Sodium-sulfur battery

Claim 2

A sodium sulfur battery, comprising: (a) first means for containing sulphur in a molten state; (b) second means for containing sodium in a molten state, said second means including a beta-alumina electrolyte tube located at least partially within the sulfur in said sulfur containing means; and (c) means for physically separating the sulfur in said first means from the sodium in said second means, said separating means including a header located between said first and second means and having an inner circumferential surface defining an opening through which said beta-alumina tube extends, said surface forming a continuous mechanical seal around and against said tube sufficient to prevent said sulfur or sodium from passing therebetween.

Claim 3

A battery according to claim 1 wherein said header is constructed of a material which will expand to a limited extent when heated and which will contract to a limited extent when cooled down.

Claim 4

A battery according to claim 2 wherein said material is aluminum.

Claim 5

A battery according to claim 3 including means for electrically insulating said header from at least one of said first and second containing means.

Claim 6

A battery according to claim 4 wherein said header includes opposite sides in contact with said first and second means, respectively, at least one of said sides being anodized to provide said electrical insulating means.

Claim 7

A battery according to claim 4 wherein said header includes opposite sides in contact with said first and second means, respectively, at least one of said sides being sulfidated to provide said electrical insulating means.

Claim 8

A battery according to claim 2 wherein said header includes an inner circumferential segment including said inner surface and an outer circumferential segment, said inner segment being thinner in cross section than said outer segment.

Claim 9

A battery according to claim 2 wherein said material is aluminum and such that, when said header is heated to a temperature at least equal to about 580° C.-630° C., it expands sufficient to allow said beta-alumina tube to be readily inserted through said opening and, when said header is at or below about 350° C., said opening, if left unobstructed, would be too small to allow said tube to be inserted therethrough.

Claim 10

A battery according to claim 1 wherein aluminum foil is located between the header and the electrolyte tube.

Claim 11

A battery according to claim 1 wherein said tube tapers inwardly from its top end to its bottom end.

Claim 12

A sodium-sulfur battery, comprising: (a) a first metal container for containing sulfur in a molten state; (b) a second metal container for containing sodium in a molten state; (c) a beta-alumina tube extending at least partially within the molten sulfur in said first container and also containing sodium therein, the interior of said tube being in fluid communication with the interior of said second container, whereby molten sodium from said second container can readily flow into said tube; and (d) means for physically separating and electrically insulating the sulfur in said first container from the sodium in said second container and in said beta-alumina tube, said means including (i) a disc shaped aluminum header located between said first and second containers and having an inner circumferential surface defining an opening through which said beta-alumina tube extends, said circumferential surface forming a continuous mechanical seal around and directly against said tube sufficient to prevent said sulfur or sodium from passing therebetween, said header having an inner circumferential segment including said inner surface and an outer circumferential segment, said inner segment being thinner in cross section than said outer segment, (ii) means for electrically insulating said aluminum header from at least one of said containers, and (iii) means for providing a continuous seal between said header and said first container and said header and said second container, whereby to prevent said sulfur and sodium from escaping from respective containers between the containers and said header.

Claim 13

A sodium-sulfur battery, comprising: (a) a first metal container for containing sulfur in a molten state; (b) a second metal container for containing sodium in a molten state; (c) a beta-alumina tube extending at least partially within the molten sulfur in said first container and also containing sodium therein, the interior of said tube being in fluid communication with the interior of said second container, whereby molten sodium from said second container can readily flow into said tube; and (d) means for physically separating and electrically insulating the sulfur in said first container from the sodium in said second container and in said beta-alumina tube, said means including (i) a disc shaped aluminum header located between said first and second containers and having an inner circumferential surface defining an opening through which said beta-alumina tube extends, said circumferential surface forming a continuous mechanical seal around and directly against said tube sufficient to prevent said sulfur or sodium from passing therebetween, said header having an inner circumferential segment including said inner surface and an outer circumferential segment, said inner segment being thinner in cross section than said outer segment, (ii) means for electrically insulating said aluminum header from at least one of said containers, and (iii) means for providing a continuous seal between said header and said first container and said header and said second container, whereby to prevent said sulfur and sodium from escaping from respective containers between the containers and said header.

Claim 14

A battery according to claim 11 wherein said header is such that, when said header is heated to a temperature at least equal to about 580° C-630°C., it expands sufficient to allow said beta-alumina tube to be readily inserted through said opening and, when said header is at or below about 350° C., said opening, if left unobstructed, would be too small to allow said tube to be inserted therethrough.

Claim 15

In a sodium-sulfur battery including a first container for containing sulfur in a molten state, a second container including sodium in an molten state and a beta-alumina electrolyte tube located partially within each of said containers, a method of preventing the sulfur and sodium from moving between said containers along the outer surface of said beta-alumina tube, said method comprising: (a) providing a header constructed of a material which will expand to a limited extent when heated and which will contract to a limited extent when cooled down, said header including an inner circumferential surface defining a through opening which is sized to prevent said tube from being inserted therethrough when said header is at or below a first predetermined temperature but which will expand sufficient to allow said tube to be readily inserted therethrough when said header is heated to a second, higher predetermined temperature; (b) heating said header at least to said second predetermined temperature; (c) while said header is at or above said second temperature, inserting said beta-alumina tube through said opening; and (d) cooling said header down at least to said first, lower temperature, whereby said inner circumferential surface forms a continuous mechanical seal around and against said tube sufficient to prevent said sulfur and sodium from passing therethrough.

Claim 16

In a sodium-sulfur battery including a first container for containing sulfur in a molten state, a second container including sodium in an molten state and a beta-alumina electrolyte tube located partially within each of said containers, a method of preventing the sulfur and sodium from moving between said containers along the outer surface of said beta-alumina tube, said method comprising: (a) providing a header constructed of a material which will expand to a limited extent when heated and which will contract to a limited extent when cooled down, said header including an inner circumferential surface defining a through opening which is sized to prevent said tube from being inserted therethrough when said header is at or below a first predetermined temperature but which will expand sufficient to allow said tube to be readily inserted therethrough when said header is heated to a second, higher predetermined temperature; (b) heating said header at least to said second predetermined temperature; (c) while said header is at or above said second temperature, inserting said beta-alumina tube through said opening; and (d) cooling said header down at least to said first, lower temperature, whereby said inner circumferential surface forms a continuous mechanical seal around and against said tube sufficient to prevent said sulfur and sodium from passing therethrough.

Claim 17

A method according to claim 13, wherein said first, lower temperature is at most about 350° C.

Claim 18

A method according to claim 13, wherein said second, higher temperature is at least about 580° C.-630° C.

Claim 19

A method according to claim 13 including: (a) heating said beta-alumina tube to a predetermined temperature prior to its insertion through said opening.

Claim 20

A method according to claim 16 wherein said tube is heated to a temperature of about 100° C.-300° C.

Claim 21

A method according to claim 13 wherein said first, lower temperature is at most about 350° C., said second, higher temperature is at least about 580° C.-630° C. and including: (a) heating said beta-alumina tube to about 100° C.-300° C. prior to its insertion through said opening.

Claim 22

A method according to claim 13 wherein said header is constructed of aluminum and is in the form of a disc having opposite sides, said method including: (a) anodizing at least one of said opposite surfaces.

Claim 23

A method according to claim 13 wherein said header is constructed of aluminum and is in the form of a disc having opposite sides, said method including: (a) sulfidating at least one of said opposite sides.

Claim 24

In a sodium-sulphur battery including a first continuous container for containing sulphur in a molten state, a second container including sodium in a molten state and a beta-alumina electrolyte tube located partially within each of said containers, a method of preventing the sulphur and sodium from moving between said containers along the outer surface of said beta-alumina tube, said method comprising: (a) providing an aluminum header which will expand to a limited extent when heated and which will contract to a limited extent when cooled down. Said header including an inner circumferential surface defining a through opening which is sized to prevent said tube from being inserted therethrough when said header is at or below the temperature of about 350° C. but which will expand sufficient to allow said tube to be readily inserted therethrough when said header is heated to the temperature of at least about 580° C.-630° C., said header having an inner circumferential segment including said inner circumferential surface and an outer circumferential segment which is thicker in cross section than said inner segment; (b) heating said aluminum header to 580° C.-630° C.; (c) heating said beta-alumina tube to a temperature of about 100° C.-300° C.; (d) while said aluminum header and said beta-alumina tube are at their respective heated temperatures, inserting said beta-alumina tube through said opening; and (e) cooling said header down at least to said 350° C., whereby said inner circumferential surface forms a continuous mechanical seal around and against said tube sufficient to prevent said sulfur and sodium from passing therebetween.

Claim 25

In a sodium-sulphur battery including a first continuous container for containing sulphur in a molten state, a second container including sodium in a molten state and a beta-alumina electrolyte tube located partially within each of said containers, a method of preventing the sulphur and sodium from moving between said containers along the outer surface of said beta-alumina tube, said method comprising: (a) providing an aluminum header which will expand to a limited extent when heated and which will contract to a limited extent when cooled down. Said header including an inner circumferential surface defining a through opening which is sized to prevent said tube from being inserted therethrough when said header is at or below the temperature of about 350° C. but which will expand sufficient to allow said tube to be readily inserted therethrough when said header is heated to the temperature of at least about 580° C.-630° C., said header having an inner circumferential segment including said inner circumferential surface and an outer circumferential segment which is thicker in cross section than said inner segment; (b) heating said aluminum header to 580° C.-630° C.; (c) heating said beta-alumina tube to a temperature of about 100° C.-300° C.; (d) while said aluminum header and said beta-alumina tube are at their respective heated temperatures, inserting said beta-alumina tube through said opening; and (e) cooling said header down at least to said 350° C., whereby said inner circumferential surface forms a continuous mechanical seal around and against said tube sufficient to prevent said sulfur and sodium from passing therebetween.

Claim 26

A sodium-sulfur battery, comprising: (a) a first metal container for containing sulfur in a molten state; (b) a second metal container for containing sodium in a molten state; (c) a beta-alumina tube extending at least partially within the the molten sulfur in said first container and also containing sodium therein, the interior of said tube being in fluid communication with the interior of said second container, whereby molten sodium from said second container can readily flow into said tube; and (d) means for physically separating and electrically insulating the sulfur in said first container from the sodium in said second container and in said beta-alumina tube, said means including (i) a disc shaped metal header located between said first and second containers and having an inner circumferential surface defining an opening through which said beta-alumina tube extends; (ii) means for electrically insulating said header from at least one of said containers, and (iii) means for providing a continuous seal between said header and said first container and said header and said second container, whereby to prevent said sulfur and sodium from escaping from respective containers between the containers and said header.

Claim 27

A sodium-sulfur battery, comprising: (a) a first metal container for containing sulfur in a molten state; (b) a second metal container for containing sodium in a molten state; (c) a beta-alumina tube extending at least partially within the the molten sulfur in said first container and also containing sodium therein, the interior of said tube being in fluid communication with the interior of said second container, whereby molten sodium from said second container can readily flow into said tube; and (d) means for physically separating and electrically insulating the sulfur in said first container from the sodium in said second container and in said beta-alumina tube, said means including (i) a disc shaped metal header located between said first and second containers and having an inner circumferential surface defining an opening through which said beta-alumina tube extends; (ii) means for electrically insulating said header from at least one of said containers, and (iii) means for providing a continuous seal between said header and said first container and said header and said second container, whereby to prevent said sulfur and sodium from escaping from respective containers between the containers and said header.

Claim 28

A battery according to claim 22 wherein said header is electrically insulated from only one of said containers and wherein said continuous seal between said header and said other container is a metal-to-metal bond.

Claim 29

A battery according to claim 23 wherein said header is aluminum.