JP2020510968A - Bipolar battery and plate - Google Patents

Abstract

A bipolar battery plate for a bipolar battery is disclosed. The bipolar battery plate includes a frame, a base material arranged in the frame, a first lead layer arranged on one side of the base material, a second lead layer arranged on the other side of the base material, and a surface of the first lead layer. And a negative electrode active material (NAM) disposed on the surface of the second lead layer. The substrate has a plurality of perforations and a plurality of standoffs integrally formed on opposite sides thereof. The first and second lead layers are electrically connected to each other via the plurality of perforations.

Description

(Cross-reference to related applications)
This application claims the benefit of U.S. application Ser. No. 15 / 449,238, filed Mar. 3, 2017, which is filed on Sep. 9, 2011. Claims priority of filed U.S. application Ser. No. 13 / 229,251 and is currently patented as U.S. Pat. No. 9,634,319.

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

  Conventional bipolar batteries generally include an electrode having a metal conductive substrate in which a positive electrode active material forms one surface and a negative electrode active material forms an opposite surface. The active material is held by various means on a metal conductive substrate that is non-conductive to electrolyte ions. The electrodes are arranged in a parallel stacked relationship to provide a multi-cell battery with electrolyte and separator plates providing an interface between adjacent electrodes. Conventional monopolar electrodes used at both ends of the stack are electrically connected to the output terminals. Most bipolar batteries developed to date use metal substrates. Specifically, bipolar lead-acid battery systems utilize an alloy of lead and lead for this purpose. The use of a lead alloy such as antimony provides strength to the substrate but increases corrosion and outgassing.

  In most known plates for bipolar batteries, the positive electrode active material, usually in the form of a paste, is applied to one side of the metal conductive substrate, while the negative electrode active material is similarly applied to the other side. The plates may be provided on a frame that seals the electrolyte between the plates so that they cannot move through the plates.

  U.S. Pat. No. 4,275,130 discloses a bipolar battery structure 20 having a plurality of conductive bipolar plates 21. Each bipolar plate 21 can include a composite base sheet 34 that includes a continuous phase resin material that is non-conductive to electrolyte ions. The composite substrate sheet 34 also includes conductive fibers 33 uniformly distributed and randomly dispersed embedded in the material. The binder resin is a synthetic organic resin, and may be thermosetting or thermoplastic. The composite substrate sheet 34 has sufficiently flat opposing sides 35 that include on their surface an exposure of a portion of the embedded graphite fibers 33. The embedded graphite fibers not only provide conductivity through the substrate sheet 34, but also impart a high degree of stiffness, stiffness, strength, and stability to the thermoplastic material. The base sheet 34 may be made in any suitable manner, such as by thoroughly mixing a thermoplastic material in particulate form with the graphite fibers. After heating the mixture in a mold, it is pressure molded into a substrate sheet of the selected size and thickness. After the sheet is cured, the sufficiently flat sides 35 may be immediately handled or treated, for example, by buffing, to remove side pinholes or other irregularities.

  As disclosed, the lead stripes are joined to the composite substrate sheet 34 by known plating processes. On the side surface 35 of the positive electrode, the surface area between the lead stripes 38 is made of a corrosion-resistant resin 36, such as Teflon (polytetrofluoroethylene), which is suitable for protecting against graphite anodic corrosion of adjacent graphite fibers and polyethylene of the substrate 34. Covered with coating. On the side surface 35 of the negative electrode, the surface area between the lead stripes 37 may be protected by a thin coating of resin impermeable to the electrolyte, such as a polyethylene coating 36a. In the manufacture of the bipolar plate 21, after the composite base sheet 34 is formed, a thin Teflon sheet may be joined to the side surface 35 of the positive electrode. Prior to bonding, an opening, such as a window, whose length and width correspond to the lead stripe, is cut out. Subsequent plating joins the lead stripes 38 to the exposed conductive graphite surface on the substrate side 35. Utilizing the same manufacturing process on the negative side 35, non-striped areas may be coated with polyethylene or other similar material. The plating of the stripes of the negative electrode may be realized in the same manner as the stripes of the positive electrode.

  The separator plate 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 such as microporous polyethylene.

  The battery structure 20 includes a plurality of conductive bipolar plates 21, the peripheral boundaries or margins of which are supported and carried within a peripheral insulating casing member 22. A plurality of separator plates 23 are interposed between the bipolar plates 21 and arranged. The separator plate carries a positive electrode active material 24 on one side and a negative electrode active material 25 on the other side. The casing member 22, together with the bipolar plate 21 and the separator plate 23, provide a chamber 26 for containing the electrolyte solution. At each end of the battery structure 20, a standard bipolar plate 21 interfaces with a current collector, 27 is a negative current collector, and 28 is a positive current collector. Outside the end collectors 27 and 28 are provided pressure members 30 interconnected by rods 31 having threads for drawing the pressure member plates together and applying axial compression to the stacked arrangement of bipolar and separator plates. .

  The bipolar plate 21 is lightweight and rigid, but has a bond line between the lead stripe edge and the protective coating to resist corrosion and structural degradation of the substrate. In addition, a plating process is required to join the lead stripes 37, 38 to a conductive substrate having graphite fibers. The conductivity is limited by the size and amount of graphite fibers in the substrate. In addition, the bipolar plates 21 and layers need to fit in separate casing members 22 and outer frames, all of which require additional processing steps for more components. The bipolar battery structure 20 is a complex design having many layers of materials and substrates assembled into a plurality of chambers 26 and a body 43 secured together by a complex outer frame.

  It is an object of the present invention, inter alia, to provide a bipolar battery having a simplified bipolar plate design.

The active material is placed in an insulating frame with a moldable substrate with perforations to improve the conductivity between the active materials, the bipolar battery can be manufactured inexpensively, and the complexities for supporting the bipolar plate Does not require an external frame.
Each bipolar battery plate includes a frame, a substrate disposed in the frame, a first lead layer disposed on one side of the substrate, a second lead layer disposed on the other side of the substrate, and a first lead layer. And a negative electrode active material (NAM) disposed on the surface of the second lead layer. The substrate has a plurality of perforations and a plurality of standoffs integrally formed on opposite sides thereof. The first and second lead layers are electrically connected to each other through a plurality of perforations.

The invention will be explained in more detail below with reference to the figures shown in the drawings, which show exemplary embodiments of the invention.
1 is a front view of a bipolar plate according to the present invention. FIG. 2 is a sectional view of the bipolar plate taken along line 2-2 in FIG. 1. 1 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. FIG. 2 is a partial sectional view of a bipolar battery according to the present invention having a casing. FIG. 4 is another partial cross-sectional view of a bipolar battery according to the present invention without a casing. 1 is an enlarged view of a bipolar plate according to the present invention, showing perforations in the base material of the bipolar plate. FIG. 4 is another enlarged view of the bipolar plate according to the present invention, showing the non-conductive frame of the bipolar plate. FIG. 4 is another enlarged view of the bipolar plate according to the present invention, showing another non-conductive frame of the bipolar plate. FIG. 9 is a perspective view of a bipolar plate according to an additional embodiment of the present invention.

  The present invention is described in more detail below with reference to the drawings, wherein like reference numerals refer to like elements. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are thoroughly described. It is complete and provided to fully convey the concepts of the invention to those skilled in the art.

  Referring to FIGS. 1 to 10, a bipolar battery 100 according to the present invention includes a plurality of bipolar plates 10, spacers 22 for holding electrolytes 20, and terminals 30. Each of these components is stacked together to complete the bipolar battery 100 according to the present invention, which is an adaptable design with a minimal number of parts that lack complex external support structures.

  Here, the bipolar plate 10 according to the present invention will be described with reference to FIGS. The bipolar plate 10 includes a frame 11, a base material 12, a plurality of perforations 13 extending along the front and rear surfaces of the base material 12, a lead foil 14, a first active material 16, and a second active material 18.

  Generally, the base material 12, the lead foil 14, the first active material 16, and the second active material are put in the frame 11, and support and protect the bipolar plate 10. The base material 12 is disposed at the center of the frame 11, the lead foils 14 are disposed on both sides of the base material, and the active materials 16, 18 are then disposed on the lead foil 14. The frame 11 is non-conductive. In the embodiment shown, frame 11 is a moldable insulating polymer such as polypropylene, acrylonitrile butadiene styrene (ABS), polycarbonate, copolymer, or polymer blend. Since the frame 11 is moldable, the number of shapes and sizes of configurations is abundant, which provides the bipolar plate 10 according to the invention, which can be adjusted for different applications.

  In the embodiment shown, the frame 11 has a generally rectangular shape and supports the substrate 12 when disposed within the frame 11. The frame 11 is a casing of the bipolar plate 10 like the bipolar battery 10. 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, in particular along the outer surface of the frame 11. When assembled with the spacers 22 and the terminals 30, the frame 11 supports itself like the bipolar plate 10, especially when the bipolar plate 10 stands upright against a flat opposing surface.

  As shown in FIG. 2, the frame 11 further includes a base material accommodating passage 11a and a material accommodating passage 11b. The base material accommodating passage 11a is a groove or a channel, while the material accommodating passage 11b is an opening of the frame 11 accommodating the lead foils 14 and the active materials 16, 18 on both sides of the bipolar plate 10 which can be laminated.

  The base material accommodating passage 11 a is a groove used for housing and fixing the base material 12 when the base material 12 is disposed in the frame 11. Other configurations of the substrate receiving passage 11a are possible, including notches, depressions, recesses, or any securing mechanism that secures the substrate 12 within the frame 11. For example, the substrate 12 can be fixed to the frame 11 using welding, by adhesive, or by fasteners. However, in the illustrated embodiment, the substrate 12 is fixed to the substrate receiving passage 11a during the manufacture of the bipolar plate 10.

  Each material accommodating passage 11b is divided by the substrate 12 when the substrate 12 is disposed in the substrate accommodating passage 11a, and is disposed substantially at the center of the frame 11. Further, the lead foil 14 and the active materials 16 and 18 are put on the outer surface of the frame 11. These gaps are sized to securely receive the lead foil 14 and the active materials 16, 18 in the frame 11.

  In the embodiment shown, the substrate 12 is a separate piece of insulating material with respect to the frame 11, and the substrate 12 is received and fixed in the substrate receiving passage 11 a of the frame 11. However, frame 11 and substrate 12 can be formed together as a monolithic structure from generally the same material. During manufacture, frame 11 and substrate 12 are integrally formed from the same material. This can be performed by a process such as injection molding or other known methods.

  The substrate 12 in the illustrated embodiment is a generally non-conductive insulating plastic, ie, polypropylene, acrylonitrile butadiene styrene (ABS), polycarbonate, copolymer, or polymer blend in the illustrated embodiment. As briefly described above, regardless of whether the frame 11 and the substrate 12 are prepared from a unitary structure, the substrate 12 can be prepared from the same material as the frame 11.

  In another embodiment, as shown in FIG. 7, the substrate 112 is generally non-conductive and is prepared from an insulating plastic. However, the conductive fibers and materials are evenly dispersed throughout the insulating plastic. For example, the substrate 112 may be prepared from a non-corrosive plastic sold by Integral Technologies under the trade name Electriplast with a highly conductive region. As shown in FIG. 7, the substrate 112 is fully homogenized within the non-conductive resin-based material or thermoplastic 112a with micron powder of conductive particles, and / or the resin or thermoplastic 112a. It comprises a combination of micron fibers 112b. As clearly shown in FIG. 7, the conductive particles or fibers 112b are homogenized throughout the body of the resin or thermoplastic 112a. In this example, the diameter D of the conductive particles in the powder or conductive particles of the fibers 112b is about 3 to 12 microns. The conductive fibers of the conductive particles or fibers 112b have a diameter in the range of about 3 to 12 microns, typically 10 microns or about 8 to 12 microns, and a length of about 2 to 14 millimeters. The micron conductive fibers of the conductive particles or fibers 112b can be metal fibers or metal plated fibers. Further, the metal-plated fibers may be formed by plating metal on metal fibers or by plating metal on non-metal fibers. Exemplary metal fibers include, but are not limited to, stainless steel fibers, copper fibers, nickel fibers, silver fibers, aluminum fibers or 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. Plateable fibers may be used as the core of the non-metallic fibers. Exemplary non-metallic fibers include, but are not limited to, carbon, graphite, polyester, basalt, artificial and natural materials, and the like. In addition, superconductor metals such as titanium, nickel, niobium, and zirconium, and alloys of titanium, nickel, niobium, and zirconium may also be used as metal plating on micron conductive fibers and / or fibers.

  The conductive particles and / or fibers 112b are sufficiently homogenized within the resin or thermoplastic 112a. The substrate 112 comprises a controlled area of a conductive surface on the substrate 112, and the conductive material from the conductive particles or fibers 112b is a resin or thermoplastic 112a conductively connected by a homogenization process. Exposed through. The conductive surface of the substrate 112 is controlled by additional manufacturing techniques such as etching or abrasive blasting, and the surface is roughened by driving a flow of abrasive material against the surface under chemical or high pressure. Next, the conductive particles and / or fibers 112b are exposed, providing conductive areas of the substrate 112. This process provides a controlled amount of conductive substrate 112 having a conductive size and area.

  It is also possible that the substrate 112 comprises a combination of both conductive particles, powder, and / or fibers 112b that are sufficiently homogenized together within the insulating resin or thermoplastic 112a during the molding process. The homogenized material is shaped into a polygon as the substrate 112 and conforms to the various custom designs or properties required for the bipolar plate 10 according to the present invention. Next, the substrate 112 may be molded with the frame 11 in a single manufacturing technique. This simplifies the bipolar plate 10 and the bipolar battery 100, uses minimal components, and eliminates production steps. Further, the properties of the substrate 112 and the battery 100 can be focused by providing and controlling a conductive region along the surface of the substrate 112. Since the frame 11 is insulative and the base materials 12 and 112 are arranged in the base material accommodating passage 11a, the bipolar plate 10 can function as a frame of the bipolar battery 100 when assembled.

  During manufacture, the substrate 12 is insert molded into the substrate receiving passage 11a or the frame 11 is overmolded on the substrate 12. However, if the frame 11 and the substrate 12 can be molded together, ie by inserting two parts together, by overmolding or by injection molding one monolithic part, the manufacturing steps of the bipolar plate 10 Can be simplified by reducing the number of parts. Furthermore, this process allows for the ability to customize the size and shape of the bipolar plate 10 and the bipolar battery 100 according to the present invention.

  Referring now back to FIGS. 1 and 2, the substrate 12 and substrate 112 shown in FIGS. 4-8 have a body extending along the surface of the substrate 12, 112 and through the opposite surface. With a perforation 13 passing therethrough. In the embodiment shown, the perforations 13 are circular, but can be any other shape. The perforations 13 are arranged in a symmetric grid pattern. The perforations 13 are arranged in four quadrants of the substrates 12, 112 shown. Having a number of perforations 13 arranged in a symmetric grid arrangement provides for uniform conduction through the substrates 12,112 when the lead foil 14 is disposed on the opposite side of the substrates 12,112.

  In addition, the substrate 112 includes conductive particles, powder, and / or fibers 112b that pass along the surface and through the body of the substrate 112, as clearly shown in FIGS. Generally, surface areas of the substrate 112 are insulative, while other areas are conductive resulting from conductive particles, powder, and / or fibers 112b. As described above, the amount of the conductive region can be controlled throughout the manufacture of the substrate 112. For example, the surface of the substrate can be roughened to expose conductive areas that can be custom in size and shape with respect to the entire exposed surface side of the substrate 12, or conductive particles, powders and / or fibers The amount of 112b can be controlled with respect to the amount of insulating resin or thermoplastic 112a. In the embodiment shown in FIGS. 5-9, the entire outer surface of substrate 112 has been roughened to expose conductive particles, powder, and / or fibers 12b. Thus, the substrate is conductive on the exposed side of the substrate, and the lead foil 14 is disposed on the conductive particles, powder, and / or fibers 112b.

  Here, with reference to FIGS. 1, 2, 7 and 8, the lead foil 14 arranged in the material accommodating passage 11 b on the opposite side of the base materials 12 and 112 will be described. The lead foils 14 are conductive and are connected to each other via the perforations 13. More specifically, in the embodiment shown, the lead foils 14 are mechanically and electrically connected to each other. The substrates 12, 112 are generally insulating or include only a limited area or conductivity based on conductive particles and / or fibers 112b in an insulating resin or thermoplastic 112a. As a result, the perforations 13 are used to connect the lead foils 14 of the bipolar plate 10 to one another, particularly in the case of a bipolar plate 10 having a substrate 12 prepared only from an insulating material. Lead foils 14 are welded together by resistance welding or other processes known in the art, as shown in FIG. On the other hand, as shown in FIG. 7, the bipolar plate 10 provided with the base material 112 including the conductive particles or fibers 112b homogenized with the resin or the thermoplastic substance 112a can also be provided with the perforations 113, and the bipolar plate according to the present invention is provided. Further control and efficiency of the electrical conductivity between the lead foil 14 of the plate 10 and the active materials 16, 18 are possible.

  In either case, the perforations 13 can vary in size, shape, or lattice pattern, but are large enough to allow the lead foil 14 to be placed through the perforations 13 and connected to an adjacent lead foil 14. The perforations 13 can be formed or milled into the substrate 12 during manufacture. Referring to FIGS. 1, 2 and 8, a lead foil 14 is shown, located on both exposed surfaces of the substrates 12, 112, respectively, and sized to fit within the material receiving passage 11b of the frame 11. is there. The lead foil 14 is dimensioned to fit tightly into the material receiving passage 11b such that the frame 11 contains the respective lead foils 14 arranged on both sides of the substrates 12,112. The lead foil 14 is mechanically and electrically connected through the perforations 13 as shown in FIG.

  As shown in FIG. 9, the lead foil 14 may be inserted into the base material accommodating passage 11a together with the base materials 12, 112 during manufacturing and assembly. The lead foil 14 may be encased in a frame during insert molding, overmolding, or similar manufacturing techniques in which the lead foil 14 and the substrates 12, 112 are manufactured in the substrate receiving passageway 11a. Lead foils 14 are placed on opposing surfaces of substrates 12, 112 and then inserted or manufactured into frame 11. The lead foil 14 can be applied by a known plating, vapor deposition, or cold flame spray method.

  In addition, the lead foil 14 can be a paste having lead disposed along the front and back surfaces of the base materials 12 and 112. The paste spreads in the perforations 13 over the opposite surfaces (ie, front and back) of the substrates 12,112. The paste connects both sides of the substrates 12, 112 via the perforations 13. The paste is thick enough to provide connectivity between the pastes on each side, but is thicker than the material containing passage 11b considering that the active materials 16, 18 are also located in the material containing passage 11b. must not.

  Referring to FIG. 2 and FIGS. 5 to 9, active materials 16 and 18 are shown, and are disposed on an exposed surface of the lead foil 14 facing the side opposite to the substrates 12 and 112. The first layer of the active material 16 is a positive electrode active material paste (PAM) applied on one lead foil 14, while the negative electrode active material (NAM) is a second lead material that is a second active material 18. 14 is applied. In the illustrated embodiment, the positive active material paste (PAM) and the negative active material (NAM) are lead or a paste of lead oxide mixed with sulfuric acid, water, fibers, and carbon.

The thickness of the active materials 16, 18 (ie, NAM and PAM) should not extend outside the material receiving passage 11 b of the frame 11. Rather, the thickness T _m of a whole of the substrate 12 and 112, lead foil 14, and the active material 16, 18 is smaller than the thickness T _f of the frame 11.

  The frame 11 contains the base materials 12 and 112, the lead foil 14, and the active materials 16 and 18. As a result, when bipolar battery 100 is assembled into a stack of bipolar plates 10, frame 11 functions as a support and outer surface for bipolar battery 100. Assembly procedures and the number of parts can be minimized. Furthermore, since the bipolar battery 100 and the bipolar plate 10 can form the frame 11 and the base material 12 into various shapes and sizes, the bipolar battery 100 and the bipolar plate 10 can be easily customized for various applications.

  Referring now to FIGS. 3 and 4, there is shown a spacer 22 used to stack and seal with a bipolar plate 10 according to the present invention and to hold an electrolyte 20 for a bipolar battery 100.

  Spacers 22 are shown between adjacent bipolar plates 10 to be stacked. The spacer 22 is essentially a casing having the same dimensions as the frame 11, and includes an electrolyte accommodating space 22a as shown in FIGS. The electrolyte accommodating space 22a is a hole that penetrates the electrolyte accommodating space 22a, is located substantially at the center of the spacer 22, and holds the electrolyte 20. The spacer 22, when sealed between two adjacent bipolar plates 10, prevents leakage of the electrolyte 20 and allows the electrolyte 20 to provide conductivity between the bipolar plates 10.

  As shown in FIGS. 5 and 6, at least one electrolyte containing channel 22b is provided in the spacer 22, is disposed on the outer surface of the spacer 22, and is directed to the electrolyte containing space 22a. After the spacer 22 is assembled and sealed with the adjacent bipolar plate 10, the user can provide the electrolyte 20 to the electrolyte receiving space 22a through the electrolyte receiving channel 22b. Generally, the electrolyte containing channel 22b is an opening in the spacer 22 that extends through the spacer 22 and into the electrolyte containing space 22a. However, other mechanisms or structures known in the art can be used to cause the electrolyte 20 to enter the electrolyte receiving space 22a. Electrolyte containing channel 22b may become plugged or plugged with some volume when not used or when used to evacuate gas from electrolyte containing space 22a.

  Electrolyte 20 can be a variety of materials including acids. However, the substance must be a substance containing free ions that make the substance conductive. The electrolyte 20 may be a solution, a molten material, and / or a solid, which helps to create a battery circuit via the ions of the electrolyte. In the bipolar battery 100 according to the present invention, the active materials 16, 18 provide a reaction that converts chemical energy into electrical energy, and the electrolyte 20 separates the electrical energy from the bipolar plate 10, as well as the electrodes 36 of the battery 100. To the bipolar plate 10.

  In the embodiment shown, the electrolyte 20 is an acid retained on an absorbing glass mat (AGM) 21, as shown in FIGS. Electrolyte 20 is held on glass mat 21 by capillary action. Very fine glass fibers are woven into the glass mat 21 to increase the surface area sufficient to retain sufficient electrolyte 20 on the cell over its lifetime. The fibers containing the fine glass fiber glass mat 21 do not absorb and are not affected by the acidic electrolyte 20 in which they are present. The size of the dimensions of the glass mat can vary. However, in the illustrated embodiment, the glass mat 21 fits within the electrolyte receiving space 22a, but is thicker than the spacer 22. Furthermore, in the illustrated embodiment, the electrolyte receiving space 22a further comprises a space for a part of the electrolyte 20, more specifically for the glass mat 21. As a result, the design of the bipolar battery 100 according to the present invention allows the spacers 22 holding the glass mat 21 to be evenly stacked with the adjacent bipolar plate 10, and the active materials 16, 18 are made of a glass mat containing the electrolyte 20. 21.

  Further, the glass mat 21 is removed, and the electrolyte 20 such as a gel electrolyte can freely flow between the adjacent active materials 16 and 18 between the adjacent stacked bipolar plates 10 on both sides of the spacer 22.

  In other embodiments, the spacer 22 can be an extension of the frame 11. In general, like the electrolyte 20, the frame 11 includes a deeper material accommodating passage 11b for receiving the lead foil 14 and the active material 16,18. Furthermore, if the dimensions of the frame 11 can be determined so that the material accommodating passages 11b of the stackable bipolar plate 10 can also hold the glass fiber mat 21 therebetween, the housed lead foil 14, active materials 16, 18, It surrounds the glass mat 21 and the electrolyte 20 in the laminated and sealed bipolar plate 10. The frame 11 may include an electrolyte containing channel 22b that extends through the frame and into the material containing passage 11b. In this embodiment, the bipolar plates 10 can be stacked and sealed together.

  Here, with reference to FIGS. 4 to 6, the terminal portion 30 of the bipolar battery 100 that covers an end of the bipolar battery 100 will be described. The terminals 30 are stacked on opposite sides of the stacked bipolar plate 10, and the number of stacked bipolar plates 10 adjacent to each other depends on the potential required for a particular battery design and shape.

  Each terminal section 30 includes an additional active material layer 32, a terminal plate 34, an electrode 36, and an end plate 38. The end plate 38 is arranged at the opposite end of the stacked bipolar plate 10 with the active material 32, the terminal plate 34, and the electrode 36 arranged in the end plate 38.

  Active material 32 is provided to increase the flow of electricity through bipolar battery 100 from one terminal 30 to the other. Active material 32 is made of a material that interacts with adjacent active materials 16, 18 from adjacent bipolar plate 10. As described above, since the spacer 22 and the electrolyte 20 are arranged on each of the stackable sides of the bipolar plate 10, the spacer 22 is arranged between the terminal portion 30 and the outer bipolar plate 10. As a result, ions can flow freely through the electrolyte 20 and reach the active material 32 of the terminal portion 30.

  As shown in FIGS. 5 and 6, a terminal plate 34 is provided and is inserted into the terminal portion 30. Terminal plate 34 is conductive and is generally metal. The terminal plate 34 is attached to an electrode 36 which is either an anode or a cathode of the bipolar battery 100. The anode is defined as the electrode 36 where electrons exit 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 can 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 can be integrally formed.

  As shown in FIGS. 4-6, the end plate 38 is non-conductive and provides structural support to the edge of the bipolar battery 100 according to the present invention. The end plate 38 includes a terminal accommodating passage 38a, which is a recess in which the terminal plate 34, the electrode 36, and the active material 32 are arranged. Further, similarly to the material accommodating passage 11b, the terminal accommodating passage 38a is provided with respect to the amount of the electrolyte 20 that is put into the material accommodating passage 11b together with the terminal portion 30, specifically, the active material 32, the terminal plate 34, and the electrode 36. Provide sufficient clearance. In the embodiment shown in FIGS. 5 and 6, the terminal receiving passage 38 a also provides sufficient space to receive and surround a portion of the glass mat 21.

  With reference to FIGS. 3 to 8, the assembly of the bipolar battery 100 according to the present invention will be further described.

  The bipolar plate 10 is manufactured and assembled together with the substrates 12 and 112 fixed to the frame 11. Substrates 12, 112 include perforations 13 and / or conductive particles or fibers 112b and are generally molded with frame 11 as a single or separate component. When the substrates 12, 112 are disposed in the frame 11, the lead foil 14 is disposed together with the material accommodating passages 11 b of the frame 11 on both exposed surfaces of the substrates 12, 112. The lead foils 14 are mechanically connected together via the perforations 13 and are electrically connected via conductive particles or fibers 112 b provided on the base materials 12 and 112. Next, the first active material 16 is arranged in the material accommodating passage 11b on one side of the substrate 12, while the second active material 18 is arranged on the other side of the substrate in the material accommodating passage 11b. As a result, the frame 11 places the base material 12, the lead foil 14, and the active materials 16 and 18 within the surface boundary of the bipolar plate 10.

  The bipolar plates 10 are then stacked adjacent to each other with spacers 22 provided between each stacked bipolar plate. The electrolyte 20 is provided in an electrolyte storage space 22 a having the same dimensions as the material storage passage 11 b of the frame 11. Similarly, a glass fiber mat 21 can be provided in the electrolyte containing space 22a, and the electrolyte 20 is provided on the glass fiber mat 21 through the electrolyte containing channel 22b. The spacer 22 and the bipolar plate 10 are evenly stacked adjacent to each other and then sealed. The spacer 22 and the frame 11 of the bipolar plate 10 form the outer shell of the bipolar battery 100 because the spacer 22 and the stacked bipolar plate 10 have a non-conductive outer surface. The frame 11 and the spacer 22 of the bipolar plate 10 can be fixed to each other by any method known in the art such that the contact surfaces of the spacer 22 and the frame 11 are fixed and sealed to each other. For example, adhesives can be used to connect and seal the surfaces together. In addition, once the terminals 30 have been assembled, they can be placed on the laminated bipolar plate 10 and the spacers 22 and then sealed in the same manner.

  The end plate 38, the spacer 22, and the frame 11 may be provided with a fixing mechanism (not shown) such as a joining technique or a fastener to connect the components of the bipolar battery 100 to each other. A sealant may then be applied to provide a seal around the bipolar battery 100, and more specifically, around the connection end plate 38, the spacer 22, and the frame 11.

  It is also possible to stack the bipolar plates 10 and fix them adjacent to each other without the spacer 22. However, the material receiving passage 11b must be large enough to hold and contain the electrolyte 20, including the lead foil 14, the active materials 16, 18 and the fiberglass mat 21, when the laminated bipolar plate 10 is sealed together. . In addition, the frame 11 should have at least one electrolyte containing channel 22b arranged on an extension of the frame 11, so that the electrolyte 20 is provided in the material containing passage 11b of the frame 11 or the electrolyte 20 is allowed to vent. Can be

  The number of bipolar plates 10 used in the bipolar battery 100 is a design issue and depends on the size of the battery 100 and the required potential. In the embodiment shown, at least three bipolar plates 10 are stacked adjacent to each other. At the opposite ends of the stacked bipolar plate 10 and the electrolyte 20, similarly to the end plate 38, there is a terminal portion 30 including a layer of the active material 32, a terminal plate 34 and an electrode 36. In the embodiment shown, the outer surfaces of the spacer 22 and the frame 11 are sufficiently flush with each other when stacked and sealed. This design provides a smooth outer support surface. However, there may be irregularities on the surface. For example, the spacer 22 may be larger than the frame 11, but the electrolyte accommodating space 22a cannot be larger than the frame 11. Further, the material accommodating passage 11b cannot be larger than the spacer 22. In either case, sealing the spacer 22 and the bipolar plate 10 can be difficult, the electrolyte 20 can leak from the bipolar battery 100 after assembly, and the electrolyte 20 can be placed between adjacent bipolar plates 10. Is done.

  Furthermore, when the end plates 38 are stacked next to the adjacent spacers 22 and / or the adjacent bipolar plate 10 frames 11, the end plates 38, the spacers 22 and the outer surface of the frame 11 should be sufficiently flush. . However, there may be irregularities on the surface. For example, end plate 38 may be slightly larger than spacer 22, which may be larger than frame 11. Nevertheless, the terminal receiving passage 38a must not be larger than the receiving channel 22b or the frame 11. Further, the terminal receiving passage 38a must not be larger than the material receiving passage 11b or the frame, or the end plate 38 must not be smaller than the spacer 22. In either case, the electrolyte 20 may leak from the bipolar battery 100 after assembly, and the electrolyte 20 is provided between the stacked bipolar plates 10. Generally, frame 11 supports bipolar plate 10 and, like electrolyte, encloses substrate 12, lead foil 14, and active materials 16,18. When stacked, the bipolar plate 10 with adjacent spacers 20 and stacked terminal portions 30 provides an outer support surface for the bipolar battery 100. This structure provides a simplified design of the bipolar battery 100 with fewer manufacturing steps and components than required in the prior art. Because the frame 10, spacer 22, and end plate 38 are insulative plastic and are moldable, the bipolar battery 100 can be customized to meet shape and size requirements depending on potential and use.

  In another embodiment, as shown in FIG. 5, a protective casing 200 surrounding the bipolar battery 100 according to the present invention is further provided. The casing 200 will include a body 202, a cover 204, and an electrode receiving space 206 for the electrodes 36 to extend out of the casing 200. Unlike the external structure of the bipolar battery 100, the casing 200 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 embodiment can further include a plurality of standoffs 40 disposed on each side of the substrates 12,112. Standoffs 40 are integrally formed on each side of the substrates 12, 112 and are spaced apart from the perforations 13. In the embodiment shown in FIG. 10, the lead foil 14 disposed on the base material 12, 112 has a hole 41 corresponding to the standoff 40, and the lead foil 14 accommodates the standoff 40, 112 on the surface.

  When the bipolar plate 10 with the standoffs 40 is assembled into a bipolar battery, the frame 11 and the standoffs 40 of one bipolar plate 10 are attached to the frame 11 and the standoffs 40 of another bipolar plate 10, respectively. Provides uniform spacing and structural integrity between the bipolar plates 10 of the assembly. The frame 11 of one bipolar plate 10 may be connected to the frame 11 of another bipolar plate 10 by any type of welding known to those skilled in the art, including ultrasonic welding, chemical welding, solvent welding, spin welding, or hot plate welding. It may be attached to. Alternatively, frame 11 may be attached to another frame 11 by any mechanical connection known to those skilled in the art, including hook and latch or ball and socket connections. The standoffs 40 of one bipolar plate 10 may be connected to another bipolar plate 10 by any type of plastic welding known to those skilled in the art, including ultrasonic welding, chemical welding, solvent welding, spin welding, or hot plate welding. It may be attached to the standoff 40. Alternatively, standoffs 40 may be attached to other standoffs 40 by any type of mechanical connection known to those skilled in the art, including hook and latch or ball and socket connections.

  The above shows some possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the present invention. Therefore, it is intended that the foregoing description be regarded as illustrative rather than limiting, and the scope of the present invention is provided by the appended claims, along with their full scope of equivalents.

Claims (20)

Frame and
Placed in the frame,
Multiple perforations,
A plurality of standoffs integrally formed on both side surfaces, and a base material,
A first lead layer disposed on one side of the substrate,
A second lead layer disposed on another side of the substrate, wherein the first lead layer and a second lead layer electrically connected to each other through the plurality of perforations;
A positive electrode active material (PAM) disposed on a surface of the first lead layer;
A negative electrode active material (NAM) disposed on the surface of the second lead layer;
A bipolar battery plate for a bipolar battery, comprising:   The first lead layer and the second lead layer correspond to the plurality of standoffs that are aligned with the standoff when the first lead layer and the second lead layer are located on each side of the substrate. 2. The bipolar battery plate according to claim 1, having holes.   The bipolar battery plate according to claim 1, wherein the frame is a moldable insulating polymer.   The bipolar battery plate according to claim 1, wherein the frame is an outer wall of the bipolar battery that structurally supports the bipolar battery.   The bipolar battery plate according to claim 1, wherein the substrate is prepared in one piece from the same material as the frame.   The bipolar battery plate according to claim 1, wherein the substrate is a non-conductive insulating plastic having conductive particles uniformly dispersed throughout the insulating plastic.   7. The bipolar battery plate according to claim 6, wherein the substrate has a conductive surface, the surface of the substrate is roughened by chemical or abrasion, and the conductive particles are exposed outside the insulating plastic. .   The bipolar battery plate according to claim 1, wherein the perforations are disposed along the substrate and extend through the substrate.   9. The bipolar battery plate according to claim 8, wherein the lead layer is a lead foil having conductivity through the perforations.   The bipolar battery plate according to claim 9, wherein the lead foils are mechanically and electrically connected to each other via the perforations.   The bipolar battery plate according to claim 10, wherein the lead foils are welded to each other by resistance welding.   The bipolar battery plate according to claim 1, wherein the first and second lead layers are lead pastes disposed along the front and back surfaces of the base material.   13. The bipolar battery plate of claim 12, wherein a first lead layer connects to the opposite second lead layer by extending into at least one of the perforations across the entire front surface of the substrate.   The bipolar battery plate according to claim 1, wherein the positive electrode active material is a paste applied to the first lead layer, and the negative electrode active material is a paste applied to the second lead layer. Comprising a plurality of plates arranged adjacent to each other, each plate comprising:
Frame and
Placed in the frame,
Multiple perforations,
A plurality of standoffs integrally formed on both side surfaces, and a base material,
A first lead layer disposed on one side of the substrate,
A second lead layer disposed on another side of the substrate, wherein the second lead layer is electrically connected to the first lead layer and the plurality of perforations, respectively.
A positive electrode active material (PAM) disposed on a surface of the first lead layer;
A negative electrode active material (NAM) disposed on the surface of the second lead layer;
A pair of terminal portions arranged at opposite ends of the stacked bipolar plates,
An electrolyte disposed between each of the plurality of bipolar plates and the pair of terminal portions,
A bipolar battery comprising:   The first lead layer and the second lead layer have holes corresponding to the plurality of standoffs that are aligned with the standoffs when the first and second lead layers are located on each side of the substrate. The bipolar battery according to claim 15, comprising:   The bipolar battery according to claim 15, wherein the frames on the plurality of plates are attached to each other.   The bipolar battery 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 according to claim 18, wherein the standoff of one plate is attached to the standoff of another plate by ultrasonic welding, chemical welding, solvent welding, spin welding, or hot plate welding.   19. The bipolar battery according to claim 18, wherein the standoffs of one plate are attached to the standoffs of another plate by hook and latch or ball and socket connections.

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