Alkali metal cells and batteries and the manufacture thereof

Claim 2

A sodium sulphur cell comprising a metal housing, tubular ceramic electrolyte material within said housing separating a first electrode region within the tubular electrolyte from a second electrode region between the electrolyte and the housing, one of said electrode regions containing sodium and the other containing carbon fibre material impregnated with sulphur/sodium polysulphides, and a first current collector extending into the first electrode region but electrically insulated from the electrolyte by an electrically insulating element and wherin the metal housing forming a second collector is sealed to said insulating element in a region around said first current collector, which region has a maximum cross section substantially less than the cross section of the electrolyte tube, and wherein the internal length of electrolyte tube is between 1.5 times and 0.7 times the mean internal diameter of that tube.

Claim 3

A sodium sulphur cell as claimed in claim 1 wherein said region around the current collector lies wholly within the outer periphery of the electrolyte tube.

Claim 4

A sodium sulphur cell as claimed in claim 1 wherein the electrolyte tube is cylindrical and wherein said region around the said first current collector is an annular region having a maximum diameter substantially less than the diameter of the electrolyte tube.

Claim 5

A sodium sulphur cell as claimed in claim 1 wherein said metal housing comprises a cylindrical metal container portion having a metal closure member at one end thereof, said metal closure member having an aperture around said first current collector with the peripheral portion of the closure around the aperture sealed to said insulating element.

Claim 6

A sodium sulphur cell as claimed in claim 1 wherein said electrically insulating element comprises a sleeve around said first current collector.

Claim 7

A sodium sulphur cell as claimed in claim 5 wherein said tubular electrolyte material comprises a cylindrical beta alumina tube with an annular ceramic closure element sealed to the beta alumina tube at one end thereof and sealed to said sleeve.

Claim 8

A sodium sulphur cell as claimed in claim 6 wherein said ceramic closure element is formed of alpha alumina.

Claim 9

A sodium sulphur cell as claimed in claim 6 wherein said ceramic closure element is formed of beta alumina.

Claim 10

A sodium sulphur cell as claimed in claim 1 wherein said tubular electrolyte material comprises a cylindrical beta alumina tube and wherein said electrically insulating element comprises an annular alpha alumina element sealed to the beta alumina tube at one end thereof.

Claim 11

A sodium sulphur cell having an outer metal housing containing a cylindrical ceramic electrolyte tube having an internal length between 1.5 times and 0.7 times its means internal diameter and which separates an anodic region containing liquid sodium from a cathodic region containing sulphur/sodium polysulphides, one of said regions, referred to as the inner region, being within the electrolyte tube and the other, referred to as the outer region, being outside the electrolyte tube, a ceramic closure across one end of the electrolyte tube, a metal first current collector extending from the inner region through the closure, said housing constituting a second current collector and comprising a tubular metal element having a metal closure member at its open end, which metal closure member is secured around its periphery to said tubular metal element and is sealed to said ceramic closure, or to a non-electrically coductive member secured thereto, in an annular region around said first current collector which annular region has a maximum diameter substantially less than the diameter of the electrolyte tube.

Claim 12

A sodium sulphur cell having an outer metal housing containing a cylindrical ceramic electrolyte tube having an internal length between 1.5 times and 0.7 times its means internal diameter and which separates an anodic region containing liquid sodium from a cathodic region containing sulphur/sodium polysulphides, one of said regions, referred to as the inner region, being within the electrolyte tube and the other, referred to as the outer region, being outside the electrolyte tube, a ceramic closure across one end of the electrolyte tube, a metal first current collector extending from the inner region through the closure, said housing constituting a second current collector and comprising a tubular metal element having a metal closure member at its open end, which metal closure member is secured around its periphery to said tubular metal element and is sealed to said ceramic closure, or to a non-electrically coductive member secured thereto, in an annular region around said first current collector which annular region has a maximum diameter substantially less than the diameter of the electrolyte tube.

Claim 13

A cell as claimed in claim 10 wherein the ceramic closure element is integral with the electrolyte tube.

Claim 14

A cell as claimed in claim 10 wherein the ceramic closure element is sealed to the electrolyte tube.

Claim 15

A cell as claimed in claim 10 wherein the maximum diameter of the seal between the metal closure element and the ceramic clousre is less than half the diameter of the electrolyte tube.

Claim 16

A cell as claimed in claim 10 wherein the maximum diameter of the seal between the metal closure element and the ceramic closure is less than one quarter the diameter of the electrolyte tube.

Claim 17

A cell as claimed in claim 10 wherein the electrolyte tube is of beta alumina and wherein the ceramic closure is a plate of alpha alumina sealed by glazing to the open end of the electrolyte tube.

Claim 18

A cell as claimed in claim 10 wherein the electrolyte tube is of beta alumina and the ceramic closure is a plate also of beta alumina with a nonconductive region around the current collector formed of alpha alumina.

Claim 19

A cell as claimed in claim 10 and having liquid sodium within the electrolyte tube and having sulphur/sodium polysulphides in the region around the electrolyte tube within the housing and between said ceramic closure and said metal closure member.

Claim 20

A cell as claimed in claim 10 wherein the metal closure element is sealed to the housing by welding around the periphery of the metal housing.

Claim 21

A cell as claimed in claim 10 wherein said metal current collector is a rod sealed into said ceramic closure by forcing the rod through an aperture in said ceramic closure.

Claim 22

A sodium sulphur cell as claimed in claim 10 wherein electrolyte tube has top and bottom ceramic end closures of solid electrolyte material.

Claim 23

A cell as claimed in claim 10 wherein said electrolyte tube is a cup-shaped member of beta alumina closed at one end and sealed at the other end by a plate of beta-alumina sealed to the tube.

Claim 24

A liquid alkali metal cell having a metal housing, a cylindrical electrolyte tube having an internal length between 1.5 times and 0.7 times its mean internal diameter and separating an inner region within the tube from an annular region between the outside of the tube and said housing, one of said regions containing the anodic material and the other the cathodic material of the cell, said electrolyte tube having an open end with an inwardly-extending ceramic flange sealed thereto, said flange having a central aperture, a first current collector extending through said central aperture and a metal closure element of annular form welded around its outer periphery to the housing and bonded around its inner periphery to said flange or to a ceramic element sealed thereto in a region around said first current collector of smaller diameter than the electrolyte tube, said housing forming a second current collector.

Claim 25

A liquid alkali metal cell having a metal housing, a cylindrical electrolyte tube having an internal length between 1.5 times and 0.7 times its mean internal diameter and separating an inner region within the tube from an annular region between the outside of the tube and said housing, one of said regions containing the anodic material and the other the cathodic material of the cell, said electrolyte tube having an open end with an inwardly-extending ceramic flange sealed thereto, said flange having a central aperture, a first current collector extending through said central aperture and a metal closure element of annular form welded around its outer periphery to the housing and bonded around its inner periphery to said flange or to a ceramic element sealed thereto in a region around said first current collector of smaller diameter than the electrolyte tube, said housing forming a second current collector.

Claim 26

A cell as claimed in claim 22 wherein the electrolyte tube has one integral closed end, said first current conductor and seal being formed at the other end of the tube.

Claim 27

A cell as claimed in claim 22 wherein the electrolyte tube has ceramic closure plates at both ends.

Claim 28

A cell as claimed in claim 22 wherein the liquid alkali metal is sodium and wherein the cathodic reactant is sulphur/sodium polysulphides.