CN110546800A

CN110546800A - Bipolar battery and plate

Info

Publication number: CN110546800A
Application number: CN201880024881.7A
Authority: CN
Inventors: 斯蒂芬·K·费尔柴尔德; 小肯尼思·R·登格勒
Original assignee: East Penn Manufacturing Co Inc
Current assignee: East Penn Manufacturing Co Inc
Priority date: 2017-03-03
Filing date: 2018-03-05
Publication date: 2019-12-06
Also published as: MX2019010425A; CA3054581A1; CA3054581C; BR112019018287A2; JP2020510968A; WO2018161075A1; EP3590146A1

Abstract

A bipolar battery plate for a bipolar battery is disclosed. The bipolar battery plate has a frame, a substrate located within the frame, a first lead layer located on one side of the substrate, a second lead layer located on the other side of the substrate, a Positive Active Material (PAM) located on a surface of the first lead layer, and a Negative Active Material (NAM) located on a surface of the second lead layer. The base plate has a plurality of through holes, and a plurality of standoffs integrally formed on opposite side surfaces thereof. The first lead layer and the second lead layer are electrically connected to each other through a plurality of through holes.

Description

Bipolar battery and plate

Cross Reference to Related Applications

this application claims priority to U.S. continuation with application No. 15/449,238 filed on 3/2017; this U.S. continuation-in-part application claims priority to U.S. application No. 13/229,251, now U.S. patent 9,634,319, filed on 11/9/2011.

Technical Field

The present invention relates to a battery, and more particularly to a bipolar battery having a series of bipolar battery plates.

background

conventional bipolar batteries generally include an electrode having a metal conductive substrate on which a positive electrode active material forms one surface and a negative electrode active material forms the opposite surface. The active material is held on the metal conductive substrate, which is not conductive to electrolyte ions, by various means. The electrodes are arranged in a parallel stacked relationship to provide a multi-cell battery having an electrolyte and a separator that provides an interface between adjacent electrodes. A conventional unipolar electrode used at the end of the stack is electrically connected with an output terminal. Most bipolar batteries developed so far use a metal substrate. In particular, bipolar lead acid systems have used lead and lead alloys for this purpose. The use of lead alloys such as antimony may improve the strength of the substrate, but may increase corrosion and gassing.

In most known plates for bipolar batteries, a positive active material, typically in the form of a paste, is applied to one side of a metallic conductive substrate, while a negative active material is similarly applied to the opposite side. The plates may be received by a frame that seals the electrolyte between the plates so that the electrolyte cannot migrate through the plates.

in U.S. patent No.4,275,130, a bipolar battery construction 20 having a plurality of electrically conductive bipolar plates (biplates) 21 is disclosed. Each bipolar plate 21 may include a composite substrate sheet 34, the composite substrate sheet 34 including a continuous phase resin material that is non-conductive to electrolyte ions. The composite substrate sheet 34 also includes uniformly distributed, randomly dispersed conductive fibers 33 embedded in the material. The binder resin is a synthetic organic resin, and may be thermosetting or thermoplastic. The composite substrate sheet 34 has substantially flat opposing sides 35, the opposing sides 35 including portions at their surfaces that expose the embedded graphite fibers 33. The embedded graphite fibers not only provide electrical conductivity through the substrate sheet 34, but also impart a high degree of rigidity, stiffness, strength and stability to the thermoplastic material. The substrate sheet 34 may be manufactured in any suitable manner, such as by thoroughly mixing the thermoplastic material in particulate form with the graphite fibers. The mixture is heated in a mold and then pressure formed into a substrate sheet of a selected size and thickness. After the sheet is cured, the substantially flat side 35 can be easily treated or machined, such as by polishing, to eliminate pinholes or other irregularities in the side.

As disclosed, lead strips (lead strips) are bonded to the composite substrate sheet 34 by known plating processes. On the positive side 35, the frontal area between the lead strips 38 is suitably covered by a coating of a corrosion resistant resin 36, the corrosion resistant resin 36 being a fluorocarbon resin such as polytetrafluoroethylene (ptfe) which protects the adjacent graphite fibers and the polyethylene of the substrate 34 from anodic corrosion. On the negative electrode side 35, the front area between the lead strips 37 may be protected by a thin resin coating impermeable to the electrolyte, such as a polyethylene coating 36 a. In the manufacture of the bipolar plate 21, and after the composite substrate sheet 34 has been formed, a thin sheet of polytetrafluoroethylene may be bonded to the positive side 35. Prior to bonding, a window-like opening corresponding to the lead tape in length and width is cut out. Plating is then performed to bond the lead strip 38 to the exposed conductive graphite surface on the substrate side 35. The same manufacturing process can be used on the negative side 35 to coat the non-banded regions with polyethylene or other similar material. The plating of the negative strip can be carried out as well as the positive strip.

The separator 23 serves to support the positive electrode active material 24 and the negative electrode active material 25, and may be made of a suitable synthetic organic resin, preferably a thermoplastic material (e.g., microporous polyethylene).

The cell construction 20 includes a plurality of electrically conductive bipolar plates 21 whose peripheral boundaries or edges are supported and carried in a peripheral insulative housing member 22. A plurality of separators 23 are sandwiched and arranged between the bipolar plates 21. The separator carries a positive electrode active material 24 on one side thereof and a negative electrode active material 25 on the opposite side thereof. The housing member 22, together with the bipolar plate 21 and the separator plate 23, provides a chamber 26 for containing an electrolyte liquid. At each end of the cell construction 20, a standard bipolar plate 21 is attached to a current collector plate, of which 27 is a negative current collector plate and 28 is a positive current collector plate. Outside the end collectors 27 and 28, pressure members 30 are provided, which pressure elements 30 are interconnected by rods 31 having threaded portions for drawing the pressure member plates together and applying axial compression to the stacked arrangement of bipolar plates and separator plates.

The bipolar plate 21 is lightweight, rigid, but includes a bond line between the lead strip edge and the protective coating to resist corrosion and structural degradation to the substrate. Furthermore, a plating process is required to bond the lead strips 37, 38 to the conductive substrate with graphite fibers. The conductivity is limited by the size and type of amount of graphite fibers in the substrate. Additionally, multiple bipolar plates 21 and layers are required to be placed in separate housing members 22 and outer frames, all of which housing members 22 and outer frames require further processing steps for more components. The bipolar battery construction 20 is a complex design with multiple layers of materials and substrates assembled in multiple chambers 26 and bodies 43 secured together by a complex external frame.

disclosure of Invention

It is, among other objects, an object of the present invention to provide a bipolar battery having a simplified bipolar plate design in which active materials are incorporated into an insulating frame having a moldable substrate with perforations to improve electrical conductivity between the active materials. Furthermore, the bipolar cell is inexpensive to produce and does not require a complex external frame to support the bipolar plate.

Each bipolar battery plate has a frame, a substrate located within the frame, a first lead layer located on one side of the substrate, a second lead layer located on the other side of the substrate, a Positive Active Material (PAM) located on the surface of the first lead layer, and a Negative Active Material (NAM) located on the surface of the second lead layer. The base plate has a plurality of through holes, and a plurality of standoffs integrally formed on opposite side surfaces thereof. The first lead layer and the second lead layer are electrically connected to each other through a plurality of through holes.

drawings

The invention will be described in more detail below with reference to the appended drawings, which show exemplary embodiments of the invention and in which:

Figure 1 is a front view of a bipolar plate according to the present invention;

Figure 2 is a cross-sectional view of the bipolar plate taken along line 2-2 of figure 1;

fig. 3 is a perspective view of a bipolar battery according to the present invention;

Fig. 4 is an exploded perspective view of the bipolar battery of fig. 4;

fig. 5 is a partial cross-sectional view of a bipolar battery according to the present invention with a housing;

Fig. 6 is another partial cross-sectional view of a bipolar battery according to the present invention without a housing;

Figure 7 is a close-up view of a bipolar plate according to the present invention showing perforations in the base plate of the bipolar plate;

Figure 8 is another close-up view of a bipolar plate according to the present invention showing the non-conductive frame of the bipolar plate; and

figure 9 is another close-up view of a bipolar plate according to the present invention showing another non-conductive frame of the bipolar plate.

figure 10 is a perspective view of a bipolar plate according to an additional embodiment of the present invention.

Detailed Description

The present invention is described in more detail below with reference to the attached drawing figures, wherein like reference numerals refer to like elements. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

With reference to fig. 1 to 10, a bipolar battery 100 according to the present invention includes a plurality of bipolar plates 10, a spacer 22 holding an electrolyte 20, and a terminal portion 30. Each of these components is stacked together to complete a bipolar battery 100 according to the present invention, which bipolar battery 100 is of a compliant design with a minimal number of parts and without complex external support structures.

Referring now to fig. 1 and 2, a bipolar plate 10 according to the present invention will be discussed. The bipolar plate 10 includes a frame 11, a substrate 12, a plurality of perforations 13 extending along and through the front and back surfaces of the substrate 12, a lead foil 14, a first active material 16, and a second active material 18.

Typically, the substrate 12, lead foil 14, first active material 16, and second active material are incorporated into a frame 11 that provides support and protection for the bipolar plate 10. The substrate 12 is placed in the center of the frame 11, the lead foil 14 is placed on both sides of the substrate, and then the active materials 16, 18 are placed on the lead foil 14. The frame 11 is non-conductive. In the embodiment shown, the frame 11 is a moldable insulating polymer such as polypropylene, Acrylonitrile Butadiene Styrene (ABS), polycarbonate, a copolymer or a polymer blend. Since the frame 11 is moldable, the number of shape and size configurations is sufficient, which provides a bipolar plate 10 according to the invention that can be adapted to different uses.

In the illustrated embodiment, the frame 11 has a generally rectangular shape that provides support for the substrate 12 in the position frame 11. The frame 11 is a casing for the bipolar plate 10 and the bipolar battery 100. The outer surface of the frame 11 is the outer surface of the bipolar plate 10 and the bipolar battery 100. The surface of the frame 11 is generally flat, and in particular along the outer surface of the frame 11. The frame 11 supports itself and the bipolar plate 10 when assembled with the spacers 22 and terminal portions 30, particularly when the bipolar plate 10 is standing up against a flat opposing surface.

the frame 11 further includes a substrate receiving passage 11a and a material receiving passage 11b, as shown in fig. 2. The substrate receiving channel 11a is a groove or channel and the material receiving channel 11b is an opening in the frame 11 that receives the lead foil 14 and the active material 16, 18 on both stackable sides of the bipolar plate 10.

The substrate receiving passage 11a is a groove for receiving and fixing the substrate 12 when the substrate 12 is positioned in the frame 11. Other configurations of the substrate-receiving passage 11a are possible, including notches, recesses, or any securing mechanism that secures the substrate 12 within the frame 11. For example, the substrate 12 may be fixed to the frame 11 using welding, by an adhesive, or by a fastener. However, in the illustrated embodiment, the substrate 12 is secured in the substrate-receiving channel 11a during fabrication of the bipolar plate 10.

when the substrate 12 is positioned within the substrate-receiving channel 11a, each material-receiving channel 11b is positioned in a substantial center of the frame 11, which is separated from each other by the substrate 12. In addition, the lead foil 14 and the active materials 16, 18 are incorporated into the outer surface plane of the frame 11. These pairs of cavities are sized to securely receive the lead foil 14 and active materials 16, 18 within the frame 11.

In the illustrated embodiment, the substrate 12 is a separate insulating material with respect to the frame 11, wherein the substrate 12 is received and secured within the substrate receiving channel 11a of the frame 11. However, the frame 11 and the substrate 12 may be integrally formed of the same material as a unitary structure. During manufacture, the frame 11 and the base plate 12 are made in one piece from the same material. This may be performed by a process such as injection molding or other known methods.

In the illustrated embodiment, the substrate 12 is a generally non-conductive, insulative plastic, i.e., polypropylene, Acrylonitrile Butadiene Styrene (ABS), polycarbonate, a copolymer, or a polymer blend in the illustrated embodiment. As discussed briefly above, the base plate 12 may be made of the same material as the frame 11, regardless of whether the frame 11 and the base plate 12 are made of a one-piece construction.

In an alternative embodiment, as shown in FIG. 7, the substrate 112 is generally non-conductive and is made of an insulating plastic. However, the conductive fibers and material are uniformly dispersed throughout the insulating plastic. For example, the substrate 112 may be made of a non-corrosive plastic sold by Integral Technologies under the trade name Electroplate, which includes highly conductive regions. As shown in fig. 7, the substrate 112 includes a non-conductive resin-based material or thermoplastic 112a having a substantially homogeneous combination of micron-sized conductive particle powder and/or micron-sized fibers 112b within the resin or thermoplastic 112 a. As best shown in fig. 7, the conductor particles or fibers 112b are homogeneous throughout the bulk of the resin or thermoplastic 112 a. In this example, the diameter D of the conductor particles or fibers 112b in the powder is between about 3 microns and 12 microns. The conductive fibers of the conductive particles or fibers 112b have a diameter of between about 3 microns and 12 microns, typically in the range of 10 microns or in the range of about 8 microns to 12 microns, and a length of between about 2 millimeters and 14 millimeters. The micron conductive fibers of the conductor particles or fibers 112b may be metal fibers or metal-plated fibers. Furthermore, the metal-plated fibers may be formed by plating a metal onto the metal fibers or by plating a metal onto the non-metal fibers. Exemplary metal fibers include, but are not limited to, stainless steel fibers, copper fibers, nickel fibers, silver fibers, aluminum fibers, and the like or combinations thereof. Exemplary metal plating materials include, but are not limited to, copper, nickel, cobalt, silver, gold, palladium, platinum, ruthenium, and rhodium, and alloys thereof. Any plateable fiber can be used as the core of the non-metallic fiber. Exemplary non-metallic fibers include, but are not limited to, carbon, graphite, polyester, basalt, man-made and naturally occurring materials, and the like. In addition, superconductor metals (e.g., titanium, nickel, niobium, and zirconium, and alloys of titanium, nickel, niobium, and zirconium) may also be used as micron-sized conductive fibers and/or as metal plated on the fibers.

The conductor particles and/or fibers 112b are substantially homogeneous within the resin or thermoplastic 112 a. The substrate 112 comprises controlled areas of conductive surfaces on the substrate 112, wherein conductive material from the conductive particles or fibers 112b is exposed through a resin or thermoplastic 112a, which resin or thermoplastic 112a is conductively connected by a homogenization process. The conductive surface of the substrate 112 is controlled by further manufacturing techniques, such as etching or abrasive blasting, wherein the surface is roughened by chemical means or by pushing a stream of abrasive material at high pressure against the surface. The conductive particles and/or fibers 112b are then exposed and provide conductive areas of the substrate 112. The process provides a substrate 112 having a controlled amount of electrical conductivity, including the magnitude and area of the electrical conductivity.

It is also possible that the substrate 112 comprises a combination of conductive particles, powders and/or fibers 112b, which are substantially homogenized together in the insulating resin or thermoplastic 112a during the molding process. The homogenized material is molded into a polygonal shape as the substrate 112 that accommodates various custom designs or properties required for the bipolar plate 10 according to the present invention. The substrate 112 may then be molded with the frame 11 in a single manufacturing technique. This allows the bipolar plate 10 and the bipolar battery 100 to be simplified, with minimal components used and elimination of production steps. Furthermore, the properties of the substrate 112 and the battery 100 may be concentrated by providing and controlling conductive areas along the surface of the substrate 112. Since the frame 11 is insulating and the substrates 12, 112 are located in the substrate-receiving channels 11a, the bipolar plate 10 may serve as a frame for the bipolar battery 100 when assembled.

During manufacturing, the substrate 12 is insert molded into the substrate receiving channel 11a, or the frame 11 is overmolded onto the substrate 12. However, if the frame 11 and the base plate 12 are moldable together, i.e., the two pieces are inserted or overmolded together or injection molded as a single piece, the manufacturing steps of the bipolar plate 10 may be simplified with fewer components. In addition, the process allows for the ability to customize the size and shape of the bipolar plate 10 and bipolar battery 100 according to the present invention.

Referring now again to fig. 1 and 2, the substrate 12 and the substrate 112 shown in fig. 4-8 include: perforations 13 extending along the surface of the substrate 12, 112 and through the body through the opposite surface. In the embodiment shown, the perforations 13 are circular, but may be any shape in other respects. The perforations 13 are positioned in a symmetrical grid pattern. The perforations 13 are located in four quadrants (quadrants) of the illustrated substrate 12, 112. The positioning of the plurality of perforations 13 in a symmetrical grid arrangement provides uniform electrical conduction through the substrate 12, 112 when the lead foil 14 is placed on opposite sides of the substrate 12, 112.

Additionally, as best shown in fig. 5-9, the substrate 112 includes conductive particles, powders, and/or fibers 112b along a surface of the substrate 112 and through a body of the substrate 112. Typically, surface areas of the substrate 112 are insulating, while other areas are conductive due to conductive particles, powders, and/or fibers 112 b. As described above, the amount of conductive area can be controlled by fabricating the substrate 112. For example, the surface of the substrate may be roughened to expose conductive areas that may be customized in size and shape relative to the entire exposed surface side of the substrate 12, or the amount of conductive particles, powder, and/or fibers 112b may be controlled relative to the amount of insulating resin or thermoplastic 112 a. In the embodiment shown in fig. 5-9, the entire outer surface of the substrate 112 has been roughened to expose the conductive particles, powder, and/or fibers 12 b. Thus, the substrate is electrically conductive on the exposed surface side of the substrate, and the lead foil 14 is located on the conductor particles, powder and/or fibers 112 b.

Referring now to fig. 1, 2, 7 and 8, the lead foil 14 will be discussed as being located within the material-receiving channel 11b on the opposite side of the substrate 12, 112. The lead foils 14 are electrically conductive and are connected to each other by the perforations 13. More specifically, in the illustrated embodiment, the lead foils 14 are mechanically and electrically connected to each other. The substrates 12, 112 are typically insulating or based on insulating resin or conductor particles and/or fibers 112b in a thermoplastic 112a that include only limited area or conductivity. As a result, in the bipolar plate 10, particularly in the bipolar plate 10 having the substrate 12 exclusively made of an insulating material, the lead foils 14 are connected to each other using the perforation 13. As shown in fig. 2, the lead foils 14 are welded together by resistance welding or other processes known in the art. On the other hand, as shown in fig. 7, a bipolar plate 10 having a substrate 112 comprising conductor particles or fibers 112b homogenized in a resin or thermoplastic 112a may also comprise perforations 113, which allow further control and improvement of the electrical conductivity between the lead foil 14 and the active material 16, 18 in the bipolar plate 10 according to the present invention.

In either case, the size, shape, or grid pattern of the perforations 13 may vary, but is large enough so that the lead foil 14 may be positioned in the perforations 13 and pass through the perforations 13 and connect to adjacent lead foils 14. The perforations 13 may be molded or milled into the substrate 12 during manufacturing. Referring to fig. 1, 2 and 8, there is shown a lead foil 14, which is located on both exposed surfaces of the substrates 12, 112, respectively, and which is sized to fit within the material-receiving channel 11b of the frame 11. The lead foils 14 are sized to fit securely in the material receiving channel 11b such that the frame 11 surrounds each lead foil 14 on both sides of the base plate 12, 112. The lead foils 14 are mechanically and electrically connected through the perforations 13 as shown in fig. 7.

As shown in fig. 9, the lead foil 14 may be inserted into the substrate receiving channel 11 along with the substrates 12, 112 during manufacturing and assembly. The lead foil 14 may be incorporated into the frame during an insert molding, overmolding or similar manufacturing technique during which the lead foil 14 and substrate 12, 112 are manufactured within the substrate receiving channel 11 a. The lead foil 14 is positioned on the opposite surface of the substrate 12, 112 and then inserted or fabricated into the frame 11. The lead foil 14 may be applied by known plating, vapor deposition or cold flame spraying methods.

the lead foil 14 may also be a paste with lead that is positioned along the front and back surfaces of the substrate 12, 112. The paste is spread on the opposing surfaces (i.e., the front and back surfaces) of the base plates 12, 112 and within the perforations 13. The paste connects both sides of the substrates 12, 112 through the through-holes 13. The paste will be thick enough to provide connectivity between the pastes on each side, but should not be thicker than the material receiving passageway 11b given that the active materials 16, 18 are also located within the material receiving passageway 11 b.

referring to fig. 2 and 5-9, active materials 16, 18 are shown on the exposed side of the lead foil 14, facing away from the substrate 12, 112. The first active material layer 16 is a positive active material Paste (PAM) applied on one lead foil 14, and a Negative Active Material (NAM) is applied on the other lead foil 14 as a second active material 18. In the illustrated embodiment, the positive electrode active material Paste (PAM) and the negative electrode active material (NAM) are pastes of lead or lead oxide mixed with sulfuric acid, water, fiber, and carbon.

The thickness of the active materials 16, 18 (i.e., NAM and PAM) should not extend outside of the material-receiving channel 11b of the frame 11. More specifically, the total thickness Tm of the substrate 12, 112, lead foil 14 and active material 16, 18 is less than the thickness Tf of the frame 11.

The frame 11 surrounds the substrates 12, 112, lead foil 14 and active materials 16, 18. As a result, when the assembled bipolar battery 100 is assembled in the form of a stack of bipolar plates 10, the frame 11 serves as a support and outer surface for the bipolar battery 100. The number of assembly steps and components can be minimized. In addition, because the frame 11 and substrate 12 can be molded into various shapes and sizes, the bipolar battery 100 and bipolar plate 10 can be easily customized for various applications.

Referring now to fig. 3 and 4, a spacer 22 is shown stacked and sealed with a bipolar plate 10 according to the present invention and used to hold an electrolyte 20 for a bipolar cell 100.

Spacers 22 are shown between adjacent bipolar plates 10 in the stack. The spacer 22 is substantially a case having a similar size to the frame 11, and includes an electrolyte receiving space 22a, as shown in fig. 3 to 6. The electrolyte receiving space 22a is a hole passing through the electrolyte receiving space 22a, which is substantially located at the center of the spacer 22 and holds the electrolyte 20. The spacers 22 prevent the electrolyte 20 from leaking when sealed between two adjacent bipolar plates 10 and allow the electrolyte 20 to provide electrical conductivity between the bipolar plates 10.

As shown in fig. 5 and 6, at least one electrolyte receiving channel 22b is provided in the separator 22, the electrolyte receiving channel 22b being located on an outer surface of the separator 22 and leading into the electrolyte receiving space 22 a. After the spacers 22 are assembled and sealed with the adjacent bipolar plates 10, a user may provide electrolyte 20 through the electrolyte receiving channels 22b and into the electrolyte receiving space 22 a. Typically, electrolyte receiving channel 22b is an opening in spacer 22 that extends through spacer 22 and into electrolyte receiving space 22 a. However, other mechanisms or structures known in the art may be used to allow the electrolyte 20 to enter the electrolyte receiving space 22 a. When the receiving passage 22b is not used, the receiving passage 22b may be plugged or blocked by a certain capacity, or used to discharge gas from the electrolyte receiving space 22 a.

The electrolyte 20 can be a variety of substances, including acids. However, the substance should be a substance that includes free ions that make the substance electrically conductive. The electrolyte 20 may be a solution, molten material, and/or solid that facilitates the creation of a battery circuit by ions of the electrolyte. In a bipolar battery 100 according to the present invention, the active materials 16, 118 provide a reaction that converts chemical energy to electrical energy, and the electrolyte 20 also allows electrical energy to flow from the bipolar plate 10 to another bipolar plate 10, as well as to the electrodes 36 of the battery 100.

In the illustrated embodiment, the electrolyte 20 is an acid that is held in Absorbent Glass Mat (AGM)21, as shown in fig. 4 and 5. The electrolyte 20 is held on the glass fiber wool 21 by capillary action. Very fine glass fibers are woven into the glass fiber wool 21 to increase the surface area sufficient to retain the electrolyte 20 on the cell during its useful life. The fibers of the glass fiber wool 21, including the fine glass fibers, are neither absorbent nor affected by the acidic electrolyte 20 in which the fibers reside. The size of the glass fiber wool may vary in size. However, in the illustrated embodiment, the glass fiber wool 21 is fitted within the electrolyte receiving space 22a, but has a larger thickness than the spacer 22. Additionally, in the illustrated embodiment, the electrolyte receiving space 22a additionally includes a space for a portion of the electrolyte 20, and more specifically includes a space for the glass fiber wool 21. As a result, the design of the bipolar battery 100 according to the present invention allows the spacers 22, which hold the glass fiber wool 21, to be uniformly stacked with the adjacent bipolar plate 10, with the active materials 16, 18 on the glass fiber wool 21 containing the electrolyte 20.

the glass fiber wool 21 may also be removed and the electrolyte 20 (e.g., gel electrolyte) is free to flow between adjacent active materials 16, 18 between adjacent stacked bipolar plates 10 on either side of the spacer 22.

In other embodiments, the spacer 22 may also be an extension of the frame 11. Typically, the frame 11 includes a deeper material receiving channel 11b so as to surround the lead foil 14 and the active materials 16, 18 and the electrolyte 20. Furthermore, if the frame 11 is sized such that the material-receiving channels 11b of the stackable bipolar plate 10 are also capable of holding the fiberglass wool 21 between each other, the lead foil 14, the active materials 16, 18, the fiberglass wool 21, and the electrolyte 20 are enclosed in the stacked and sealed bipolar plate 10. The frame 11 may include an electrolyte receiving channel 22b, the electrolyte receiving channel 22b extending through the frame and into the material receiving channel 11 b. In this embodiment, the bipolar plates 10 may be stacked and sealed to one another.

Referring now to fig. 4 to 6, the terminal portion 30 of the bipolar battery 100, which covers the end of the bipolar battery 100, will be discussed. Terminal portions 30 are stacked on opposite sides of the stacked bipolar plates 10, with the number of bipolar plates 10 stacked adjacent to each other depending on the electrical potential required for a particular cell design and shape.

Each terminal portion 30 includes an additional active material layer 32, a terminal plate 34, an electrode 36, and an end plate 38. End plates 38 are located on opposite ends of the stacked bipolar plates 10, with the active material 32, terminal plate 34, and electrode 36 located within the end plates 38.

The active material 32 is provided to increase the current through the bipolar battery 100 from one terminal portion 30 to the other terminal portion 30. The active material 32 is made of a material that interacts with the adjacent active material 16, 18 from the adjacent bipolar plate 10. As described above, since the spacers 22 and the electrolyte 20 are located at each stackable side of the bipolar plate 10, the spacers 22 are located between the terminal portions 30 and the outer bipolar plate 10. As a result, ions may flow freely through electrolyte 20 and onto active material 32 of terminal portion 30.

As shown in fig. 5 to 6, the terminal plate 34 is provided and enclosed in the terminal portion 30. The terminal plate 34 is electrically conductive and is typically metal. The terminal plate 34 is attached to an electrode 36, which is either the anode or the cathode of the bipolar battery 100. The anode is defined as the electrode 36 where electrons leave the cell and oxidation occurs, and the cathode is defined as the electrode 36 where electrons enter the cell and reduction occurs. Each electrode 36 may be either an anode or a cathode depending on the direction of current flow through the cell. Both the terminal plate 34 and the electrode 36 may be formed as one piece.

As shown in fig. 4-6, end plates 38 are electrically non-conductive and provide structural support for the ends of bipolar battery 100 according to the present invention. The end plate 38 includes a terminal receiving passage 38a, which is a recess in which the terminal plate 34, the electrode 36, and the active material 32 are placed. Additionally, as with material-receiving passageway 11b, terminal-receiving passageway 38a provides sufficient clearance for an amount of electrolyte 20 to be surrounded by terminal portion 30, and particularly within material-receiving passageway 11b along with active material 32, terminal plate 34, and electrode 36. In the embodiment shown in fig. 5 and 6, the terminal-receiving passageway 38a also provides sufficient space to receive and surround a portion of the glass fiber wool 21.

Referring to fig. 3 to 8, the components of the bipolar battery 100 according to the present invention will be further discussed.

The bipolar plate 10 is assembled and manufactured by using the substrates 12 and 112 to which the frame 11 is fixed. The substrates 12, 112 include perforations 13 and/or conductive particles or fibers 112b and are typically molded together with the frame 11 as a single or separate component. When the substrate 12, 112 is placed in the frame 11, the lead foil 14 is placed on both exposed surfaces of the substrate 12, 112 together with the material-receiving passage 11b of the frame 11. The lead foils 14 are mechanically connected together through the perforations 13 and are electrically connected by conductor particles or fibers 112b disposed in the substrates 12, 112. The first active material 16 is then disposed in the material-receiving channel 11b on one side of the substrate 12, while the second active material 18 is disposed in the material-receiving channel 11b on the other side of the substrate. As a result, the frame 11 incorporates the substrate 12, lead foil 14, and active materials 16, 18 within the surface boundaries of the bipolar plate 10.

the bipolar plates 10 are then stacked adjacent to one another with a spacer 22 disposed between each stacked bipolar plate. The electrolyte 20 is disposed in the electrolyte receiving space 22a, and the electrolyte receiving space 22a has a size similar to the material receiving passage 11b of the frame 11. It is also possible to provide the fiber glass fiber wool 21 in the electrolyte receiving space 22a and to supply the electrolyte 20 into the fiber glass fiber wool 21 through the electrolyte receiving passage 22 b. The spacers 22 and bipolar plates 10 are uniformly stacked adjacent to one another and then sealed. Since the spacers 22 and the stacked bipolar plates 10 comprise non-conductive outer surfaces, the spacers 22 and the frame 11 of the bipolar plates 10 form an outer casing of the bipolar battery 100. The frame 11 and the spacer 22 of the bipolar plate 10 may be secured to each other by any method known in the art such that the contact surfaces of the spacer 22 and the frame 11 are secured and sealed to each other. For example, adhesives may be used to join and seal surfaces together. Additionally, when the terminal portions 30 are assembled, they may be placed over the stacked bipolar plates 10 and spacers 22 and then sealed in the same manner.

the end plates 38, spacers 22, and frame 11 may also include a securing mechanism (not shown) (e.g., a joining technique or fasteners) to connect the pieces of the bipolar battery 100 together. A sealant may then be applied to provide a seal around bipolar battery 100 and, more specifically, around connecting end plates 38, spacers 22, and frame 11.

The bipolar plates 10 may be stacked and secured adjacent to one another without the spacers 22. However, when sealing the stacked bipolar plates 10 together, the material-receiving channel 11b should be large enough to hold and enclose the lead foil 14, active materials 16, 18, and electrolyte 20, including fiberglass fiber wool 21. In addition, the frame 11 should include at least one electrolyte receiving channel 22b in an extension of the frame 11 so that the electrolyte 20 can be supplied into the material receiving channel 11b of the frame 11 or the electrolyte 20 is allowed to be discharged.

The number of bipolar plates 10 used in the bipolar battery 100 is a matter of design choice, depending on the size of the battery 100 and the desired potential. In the embodiment shown, there are at least three bipolar plates 10 stacked adjacent to each other. Terminal portions 30 are located at opposite ends of the stacked bipolar plates 10 and electrolyte 20, the terminal portions 30 including an active material layer 32, a terminal plate 34, and an electrode 36, and an end plate 38. In the illustrated embodiment, the outer surfaces of the spacer 22 and the frame 11 are substantially flush with each other when stacked and sealed. This design provides a smooth outer support surface. However, it is possible that irregularities may exist in the surface. For example, the spacer 22 may be larger than the frame 11; however, the electrolyte receiving space 22a cannot be larger than the frame 11. Additionally, the material receiving channel 11b cannot be larger than the spacer 22. In either case, it can be difficult to seal the spacers 22 and bipolar plates 10, and the electrolyte 20 may leak from the bipolar battery 100 after assembly and when the electrolyte 20 is located between adjacent bipolar plates 10.

Furthermore, when the end plates 38 are adjacently stacked to adjacent spacers 22 and/or frames 11 of adjacent bipolar plates 10, the outer surfaces of the end plates 38, spacers 22, and frames 11 should be substantially flush. However, it is possible that irregularities may exist in the surface. For example, the end plates 38 may be slightly larger than the spacers 22, and the spacers 22 may be larger than the frame 11. However, the terminal-receiving channels 38a should not be larger than the receiving channels 22b or the frame 11. Additionally, terminal-receiving passageway 38a should not be larger than material-receiving passageway 11b or the frame, or end plate 38 should not be smaller than spacer 22. In either case, after assembly and with the electrolyte 20 disposed between the stacked bipolar plates 10, the electrolyte 20 may leak from the bipolar battery 100. Generally, a frame 11 supports the bipolar plate 10 and surrounds the substrate 12, lead foil 14 and active materials 16, 18 and electrolyte. When stacked, the bipolar plate 10, along with the adjacent spacers 20 and the stacked terminal portions 30, provide an external support surface for the bipolar battery 100. This configuration provides a bipolar battery 100 having a simplified design with fewer manufacturing steps and components than are required in the prior art. Because frame 10, spacers 22, and end plates 38 are insulating plastic and moldable, bipolar battery 100 can be customized to suit shape and size requirements depending on the potential and use.

In another embodiment, as shown in fig. 5, there is also provided a protective case 200 that encloses the bipolar battery 100 according to the present invention. The housing 200 will include a body 202, a cover 204, and an electrode receiving space 206 such that the electrode 36 extends out of the housing 200. Unlike the external structure of the bipolar battery 100, the case 20 can be used to house the bipolar battery 100 and provide greater protection.

In another embodiment, as shown in fig. 10, the bipolar plate 10 of the above-described embodiment may further include a plurality of standoffs 40 on each side of the substrate 12, 112. Standoffs 40 are integrally formed on each side of the base 12, 112 and are spaced apart from the perforations 13. In the embodiment shown in fig. 10, the lead foil 14 on the base plate 12, 112 has a hole 41 corresponding to the support 40 so that the lead foil 14 receives the support 40 and is located on the surface of the base plate 12, 112.

when assembling the bipolar plate 10 with standoffs 40 into a bipolar battery, the frame 11 and standoffs 40 of one bipolar plate 10 are attached to the frame 11 and standoffs 40, respectively, of the other bipolar plate 10, thereby providing uniform spacing and structural integrity between the plates 10 of the bipolar battery assembly. The frame 11 of one bipolar plate 10 may be attached to the frame 11 of the other bipolar plate 10 by any type of welding known to those of ordinary skill in the art, including ultrasonic welding, chemical welding, solvent welding, spin welding, or hot plate welding. Alternatively, the frame 11 may be attached to the other frame 11 by any mechanical connection known to those of ordinary skill in the art, including a hook and latch or ball and socket connection. The standoffs 40 of one bipolar plate 10 may be attached to the standoffs 40 of another bipolar plate 10 by any type of plastic welding known to those of ordinary skill in the art, including ultrasonic welding, chemical welding, solvent welding, spin welding, or hot plate welding. Alternatively, the mount 40 may be attached to another mount 40 by any type of mechanical connection known to those of ordinary skill in the art, including a hook and latch or ball and socket connection.

The above shows some possibilities for implementing the invention. Many other embodiments are possible within the scope and spirit of the invention. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents.

Claims

1. A bipolar battery plate for a bipolar battery, comprising:

A frame;

A substrate disposed within the frame and having:

A plurality of perforations; and

A plurality of seats integrally formed on the opposite side surfaces;

A first lead layer on one side of the substrate;

A second lead layer on the other side of the substrate, the first and second lead layers being electrically connected to each other through the plurality of through holes;

a positive electrode active material PAM on a surface of the first lead layer; and

and a negative active material NAM on a surface of the second lead layer.

2. The bipolar battery plate according to claim 1, wherein the first and second lead layers have holes corresponding to the plurality of standoffs, the holes being aligned with the standoffs when the first and second lead layers are on each side of the substrate.

3. The bipolar battery plate according to claim 1, wherein the frame is a moldable insulating polymer.

4. the bipolar battery plate according to claim 1, wherein the frame is an outer wall of the bipolar battery, the outer wall providing structural support for the bipolar battery.

5. The bipolar battery plate according to claim 1, wherein the substrate is made of the same material as the frame in a one-piece construction.

6. The bipolar battery plate according to claim 1, wherein the substrate is a non-conductive insulating plastic with conductive particles uniformly dispersed throughout the insulating plastic.

7. The bipolar battery plate according to claim 6, wherein the substrate includes a conductive surface, wherein the surface of the substrate is roughened by chemical or abrasion, and the conductive particles are exposed to the exterior of the insulating plastic.

8. the bipolar battery plate according to claim 1, wherein the perforations are located along and extend through the substrate.

9. The bipolar battery plate according to claim 8, wherein the lead layer is a lead foil that is electrically conductive through the perforations.

10. The bipolar battery plate of claim 9, wherein said lead foils are mechanically and electrically connected to each other through said perforations.

11. The bipolar battery plate of claim 10, wherein said lead foils are welded together by resistance welding.

12. The bipolar battery plate according to claim 1, wherein the first and second lead layers are lead pastes positioned along front and back surfaces of the substrate.

13. The bipolar battery plate according to claim 12, wherein the first lead layer is spread over the front surface of the substrate and within at least one of the perforations such that the first lead layer is connected to the second lead layer on the opposite side.

14. the bipolar battery plate according to claim 1, wherein the positive active material is a paste applied on the first lead layer and the negative active material is a paste applied on the second lead layer.

15. A bipolar battery comprising:

A plurality of plates positioned adjacent to one another, each plate having:

A frame;

A substrate disposed within the frame, having:

A plurality of perforations; and

a plurality of seats integrally formed on the opposite side surfaces;

A first lead layer on one side of the substrate;

A negative electrode active material NAM on a surface of the second lead layer;

A pair of terminal portions on opposite ends of the stacked plurality of bipolar plates; and

An electrolyte between each of the plurality of bipolar plates and the pair of terminal portions.

16. The bipolar battery plate according to claim 15, wherein the first and second lead layers have holes corresponding to the plurality of standoffs, the holes being aligned with the standoffs when the first and second lead layers are on each side of the substrate.

17. the bipolar battery plate according to claim 15, wherein the frames on the plurality of plates are attached together.

18. The bipolar battery plate according to claim 15, wherein the plurality of standoffs of one plate are attached to the plurality of standoffs of another plate.

19. the bipolar battery plate according to claim 18, wherein the standoff of one plate is attached to the standoff of the other plate by ultrasonic welding, chemical welding, solvent welding, spin welding, or hot plate welding.

20. Bipolar battery plate according to claim 18, wherein the mount of one plate is attached to the mount of the other plate by a hook and latch or ball and socket connection.