Note: Descriptions are shown in the official language in which they were submitted.
BIPOLAR BATTERY AND BIPOLAR BATTERY PLATE
[0001]
FIELD OF THE INVENTION
[0002] The invention relates to a battery and in particular to a bipolar
battery having a series of
bipolar battery plates.
BACKGROUND
[0003] A conventional bipolar battery generally includes electrodes having a
metallic
conductive substrate on which positive active material forms one surface and
negative active
material forms the opposite surface. The active materials are retained by
various means on the
metal conductive substrate which is nonconductive to electrolyte ions. The
electrodes are
arranged in parallel stacked relation to provide a multi-cell battery with
electrolyte and separator
plates that provide an interface between adjacent electrodes. Conventional
mono-polar
electrodes, used at the ends of the stack are electrically connected with the
output terminals.
Most bipolar batteries developed to date have used metallic substrates.
Specifically, bipolar lead-
acid systems have utilized lead and alloys of lead for this purpose. The use
of lead alloys, such as
antimony, gives strength to the substrate but causes increased corrosion and
gassing.
[0004] In most known plates for bipolar batteries, the positive active
material, usually in the
form of a paste is applied to the metallic conductive substrate on one side
while the negative
active material is similarly applied to the opposite side. The plates may be
contained by a frame
which seals the electrolyte between plates so that it cannot migrate through
the plate.
[0005] In U. S. Patent No. 4,275,130, a bipolar battery construction 20 is
disclosed having a
plurality of conductive biplates 21. Each bipolar plate 21 may include a
composite, substrate
sheet 34 including a continuous phase resin material, which is nonconductive
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
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may be thermosetting or thennoplastic. The composite substrate sheet 34 has
substantially flat
opposite side faces 35 which include at their surfaces exposure of portions of
the embedded
graphite fibers 33. The embedded graphite fibers not only provide electrical
conductivity through
the substrate sheet 34, but also impart to the thermoplastic material a high
degree of stiffness,
rigidity, strength and stability. Substrate sheet 34 may be made in any
suitable manner such as by
thoroughly intermixing the thermoplastic material in particle form with the
graphite fibers. The
mixture is heated in a mold and then pressure formed into a substrate sheet of
selected size and
thickness. After the sheet has been cured, the substantially flat side faces
35 may be readily
treated or processed, as for example by buffing, to eliminate pinholes or
other irregularities in the
side faces.
[0006] As disclosed, lead stripes are bonded to the composite substrate sheet
34 by known
plating processes. On the positive side face 35, the facial areas between lead
stripes 38 are
covered by a coating of corrosion resistant resin 36 suitably a fluorocarbon
resin such as Teflon
(polytetrofluoroethylene) which protects against anodic corrosion of the
adjacent graphite fibers
and polyethylene of the substrate 34. On the negative side face 35, facial
areas between lead
stripes 37 may be protected by a thin coating of resin impermeable to
electrolyte such as a
polyethylene coating 36a. In fabrication of the bipolar plate 21 and after the
composite substrate
sheet 34 has been formed, a thin Teflon sheet may be bonded to the positive
side surface 35.
Prior to bonding, window like openings corresponding in length and width to
the lead stripes are
cut. Plating thereafter will bond the lead in stripes 38 to the exposed
conductive graphite surfaces
on the substrate side face 35. The same fabrication process may be utilized on
the negative side
face 35 to coat the nonstriped areas with polyethylene or other like material.
Plating of the
negative stripes may be achieved as with the positive stripes.
[0007] A separator plate 23 serves to support the positive active material 24
and the negative
active material 25 and may be made of a suitable synthetic organic resin,
preferably a
thermoplastic material such as microporous polyethylene.
[0008] Battery construction 20 includes a plurality of conductive bipolar
plates 21, peripheral
borders or margins thereof being supported and carried in peripheral
insulating casing members
22. Interleaved and arranged between bipolar plates 21 are a plurality of
separator plates 23 The
separator plates carry positive active material 24 on one side thereof and
negative active material
25 on the opposite side thereof. The casing members 22, together with the
bipolar plates 21 and
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separator plates 23, provide chambers 26 for containing electrolyte liquid. At
each end of battery
construction 20, standard bipolar plates 21 interface with current collecting
plates, where 27 is
the negative collector plate and 28 is the positive collector plate.
Externally of end collectors 27
and 28 are provided pressure members 30 interconnected by rods 31 having
threaded portions for
drawing the pressure members plates together and applying axial compression to
the stacked
arrangement of bipolar plates and separator plates.
100091 The bipolar plate 21 is lightweight, rigid, but includes joint lines
between the lead stripe
edges and protective coatings to resist corrosion and structural deterioration
of the substrate.
Furthermore, a plating process is required in order to bond the lead stripes
37, 38 to the
conductive substrate having graphite fibers. Conductivity is limited by the
size and amount type
of graphite fibers in the substrate. Additionally, a plurality of bipolar
plates 21 and layers are
required to sit in separate casing members 22 and an external frame, all of
which require further
processing steps for more parts. The bipolar battery construction 20 is a
complicated design
having many layers of materials and substrates assembled in multiple chambers
26 and bodies 43
that are secured together by a complex external frame.
SUMMARY
[00101 It is an object of the present invention, among other objects, to
provide a bipolar battery
having a simplified bipolar plate design, wherein the active materials are
encased within an
insulated frame having a moldable substrate with perforations to improve
conductivity between
the active materials. Furthermore, the bipolar battery is inexpensive to
produce and does not
require a complex external frame to support the bipolar plates.
[0011] Each bipolar battery plate has a frame, a substrate positioned within
the frame, a first
lead layer positioned on one side of the substrate, a second lead layer
positioned on another side
of the substrate, a positive active material (PAM) positioned on a surface of
the first lead layer,
and a negative active material (NAM) positioned on a surface of the second
lead layer. The
substrate has a plurality of perforations and a plurality of standoffs
integrally formed on
opposing side surfaces thereof. The first and second lead layers are
electrically connected to each
other through the plurality of perforations.
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BRIEF DESCRIPTION OF THE DRAWINGS
100121 The invention is explained in more detail below with reference to the
Figures shown in
the drawings, which illustrate exemplary embodiments of the present invention
wherein:
[0013] Figure 1 is a front view of a bipolar plate according to the invention;
[0014] Figure 2 is a sectional view of the bipolar plate taken along the line
2-2 of Figure 1;
[0015] Figure 3 is a perspective view of a bipolar battery according to the
invention;
[00161 Figure 4 is an exploded perspective view of the bipolar battery of
Figure 4;
[0017] Figure 5 is a partial sectional view of the bipolar battery according
to the invention
having a casing;
[0018] Figure 6 is another partial sectional view of the bipolar battery
according to the
invention without the casing;
[0019] Figure 7 is a close up view of the bipolar plate according to the
invention showing a
perforation in a substrate of the bipolar plate; and
[0020] Figure 8 is another close up view of the bipolar plate according to the
invention,
showing a non-conductive frame of the bipolar plate; and
[0021] Figure 9 is another close up view of the bipolar plate according to the
invention,
showing another non-conductive frame of the bipolar plate.
[0022] Figure 10 is a perspective view of the bipolar plate according to an
additional
embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENT(S)
[0023] The invention is explained in greater detail below with reference to
the drawings,
wherein like reference numerals refer to the like elements. The invention may,
however, be
embodied in many different forms and should not be construed as being limited
to the
embodiments set forth herein; rather, these embodiments are provided so that
the description will
be thorough and complete, and will fully convey the concept of the invention
to those skilled in
the art.
[00241 With respect to Figures 1-10, a bipolar battery 100 according to the
invention includes a
plurality of bipolar plates 10, spacers 22 holding an electrolyte 20, and
terminal end sections 30.
Each of these components are stacked together to complete a bipolar battery
100 according to the
invention, which is an adaptable design with minimal number of parts devoid a
complex exterior
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support structure.
[0025] Now with reference to Figures 1 and 2, a bipolar plate 10 according to
the invention is
discussed. The bipolar plate 10 includes a frame 11, a substrate 12, a
plurality of perforations 13
along and extending through a front and rear surface of the substrate 12, lead
foils 14, a first
active material 16, and a second active material 18.
[0026] In general, the substrate 12, lead foils 14, first active material, 16
and second active
material are encased within the frame 11, which provides support and
protection for the bipolar
plate 10. The substrate 12 is positioned in a center of the frame 11, the lead
foils 14 are
positioned on both sides of the substrate, and the active materials 16, 18 are
then positioned over
the lead foils 14. The frame 11 is non-conductive. In the embodiment shown,
the frame 11 is a
moldable insulative polymer, such as polypropylene, acrylonitrile butadiene
styrene (ABS),
polycarbonate, copolymers, or polymer blends. Because the frame Ills moldable,
the number of
shape and size configurations are abundant, which provides a bipolar plate 10
according to the
invention that can be tailored to different uses.
100271 In the embodiment shown, the frame 11 has a generally rectangular
shape, which
provides support for a substrate 12 when positioned in the frame 11. The frame
11 is a casing for
the bipolar plate 10, as well as the bipolar battery 100. The outer surface of
the frame 11 is the
outer surface of the bipolar plate 10 and bipolar battery 100. The surface of
the frame 11 is
generally flat, and in particular, along the exterior surfaces of the frame
11. The frame 11
supports itself, as well as the bipolar plate 10 when assembled with the
spacers 22 and terminals
sections 30, especially when the bipolar plate 10 sits upright against a flat
opposing surface.
10028] The frame 11 further includes substrate receiving passageways 1 la and
material
receiving passageways 11b, as shown in Figure 2. The substrate receiving
passageways lla are
grooves or channels, while the material receiving passageways 11b are openings
in the frame 11
that receive the lead foils 14 and active materials 16, 18 on both statkable
side of the bipolar
plate 10.
100291 The substrate receiving passageways Ila is a groove used to receive and
secure the
substrate 12, when the substrate 12 is positioned within the frame 11. Other
configurations of
substrate receiving passageways Ila are possible, including notches,
indentations, recesses or
any securing mechanism that secures the substrate 12 within the frame 11. For
instance, the
substrate 12 could be secured to the frame 11 using a weld or by adhesive, or
by a fastener.
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However, in the embodiment shown, the substrate 12 is secured in the substrate
receiving
passageways 11 a during manufacturing the bipolar plate 10.
[00301 Each material receiving passageway llb is positioned in a substantial
center of the
frame 11 split from each other by the substrate 12, when the substrate 12 is
positioned within the
substrate receiving passageways 11a. Furthermore, the lead foils 14 and active
materials 16, 18
are encased within an outer surface plane of the frame 11. These pair of
cavities are
dimensioned to securely receive the lead foils 14 and active materials 16, 18
within the frame 11.
[0031] In the embodiment shown, the substrate 12 is a separate piece of
insulative material
with respect to the frame 11, with the substrate 12 is received and secured
within the substrate
receiving passageways 1 la of the frame 11. However, the frame 11 and
substrate 12 can be
formed together, as a monolithic structure, generally from the same material.
During
manufacturing, the frame 11 and the substrate 12 are constructed as one piece
from the same
material. This can be performed through a process such as injection molding,
or other known
methods.
[0032] The substrate 12 in the embodiment shown is an insulative plastic that
is generally non-
conductive, namely, polypropylene, acrylonitrile butadiene styrene (ABS),
polycarbonate,
copolymers, or polymer blends in the embodiment shown. As briefly discussed
above, the
substrate 12 may be prepared from the same material as the frame 11,
regardless if the frame 11
and substrate 12 are prepare from a one piece construction.
[0033] In an alternative embodiment, as shown in Figure 7, the substrate 112
is generally
nonconductive, being prepared from insulative plastic. However, conductive
fibers and material
are homogeneously dispersed throughout the insulative plastic. For instance,
the substrate 112
may be prepared from a non-corrosive plastic sold by Integral Technologies,
Inc, under the trade
name Electriplast, which includes highly electrically conductive areas. The
substrate 112, as
shown in Figure 7, includes a non-conductive resin-based material or
thermoplastic 112a with a
micron powder(s) of conductor particles and/or in combination of micron
fiber(s) 112b
substantially homogenized within the resin or thermoplastic 112a. As clearly
shown in Figure 7,
the conductor particles or fibers 112b are homogenized throughout the body of
the resin or
thermoplastic 112a. In this example, the diameter D of the conductor particles
of the conductor
particles or fibers 112b in the powder is between about 3 and 12 microns. The
conductor fibers
of the conductor particles or fibers 112b have a diameter of between about 3
and 12 microns,
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typically in the range of 10 microns or between about 8 and 12 microns, and a
length of between
about 2 and 14 millimeters. The micron conductive fibers of the conductor
particles or fibers
112b may be metal fiber or metal plated fiber. Further, the metal plated fiber
may be formed by
plating metal onto a metal fiber or by plating metal onto a non-metal fiber.
Exemplary metal
fibers include, but are not limited to, stainless steel fiber, copper fiber,
nickel fiber, silver fiber,
aluminum fiber, 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 of thereof. Any platable fiber may be used as the core for
a non-metal fiber.
Exemplary non-metal fibers include, but are not limited to, carbon, graphite,
polyester, basalt,
man-made and naturally-occurring 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 micron conductive fibers and/or as metal plating
onto fibers.
100341 The conductor particles and/or fibers 112b are substantially
homogenized within the
resin or thermoplastic 112a. The substrate 112 includes controlled areas of
conductive surfaces
on the substrate 112, wherein the conductive materials from the conductive
particles or fibers
1 12b are exposed through the resin or thermoplastic 112a, which are
conductively connected by
the homogenization process. The conductive surfaces of the substrate 112 are
controlled by
further manufacturing techniques, such as etching or abrasive blasting,
wherein the surface is
roughened by chemical or by propelling a stream of abrasive material against
the surface under
high pressure. The conductor particles and/or fibers 112b are then exposed,
and conductive areas
of the substrate 112 are provided. The process provides a substrate 112 having
a controlled
amount of conductivity, including the size and area of conductivity.
100351 It is also possible that the substrate 112 includes a combination of
both conductive
particles, powders, and/or fibers 112b, that are substantially homogenized
together within an
insulative resin or thermoplastic 112a during a molding process. The
homogenized material is
molded into a polygonal shape, as a substrate 112, which accommodates various
custom designs
or properties required for the bipolar plate 10 according to the invention.
The substrate 112 may
then be molded with the frame 11 in a single manufacturing technique. This
allows the bipolar
plate 10 and bipolar battery 100 to be simplified, wherein minimal parts are
used and production
steps are eliminated. Furthermore, the properties of the substrate 112 and
battery 100 may be
focused by providing and controlling conductive areas along the surface of the
substrate 112.
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Since the frame 11 is insulative and the substrate 12, 112 is positioned in
the substrate receiving
passageways Ila, the bipolar plate 10 can act as a frame of the bipolar
battery 100 when
assembled.
100361 During manufacturing, the substrate 12 is either insert molded into the
substrate
receiving passageways 11 a, or the frame 11 is over molded over the substrate
12. However, if
the frame 11 and the substrate 12 are moldable together, i.e. insert or over
molding two pieces
together or injection molding one monolithic piece, the manufacturing steps of
the bipolar plate
can be simplified, with less parts. Furthermore, this process allows the
ability to customize
the size and shapes of the bipolar plate 10 and bipolar battery 100 according
to the invention.
100371 Now with reference back to Figures 1 and 2, the substrate 12 and the
substrate 112
shown in Figures 4-8 includes perforations 13 along the surface of the
substrate 12, 112, and
through the body extending through an opposite surface. In the embodiment
shown, the
perforations 13 are circular, but could otherwise be any shape. The
perforations 13 are
positioned in a symmetrical grid pattern. The perforations 13 are positioned
in four quadrants of
the shown substrate 12, 112. Having a number of perforations 13 positioned in
a symmetrical
grid arrangement provides even conductions through the substrate 12, 112 when
lead foils 14 are
positioned on the opposite sides of the substrate 12, 112.
100381 Additionally, the substrate 112 includes conductive particles, powders,
and/or fibers
11 2b along the surface and through the body of the substrate 112, as clearly
shown in Figure 5-9.
In general, there are surface areas of the substrate 112 are insulative, while
other areas are
conductive resulting from the conductive particles, powders, and/or fibers
112b. As discussed
above, the amount of conductive area can be controlled through manufacturing
of the substrate
112. For instance, the surfaces of the substrate can be roughened to expose
conductive areas that
may be custom in size and shape with respect to a whole exposed surface side
of the substrate
12, or the amount of conductive particles, powders, and/or fibers 1126 can be
controlled with
respect to the amount of insulative resin or thermoplastic 112a. In the
embodiment shown in
Figures 5-9, the whole exterior surface of the substrate 112 has been
roughened to expose
conductive particles, powders, and/or fibers 12b. Hence, the substrate is
conductive on the
exposed surface sides of the substrate and the lead foils 14 are positioned on
the conductor
particles, powders, and/or fibers 112b.
[0039] Now with reference to Figures 1,2, 7, and 8, the lead foils 14 will be
discussed, which
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are positioned within the material receiving passageway 1 lb, on opposite
sides of the substrate
12, 112. The lead foils 14 are conductive and connect with each other through
the perforations
13. More specific, the lead foils 14 are mechanically and electrically
connected to each other in
the embodiment shown. The substrate 12, 112 generally is insulative, or only
includes a limited
area or conductivity based on conductor particles and/or fibers 112b in the
insulative resin or
thermoplastic 112a. As a result, perforations 13 are used to connect the lead
foils 14 with each
other in the bipolar plate 10, notably for a bipolar plate 10 having substrate
12 prepared
exclusively from insulative material. The lead foils 14 are welded together,
as shown in Figure
2, by resistance welding or other process known to the art. On the other hand,
a bipolar plate 10
having a substrate 112, as shown in Figure 7, which includes the conductor
particles or fibers
112b homogenized in the resin or thermoplastic 112a, may also include
perforations 13, which
allow for further control and efficiency in conductivity between the lead
foils 14 and active
materials 16, 18 in the bipolar plate 10 according to the invention.
[0040] In either case, the perforations 13 can vary in size, shape, or grid
pattern, but are large
enough that the lead foil 14 can be positioned in and through the perforations
13 and connected
to an adjacent lead foil 14. The perforations 13 can be molded or milled into
the substrate 12
during manufacturing. With reference to Figures 1, 2, and 8, the lead foils 14
are shown, being
positioned on the both exposed surfaces of the substrate 12, 112 respectively,
and dimensions to
fit within the material receiving passageways 1 lb of the frame 11. The lead
foil 14 is
dimensioned to securely fit in the material receiving passageway 1 lb, such
that the frame 11
encases each lead foil 14 positioned on both sides of the substrate 12, 112.
The leads foils 14
are mechanically and electrically connected through the perforations 13, as
shown in Figure 7.
[0041] As shown in Figure 9, the lead foils 14 may be inserted into the
substrate receiving
passageways 11, along with the substrate 12, 112 during manufacturing and
assembly. The lead
foils 14 may encased within the frame during insert molding, over molding, or
similar
manufacturing technique where the lead foils 14 and substrate 12, 112 are
manufactured within
the substrate receiving passageways 11 a. The lead foils 14 are positioned on
opposite surfaces of
the substrate 12, 112 and then either inserted or manufactured within the
frame 11. It is possible
to apply the lead foils 14 by known plating, vapor deposition, or cold flame
spray methods.
[0042] It is also possible that the lead foil 14 is a paste having lead, which
is positioned along
the front and rear surfaces of the substrate 12, 112. The paste is spread
across opposite surfaces
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(i.e. front and rear surfaces) of the substrate 12, 112 and within the
perforations 13. The paste
connects both sides of the substrate 12, 112 through the perforations 13. The
paste would be
thick enough to provide connectivity between the pastes on each side, but
should not be thicker
than the material receiving passageway 11b, considering an active material 16,
18 is also
positioned within the material receiving passageway 11b.
[0043] With reference to Figures 2 and 5-9, the active materials 16, 18 are
shown and
positioned on exposed sides of the lead foils 14, facing away from the
substrate 12, 112. The
first layer of active material 16 is a positive active material paste (PAM)
that is applied over one
lead foil 14, while a negative active material (NAM) is applied over the other
lead foil 14, which
is the second active material 18. In the embodiment shown, the positive active
material paste
(PAM) and the negative active material (NAM) are paste of lead or lead oxide
mixed with
sulfuric acid, water, fiber, and carbon.
[0044] The thickness of the active materials 16, 18 (i.e. NAM and PAM) should
not extend
outside the material receiving passageway 11b of the frame 11. Rather, the
overall thickness T.
of the substrate 12, 112, lead foils 14, and active materials 16, 18 is less
than the thickness Tr of
the frame 11.
[0045] The frame 11 encases the substrate 12, 112, lead foils 14, and active
materials 16, 18.
As a result, when assembled the bipolar battery 100 is assembled in stacks of
bipolar plates 10,
the frame 11 acts as a support and exterior surface for the bipolar battery
100. The number of
assembly steps and parts can be minimized. Furthermore, the bipolar battery
100 and bipolar
plate 10 can be easily customized for various applications, since the frame 11
and substrate 12
can be molded to various shapes and sizes.
[0046] Now with reference to Figures 3 and 4, spacers 22 are shown that stack
and seal with
the bipolar plates 10 according to the invention, and used to hold an
electrolyte 20 for the bipolar
battery 100.
[0047] The spacer 22 is shown between stacking adjacent bipolar plates 10. The
spacer 22 is
essentially a casing having similar dimensions as the frame 11 and includes an
electrolyte
receiving space 22a, as shown in Figures 3-6. The electrolyte receiving space
22a is a hole
through the electrolyte receiving space 22a, positioned substantially in the
center of the spacer 22
and holds an electrolyte 20. When sealed between two adjacent bipolar plates
10, the spacer 22
prevents the electrolyte 20 from leaking and allows the electrolyte 20 to
provide conductivity
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between the bipolar plates 10.
[0048) As shown in Figures 5 and 6, at least one electrolyte receiving channel
22b is provided
in the spacer 22, which is positioned on an outer surface of the spacer 22 and
directed into the
electrolyte receiving space 22a. A user can provide electrolyte 20 through the
electrolyte
receiving channel 22b and into the electrolyte receiving space 22a, after the
spacer 22 is
assembled and sealed with adjacent bipolar plates 10. In general, the
electrolyte receiving
channel 22b is an opening in the spacer 22 that extends through the spacer 22
and into the
electrolyte receiving space 22a. However, other mechanisms or structures known
to the art
could be used to allow ingress of electrolyte 20 into the electrolyte
receiving space 22a. The
receiving channel 22b can be plugged or obstructed in some capacity when not
utilized, or used
to vent gases from the electrolyte receiving space 22a.
[0049] The electrolyte 20 may be a variety of substances, including acid.
However, the
substance should be a substance that includes free ions that make that
substance electrically
conductive. The electrolyte 20 may be a solution, a molten material, and/or a
solid, which helps
create a battery circuit through the electrolyte's ions. In the bipolar
battery 100 according to the
invention, the active materials 16, 118 provide a reaction that converts
chemical energy to
electrical energy, and the electrolyte 20 allows the electrical energy to flow
from the bipolar
plate 10 to another bipolar plate 10, as well as to electrodes 36 of the
battery 100.
MOM In the embodiment shown, the electrolyte 20 is an acid that is held in
an absorbed glass
mat (AGM) 21, as shown in Figures 4 and 5. The electrolyte 20 is held on the
glass mat 21 by
way of capillary action. Very thin glass fibers are woven into the glass mat
21 to increase
surface area enough to hold sufficient electrolyte 20 on the cells for their
lifetime. The fibers that
include the fine glass fibers glass mat 21 do not absorb nor are affected by
the acidic electrolyte
20 they reside in. The dimension of the glass mat can be varied in size.
However, in the
embodiment shown, the glass mat 21 fits within the electrolyte receiving space
22a, but has a
greater thickness than that the spacer 22. Additionally, the electrolyte
receiving space 22a, in the
embodiment shown, includes additionally space for a portion of the electrolyte
20, and more
specifically the glass mat 21. As a result, the design of the bipolar battery
100, according to the
invention, allows for the spacer 22 holding the glass mat 21 to uniformly
stack with adjacent
bipolar plates 10, wherein the active materials 16, 18 sit on the glass mat 21
containing the
electrolyte 20.
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[0051] It is also possible that the glass mat 21 is removed, and an
electrolyte 20, such as a 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.
[0052] It is also possible, in other embodiments, that the spacer 22 is an
extension of the frame
11. In general, the frame 11 includes a deeper material receiving passageway
11b in order to
encase the lead foils 14 and active materials 16, 18, as well as electrolyte
20. Furthermore, if the
frame 11 may be dimensioned such that the material receiving passageways fib
of stackable
bipolar plates 10 can also hold an fiber glass mat 21 between each other,
enclosing an encasing
the lead foils 14, active materials 16, 18, glass mat 21, and electrolyte 20
within the stacked and
sealed bipolar plates 10. The frame 11 may include the electrolyte receiving
channel 22b that
extends through the frame and into the material receiving passageway 11 b. In
this embodiment,
the bipolar plates 10 can be stacked onto each other and sealed.
[0053] Now with reference to Figures 4-6, the terminal sections 30 of the
bipolar battery 100
will be discussed, which cap the ends of the bipolar battery 100. The terminal
sections 30 stack
on opposite sides of stacked bipolar plates 10, the number of bipolar plates
10 stacked next to
each other depends on the electrical potential required of a specific battery
design and shape.
[0054] Each terminal section 30 includes an additional layer of active
material 32, a terminal
plate 34, an electrode 36, and an end plate 38. The end plates 38 are
positioned on opposite ends
of the stacked bipolar plates 10, with the active material 32, the terminal
plate 34 and electrode
36 positioned within the end plate 38.
[0055] The active material 32 is provided to increase electrical flow through
the bipolar battery
100, from one terminal section 30 to the other terminal section 30. The active
material 32 is
made of material that interacts with an adjacent active material 16, 18 from
an adjacent bipolar
plate 10. Since a spacer 22 and electrolyte 20, as described above, is
positioned on each
stackable side of the bipolar plates 10, a spacer 22 is positioned between the
terminal section 30
and an outside bipolar plate 10. As a result, ions can freely flow through the
electrolyte 20 and
onto the active material 32 of the terminal section 30.
[0056] As shown in Figures 5-6, the terminal plate 34 is provided and encased
within the
terminal section 30. The terminal plate 34 is conductive and generally a
metal. The terminal
plate 34 attaches to an electrode 36, which either an anode or a cathode of
the bipolar battery
100. The anode is defined as the electrode 36 at which electrons leave the
cell and oxidation
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occurs, and the cathode as the electrode 36 at which electrons enter the cell
and reduction occurs.
Each electrode 36 may become either the anode or the cathode depending on the
direction of
current through the cell. It is possible that both the terminal plate 34 and
the electrode 36 are
formed as one piece.
100571 As shown in Figures 4-6, the end plate 38 is non-conductive and
provides structural
support to ends of the bipolar battery 100 according to the invention. The end
plate 38 includes a
terminal receiving passageway 38a, which is a recess in which the terminal
plate 34, electrode
36, and active material 32 are positioned. Additionally, like the material
receiving passageway
11b, the terminal receiving passageway 38a provides enough clearance for an
amount of
electrolyte 20 to be encased with the terminal section 30, and specifically
within the material
receiving passageway 11b along with the active material 32, terminal plate 34,
and electrode 36.
In the embodiment shown in Figures 5 and 6, the terminal receiving passageway
38a provides
enough space to receive and enclose a portion of the glass mat 21, as well.
100581 With reference to Figures 3 through 8, the assembly of the bipolar
battery 100
according to the invention will be further discussed.
100591 The bipolar plate 10 is manufactured and assembled with the substrate
12, 112 secured
with the frame 11. The substrate 12, 112 includes perforations 13 and/or
conductor particles or
fibers 112b, and is generally molded with the frame 11, either as a single or
separate component.
Once the substrate 12, 112 is positioned within the frame 11, the lead foils
14 are positioned with
the material receiving passageways llb of the frame 11 on both exposed
surfaces of the substrate
12, 112. The lead foils 14 are mechanically connected together through the
perforations 13, and
electrically connected through conductor particles or fibers 112b provided in
the substrate 12,
112. A first active material 16 is then positioned in the material receiving
passageways 11 b on
one side of the substrate 12, while the second active material 18 is
positioned on another side of
the substrate within material receiving passageways 11 b. As a result, the
frame 11 encases the
substrate 12, lead foils 14, and active materials 16, 18 within surface
boundaries of the bipolar
plate 10.
100601 The bipolar plates 10 are stacked then next to each other with spacers
22 provided
between each stacked bipolar plate. Electrolyte 20 is provided in the
electrolyte receiving space
22a, which is dimensioned similar to the material receiving passageway llb of
the frame 11. A
fiber glass matt 21 can be provided in the electrolyte receiving space 22a, as
well, and an
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electrolyte 20 is provided into the fiber glass inatt 21 through the
electrolyte receiving channel
22b. The spacers 22 and bipolar plates 10 evenly stack one next to the other,
and are
subsequently sealed. Since the spacers 22 and stacked bipolar plates 10
include non-conductive
outer surfaces, the spacers 22 and frames 11 of the bipolar plates 10 create
an outer shell for the
bipolar battery 100. The frames 11 of the bipolar plates 10 and spacers 22 can
be secured to each
other by any method known to the art such that the touching surfaces of the
spacers 22 and the
frame 11 are secured to each other and sealed. For instance, an adhesive can
be used to connect
and seal the surfaces together. Additionally, once the terminal sections 30
are assembled, they
may be positioned on the stacked bipolar plates 10 and spacers 22, and then
sealed in the same
manner.
100611 It is also possible, that the end plates 38, the spacer 22, and the
frame 11 include
securing mechanisms (not shown), such as joint technique or fastener, to
connect the pieces of
the bipolar battery 100 together. Then a sealant may be applied to provide a
seal around the
bipolar battery 100, and more specifically, a seal around the connecting end
plates 38, spacers
22, and frame 11.
100621 It is also possible, that the bipolar plates 10 are stacked and secured
next to each other
without a spacer 22. However, the material receiving passageway llb should be
large enough to
hold and encase the lead foils 14, active materials 16, 18 and an electrolyte
20, including a fiber
glass mat 21, when the stacked bipolar plates 10 are sealed together.
Furthermore, the frame 11
should include at least one electrolyte receiving channel 22b positioned in an
extension of the
frame 11, so that electrolyte 20 can be provided into the material receiving
passageway 1lb of
the frame 11, or allow venting of the electrolyte 20.
[00631 The number of bipolar plates 10 used in the bipolar battery 100 is a
matter of design
choice, dependent upon the size of battery 100 and the electrical potential
required. In the
embodiment shown, there are at least three bipolar plates 10 stacked next to
each other. On
opposites ends of the stacked bipolar plates 10 and electrolyte 20 are
terminal sections 30, which
include a layer of active material 32, a terminal plate 34 and electrode 36,
as well as an end plate
38. In the embodiment shown, 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 in the
surface may exist. For
instance, the spacer 22 may be larger than the frame 11; however, the
electrolyte receiving space
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22a cannot be larger than the frame 11. Additionally, the material receiving
passageway 11b
cannot be larger than the spacer 22. In either case, it may be difficult to
seal the spacer 22 and
bipolar plates 10, and the electrolyte 20 could leak from the bipolar battery
100 after assembly
and the electrolyte 20 is positioned between adjacent bipolar plates 10.
[0064] Furthermore, when the end plate 38 is stacked next to an adjacent
spacer 22 and/or
frame 11 of an adjacent bipolar plate 10, the outer surfaces of end plate 38,
the spacer 22 and the
frame 11 should be substantially flush. However, it is possible that
irregularities in the surface
may exist. For instance, the end plate 38 may be a bit larger than the spacer
22, which may be
larger than the frame 11. Nonetheless, terminal receiving passageway 38a
should not be larger
than the receiving channel 22b or the frame 11. Additionally, the terminal
receiving passageway
38a should not be larger than the material receiving passageway 1lb or the
frame, or the end
plate 38 should not be smaller than then 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 stacked
bipolar plates 10.In general, the frame 11 supports the bipolar plate 10,
encasing the substrate 12,
lead foils 14, and active materials 16, 18 , as well as electrolyte. When
stacked, the bipolar
plates 10, with adjacent spacers 20 and stacked terminal sections 30 provide
an outer support
surface for the bipolar battery 100. This construction provides a bipolar
battery 100 having a
simplified designed, having fewer manufacturing steps and fewer parts than
required in the prior
art. Since the frame 10, spacer 22, and end plate 38 are insulative plastic
and moldable, the
bipolar battery 100 can be customized to accommodate shape and size
requirements dependent
on electrical potential and use.
[0065] In another embodiment, as shown in Figure 5, a protective casing 200 is
further
provided, that encloses the bipolar battery 100 according to the invention.
The easing 200 would
include body 202, a cover 204, and an electrode receiving space 206, in order
for the electrode
36 to extend out of the casing 200. Unlike an external structure of the
bipolar battery 100, the
casing 20 can be used to house the bipolar battery 100 and provide greater
protection.
[0066] In another embodiment, as shown in Figure 10, the bipolar plate 10 of
the above
embodiments may further include a plurality of standoffs 40 positioned on each
side of the
substrate 12, 112. The standoffs 40 are integrally formed on each side of the
substrate 12, 112,
and are spaced apart from the perforations 13. In the embodiment shown in
Figure 10, the lead
foils 14 positioned on the substrate 12, 112, have holes 41 corresponding to
the standoffs 40,
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such that the lead foils 14 accommodate the standoffs 40 and are positioned on
the surfaces of
the substrate 12, 112.
[0067] When the bipolar plates 10 with standoffs 40 are assembled into a
bipolar battery, the
frames 11 and standoffs 40 of one bipolar plate 10 are respectively attached
to the frames 11 and
standoffs 40 of another bipolar plate 10, 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 another bipolar plate 10 by any type of welding
known to those
with ordinary skill in the art including ultrasonic welding, chemical welding,
solvent welding,
spin welding, or hot-plate welding. The frame 11 may alternatively be attached
to another frame
11 by any mechanical connection known to those with ordinary skill in the art
including a hook
and latch or a 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 with ordinary skill in the art including ultrasonic welding, chemical
welding, solvent
welding, spin welding, or hot-plate welding. The standoffs 40 may
alternatively be attached to
other standoffs 40 by any type of mechanical connection known to those with
ordinary skill in
the art including a hook and latch or a ball and socket connection.
[0068] While reference has been made to various preferred embodiments of the
invention other
variations, implementations, modifications, alterations and embodiments are
comprehended by
the broad scope of the appended claims. Some of these have been discussed in
detail in this
specification and others will be apparent to those skilled in the art. Those
of ordinary skill in the
art having access to the teachings herein will recognize these additional
variations,
implementations, modifications, alterations and embodiments, all of which are
within the scope
of the present invention, which invention is limited only by the appended
claims.
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Date Recue/Date Received 2020-04-09
