      
Application Number 18451458
Status Pending
Filing Date 2023-08-17
First Publication Date 2024-02-22
Owner FORM ENERGY, INC. (USA)
Inventor
  • Hooke, David
  • Gibson, Michael Andrew
  • Thompson, Annelise Christine
  • Pantano, Joseph Anthony
  • Syvertsen, Marc Louis

Abstract

According to one aspect, an additive for an iron negative electrode of an alkaline electrochemical cell may include a powder of discrete granules including agglomerated particles, the agglomerated particles including at least one metal sulfide.

IPC Classes  ?

  • H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 4/24 - Electrodes for alkaline accumulators

97.

Moisture and carbon dioxide management system in electrochemical cells

      
Application Number 18298009
Grant Number 12046736
Status In Force
Filing Date 2023-04-10
First Publication Date 2024-02-08
Grant Date 2024-07-23
Owner FORM ENERGY, INC. (USA)
Inventor
  • Krishnan, Ramkumar
  • Hayes, Joel
  • Fink, Shawn
  • Klug, Scott
  • Samuelson, Patrick

Abstract

An electrochemical cell utilizes an air flow device that draws air through the cell from a scrubber that may be removed while the system is operating. The negative pressure generated by the air flow device allows ambient air to enter the cell housing when the scrubber is removed, thereby enabling continued operation without the scrubber. A moisture management system passes outflow air from the cell through a humidity exchange module that transfers moisture to the air inflow, thereby increasing the humidity of the air inflow. A recirculation feature comprising a valve allow a controller to recirculate at least a portion of the outflow air back into the inflow air. The system may comprise an inflow bypass conduit and valve that allows the humidified inflow air to pass into the cell inlet without passing through the scrubber. The scrubber may contain reversible or irreversible scrubber media.

IPC Classes  ?

  • H01M 12/02 - Details
  • H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
  • H01M 8/04007 - Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
  • H01M 8/04014 - Heat exchange using gaseous fluidsHeat exchange by combustion of reactants
  • H01M 8/04089 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
  • H01M 8/04119 - Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants with simultaneous supply or evacuation of electrolyteHumidifying or dehumidifying
  • H01M 8/0668 - Removal of carbon monoxide or carbon dioxide
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type

98.

REFUELABLE BATTERY SYSTEMS, DEVICES, AND COMPONENTS

      
Application Number US2023028887
Publication Number 2024/026040
Status In Force
Filing Date 2023-07-27
Publication Date 2024-02-01
Owner FORM ENERGY, INC. (USA)
Inventor
  • Chiang, Yet-Ming
  • Woodford, William Henry
  • Raman, Kailash

Abstract

A metal-air battery including: a current collector; a metal electrode including a metal and contacting the current collector; an air electrode on the metal electrode and opposite the current collector; a solid electrolyte between the metal electrode and the air electrode; a discharge product of the metal on the air electrode; wherein the metal-air battery is configured to release the discharge product.

IPC Classes  ?

  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 4/90 - Selection of catalytic material
  • H01M 10/0562 - Solid materials
  • H01M 10/44 - Methods for charging or discharging

99.

GAS MANAGEMENT FOR METAL-AIR BATTERIES

      
Application Number US2023027690
Publication Number 2024/015540
Status In Force
Filing Date 2023-07-13
Publication Date 2024-01-18
Owner FORM ENERGY, INC. (USA)
Inventor
  • Ocampo, Jaime Andres
  • Friesen, Grant
  • Nansel, Alli
  • Banerjee, Sid
  • Smith, Danielle Cassidy
  • Parker, Ellie
  • Mckibben, Nicholas
  • Mohan, Aruna

Abstract

Systems, methods, and devices for gas management of metal-air batteries. Each one of a plurality of electrochemical cells may include at least one air electrode, a metal electrode, a vessel, and a liquid electrolyte between the at least one air electrode and the metal electrode in the vessel, with each one of the plurality of electrochemical cells defining a respective headspace above the liquid electrolyte in the vessel. A manifold may include ducting defining a shared vent and an outlet region, and the respective headspace of each one of the plurality of electrochemical cells may be fluidically coupled to the shared vent and in fluid communication with the outlet region of the ducting.

IPC Classes  ?

  • H01M 50/35 - Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages
  • H01M 50/30 - Arrangements for facilitating escape of gases
  • H01M 12/06 - Hybrid cellsManufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
  • H01M 12/08 - Hybrid cellsManufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
  • H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte

100.

OXYANION-BASED ENERGY STORAGE

      
Application Number 18300970
Status Pending
Filing Date 2023-04-14
First Publication Date 2024-01-04
Owner FORM ENERGY, INC. (USA)
Inventor
  • Chiang, Merrill K.
  • Su, Liang
  • Chiang, Yet-Ming
  • Woodford, William Henry
  • Raman, Kailash

Abstract

Systems, methods, and device of the various embodiments may support energy storage devices in which electrochemical oxidation and reduction of one or more redox-active oxyanions occurs during charging and/or discharging of the energy storage device.

IPC Classes  ?

  • H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
  • H01M 4/96 - Carbon-based electrodes
  • H01M 4/90 - Selection of catalytic material
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