Assembly Method for Liquid Metal Batteries

Electrochemical cells operating with molten electrodes and electrolyte, where the cathode is an alloy of a metal and metalloid, may be assembled in a discharged state by combining first an anodic metal with a cathodic metal to form a binary alloy. This binary alloy is then placed in a cell housing with the metalloid and the electrolyte, all in the solid state. The temperature is raised to, and maintained at, a temperature above the melting point of the highest melting component until components assembled into horizontal layers of electrolyte above a layer of a ternary alloy formed by the combination of the binary alloy and the metalloid. A charge and discharged cycle is then run through the electrochemical cell.