Bipolar battery pack

Abstract

The bipolar stacked battery pack has a plurality of bipolar electrodes. Each bipolar electrode has a current collector. A cathode layer comprising a cathode active material is formed on the first surface of the current collector. An anode layer comprising an anode active material is formed on the second surface of the current collector. A separator layer is formed on the cathode layer and the anode layer, wherein the separator layer extends beyond opposing side edges of the cathode layer and the anode layer. An insulator is formed on an exposed side edge of at least one side of the current collector and extends beyond the current collector. A pair of terminal stacks is provided in which one of the pair of terminal stacks is formed on a higher voltage side of the bipolar stacked battery pack and a second of the pair of terminal stacks is formed on a lower voltage side of the bipolar stacked battery pack.

Description

[0001] Related Applications

[0002] This patent application is related to U.S. Provisional Application No. 63 / 542,587, filed on October 5, 2023 in the name of the inventor, entitled “Bipolar Battery Pack,” the entire contents of which are incorporated herein by reference. This patent application claims the benefit of the aforementioned provisional application under 35 U.S.C. §119(e). Technical Field

[0003] The present disclosure relates generally to batteries and, more particularly, to a bipolar battery. Background Art

[0004] Electric vehicles (EVs) are becoming more and more common in the market as an alternative to traditional internal combustion engine vehicles, mainly due to their environmental friendliness and advanced technological features. The operation of an EV depends heavily on its battery pack system, which provides the necessary electrical energy to the electric motor.

[0005] Traditionally, in order to generate enough voltage to drive a high-torque electric motor in a vehicle, a large number of battery packs need to be connected in series. However, this design has several inherent disadvantages. For example, one disadvantage is that the series stacking of battery packs requires a large number of connecting components. The connecting components not only cause a loss in energy density and power density due to volume loss, but also introduce additional resistance, resulting in reduced power density. In addition, the connecting components tend to concentrate the current around the connection area, resulting in uneven temperature and current distribution among the battery packs. This ultimately leads to premature degradation of the battery pack system.

[0006] To address these challenges, bipolar batteries have been developed in which the positive and negative electrodes are arranged on either side of a current collector, significantly reducing the need for connecting components.

[0007] However, these bipolar batteries also present their own set of problems. Specifically, they present a risk of short circuits: if the current collectors of different layers come into contact, the battery cells will not be able to exhibit the necessary voltage, resulting in a lower overall voltage. Likewise, if the electrolytes of different battery layers come into contact, the cell will also not be able to generate the required voltage.

[0008] Some people use separators made of inorganic solid electrolytes to avoid electrical short circuits. This particular method involves covering the current collector with an insulating polymer to prevent electrical short circuits. However, this method still has the risk of ion short circuits. Specifically, if the electrolyte collapses due to external impact, the separator will produce small particles, causing different layers of electrolytes to contact and thus cause ion short circuits. In this case, the separator is not covered, which makes it prone to these problems. Therefore, it is necessary to provide a bipolar battery pack that helps prevent short circuits in bipolar stacked batteries. Summary of the invention

[0009] This summary is intended to introduce some concepts in a simplified form, which are further described in the detailed description below. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0010] According to one embodiment of the present invention, a bipolar stacked battery pack is disclosed. The bipolar stacked battery pack has a plurality of bipolar electrodes. Each bipolar electrode has a current collector. A cathode layer comprising a cathode active material is formed on a first surface of the current collector. An anode layer comprising an anode active material is formed on a second surface of the current collector. A separator layer is formed on the cathode layer and the anode layer, wherein the separator layer extends beyond the opposite side edges of the cathode layer and the anode layer. An insulator is formed on the exposed side edge of at least one side of the current collector, the insulator extending beyond the current collector. A pair of terminal stacks is provided, wherein one of the pair of terminal stacks is formed on a higher voltage side of the bipolar stacked battery pack, and the second of the pair of terminal stacks is formed on a lower voltage side of the bipolar stacked battery pack.

[0011] According to one embodiment of the present invention, a bipolar stacked battery pack is disclosed. The bipolar stacked battery pack has a plurality of bipolar electrodes. Each bipolar electrode has a current collector. A cathode layer comprising a cathode active material is formed on a first surface of the current collector. An anode layer comprising an anode active material is formed on a second surface of the current collector. A separator layer is formed on the cathode layer and the anode layer, wherein the separator layer extends beyond the opposite side edges of the cathode layer and the anode layer. An insulator is formed on the exposed side edge of at least one side of the current collector, the insulator extending beyond the current collector. A gap is formed between at least one of the anode layer and the insulator or between the cathode layer and the insulator; the insulator is formed on an exposed area on the first surface of the current collector forming the anode layer, wherein the separator is located in the gap between the anode layer and the insulator; the insulator is formed on an exposed area on the second surface of the current collector forming the cathode layer, wherein the separator is located in the gap between the cathode layer and the insulator. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present application will be further described in detail in conjunction with the following drawings. These drawings are not intended to limit the scope of the present application, but to illustrate certain features thereof.

[0013] Figure 1 is a top view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0014] Figure 2 is taken along line A-A' according to one embodiment of the present disclosure Figure 1 A cross-sectional view of an exemplary stacked battery;

[0015] Figure 3 According to one embodiment of the present disclosure Figure 1 A top view of layers of an exemplary stacked battery;

[0016] Figure 4 is taken along line A-A' according to one embodiment of the present disclosure Figure 3 A cross-sectional view of an exemplary layer of;

[0017] Figure 5 According to one embodiment of the present disclosure Figure 1 A top view of another exemplary layer of a stacked battery;

[0018] Figure 6 is taken along line A-A' according to one embodiment of the present disclosure Figure 5 A cross-sectional view of an exemplary layer of;

[0019] Figure 7 According to one embodiment of the present disclosure Figure 1 A top view of another exemplary layer of a stacked battery;

[0020] Figure 8 is taken along line A-A' according to one embodiment of the present disclosure Figure 7 A cross-sectional view of an exemplary layer of

[0021] Fig. 9 is a cross-sectional view of an exemplary cathode terminal stack according to one embodiment of the present disclosure;

[0022] Fig.10 is a cross-sectional view of another exemplary cathode terminal stack according to one embodiment of the present disclosure;

[0023] Fig.11 is a cross-sectional view of an exemplary anode terminal stack according to one embodiment of the present disclosure;

[0024] Fig.12 is a cross-sectional view of another exemplary anode terminal stack according to one embodiment of the present disclosure;

[0025] Fig.13 According to one embodiment of the present disclosure Figure 1A front view of an exemplary stacked battery;

[0026] Fig.14 According to one embodiment of the present disclosure Fig.13 An exploded front view of an exemplary stacked battery;

[0027] Fig.15 is a top view of an exemplary airtight bag according to one embodiment of the present disclosure;

[0028] Fig.16 According to one embodiment of the present disclosure Fig.15 A cross-sectional view of an exemplary airtight bag of FIG.

[0029] Fig.17 is a top view of an exemplary airtight bag containing stacked batteries therein according to one embodiment of the present disclosure;

[0030] Fig.18 According to one embodiment of the present disclosure Fig.17 A cross-sectional view of an exemplary airtight bag of FIG.

[0031] Fig.19 is a top view of an exemplary battery pack housing containing stacked batteries therein according to one embodiment of the present disclosure;

[0032] Fig. 20 According to one embodiment of the present disclosure Fig.19 A cross-sectional view of an exemplary battery pack housing;

[0033] Fig.21 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0034] Fig. 22 According to one embodiment of the present disclosure Fig.21 A magnified view of an exemplary stacked battery outlined by a dashed circle;

[0035] Fig.23 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0036] Fig.24 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0037] Fig.25 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0038] Fig.26 According to one embodiment of the present disclosure Fig.25 A magnified view of an exemplary stacked battery outlined by a dashed circle;

[0039] Fig. 27 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0040] Fig.28 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0041] Fig.29 According to one embodiment of the present disclosure Fig.28 A magnified view of an exemplary stacked battery outlined by a dashed circle;

[0042] Fig.30 is a cross-sectional view of an exemplary stacked battery according to one embodiment of the present disclosure;

[0043] Fig.31 is a graph of charge and discharge curves of an exemplary stacked battery according to one embodiment of the present disclosure; and

[0044] Fig.32 is a graph of charge and discharge curves of an exemplary stacked battery according to one embodiment of the present disclosure. DETAILED DESCRIPTION

[0045] The following description is intended to describe the current preferred embodiment of the present disclosure, and is not intended to represent the only form in which the present disclosure can be constructed and / or utilized. This description sets forth the functions and step sequences of constructing and operating the present disclosure. However, it should be understood that the same or equivalent functions and sequences can be implemented by different embodiments, which are also intended to be encompassed within the spirit and scope of the present disclosure.

[0046] Figures 1 to 20 1 and 2. An embodiment of a bipolar battery of the present invention is shown together. In its simplest form, the bipolar battery comprises stacked cells 13, an insulator 5 covering the entire surface of the electrodes and a separator 4, thereby greatly reducing the risk of ionic short circuits. According to one embodiment, the components of the bipolar battery can be formed in an airtight bag 23 and have a unique battery housing with an electrical connector 36 in a recess 38.

[0047] Stacked batteries

[0048] Figure 1 A schematic diagram of a stacked battery 13 is shown. Figures 3 to 12 The structure of the layers of electronic components 6 to 12 as components of a stacked battery 13 is schematically shown. Figure 13 to Figure 14 A side view of a stacked battery 13 is shown.

[0049] At the terminal of the stack on the high voltage side, an electric cathode terminal stack (cathode terminal stack 9 or cathode terminal stack 10) is used according to the position of the diaphragm 4. At the terminal of the stack on the low voltage side, an anode terminal stack (anode terminal stack 11 or anode terminal stack 12) is used according to the position of the diaphragm 4. Starting from the second layer counted from the terminal, electronic components 6, 7, 8 or a combination of these electronic components 6, 7, 8 are stacked. Each layer is laminated by the diaphragm 4. Therefore, in the direction from the high voltage side to the low voltage side, the stacked battery 13 includes a current collector layer 1, a cathode layer 2, a diaphragm 4, an anode layer 3, a current collector layer 1, a cathode layer 2, a diaphragm 4, an anode layer 3, etc., arranged in this repeating order.

[0050] like Figure 1 As shown, the edges of the stack are covered by a reinforcement member comprising an insulator 5. The insulator 5 has no electronic or ionic conductivity. Figure 1 Top view and Figure 2 As shown in the cross section of FIG. 1 , the reinforcement (insulator 5) covers the exposed edges of the current collector 1, the cathode layer 2, the anode layer 3, and the separator 4. That is, no layer is in contact with any other layer inside / between the battery stack. The sides of the stacked battery 13 are completely covered by the insulator 5, and the current collector 1, the cathode layer 2, the anode layer 3, and the separator 4 are not exposed at the edges of the stacked battery 13.

[0051] The current collector 1 can be made of metal foil, metal mesh or any other suitable material, but metal foil is preferred. Examples of metals that can be used for the current collector 1 include, but are not limited to, Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co and stainless steel. It can be a pure metal element, an admixture, an alloy or a coating. The metal surface can also be covered with carbon or other materials. This can ensure good adhesion to the cathode layer 2 and the anode layer 3. In addition to metals, carbon can also be used for the current collector 1. Resin composites with electronic conductors (metals or carbon) as fillers can also be used for the current collector 1. Possible carbon filler materials include acetylene black (AB), Ketjen black (KB), vapor grown carbon fiber (VGCF), carbon nanotubes, carbon nanohorns and fuller carbon. Possible filler metals include stainless steel, Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co. The shape of the filler can be spherical, fibrous, needle-shaped or hollow. When using needle-shaped or fibrous fillers, it may be effective to orient them. This is because the orientation controls the flow of electrons, making it easier to interrupt the current when an abnormality occurs.

[0052] The thickness of the current collector 1 may be any suitable thickness. For example, the thickness of the current collector 1 is preferably 0.1 μm to 1 mm, more preferably 1 μm to 50 μm.

[0053] The cathode layer 2 is a layer containing at least a cathode active material (CAM). Examples of CAM include layered lithium-containing oxide materials such as LiCoO2, LiMnO2, LiNiO2, LiNi x Mn y Co 1-x-y O2、LiNi x Co y Al 1-x-y O2; Lithium phosphates with olivine structure, such as LiFePO4, LiFe x Mn 1-x PO4, LiMnPO4, LiFe x Co 1-x PO4, LiCoPO4; spinel structured lithium oxide materials, such as LiNi 0.5 Mn 1.5 O4, LiMn2O4; Lithium-excess layered oxides, such as Li2MnO3, Li2RuO3, Li2Ru x Ti 1-x O3、Li2Ru x Sn 1-x O3、Li2Mn x Ti 1-x O3、Li2Mn x Sn 1-x O3; layered lithium-containing sulfide materials, such as TiS2, MoS2, NbS2, TaS2, sulfur or lithium-containing sulfides with Chevrel structure, such as LiCu x MoS 1-z .

[0054] The CAM surface can be coated with a thin layer of material (coating). Examples of coatings include crystalline phases such as Li2ZrO3, LiNbO3, Li3BO3, Li3B 11 O 18 , LiPO3, Li3PO4, LiTi2(PO4)3, LiZr(PO4)3, ZrO2, B2O3, Al2O3, Nb2O5, EtOLi, MtOLi, LiOH, Li2CO3, and / or an amorphous phase, such as a metal alkoxide, a metal phosphate. In addition to the CAM, the cathode layer 2 may also include a solid electrolyte, a binder, an electronic conductive additive. Examples of electrolytes include organic liquids, organic polymers, and inorganic solids. Preferably, the electrolyte comprises an inorganic solid because its lithium transfer number is higher than that of a liquid and its ionic conductivity is higher than that of an organic polymer. In addition, inorganic solids are generally rigid and do not show fluidity, which is preferred for constructing a stacked battery 13 without ionic short circuits.

[0055] Preferred examples of the electrolyte include materials of the following substances: Li-PON, Li-Si-O, Li-B-Si-O, Li-BO, Li-CBO, Li-Al-Si-O, Li-Ti-Al-PO, Li-Zr-Al-PO, Li-La-Zr-O, Li-La-Ta-Zr-O, Li-La-Nb-Zr-O, Li-MS (M is B, Al, Si, P, Zn, Ge, Zr, Sn or any combination thereof), Li-M'-SO (M' is B, Al, Si, P, Zn, Ge, Zr, S n or any combination thereof), Li-PSX (X is F, Cl, Br or any combination thereof), Li-PSO-X' (X' is F, Cl, Br or any combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M" is In, Zr, Sc, Ga, Nb, Ta or any combination thereof; X" is F, Cl, Br or any combination thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta or any combination thereof; X" is F, Cl, Br or any combination thereof).

[0056] Examples of the binder that may be contained in the cathode layer 2 include butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chain of the binder may be modified with a functional group.

[0057] In addition, cathode layer 2 may contain an electron conductive additive, such as various types of carbon, including acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns, and fullerene carbon.

[0058] The thickness of the cathode layer 2 is not particularly limited, but when a higher capacity is required, a thicker layer may be preferred. For example, the thickness of the cathode layer 2 is preferably 0.1 μm to 1 mm, and ideally 60 μm to 500 μm.

[0059] The anode layer 3 is a layer containing at least an anode active material (AAM). Examples of AAM include layered lithium-containing sulfides such as TiS2, MoS2, NbS2, TaS2; titanium-containing oxides such as Li4Ti5O 12 、Ti x Nb y O z , Li x Ti2(PO4)3; containing tungsten oxides, such as Nb 16 W5W 55 , Nb 18 W 16 O 93; Vanadium-containing oxides, such as LiVO2; Artificial carbon (or hard carbon); Graphite; Lithium metal alloys, such as Li x In、Li x Sn、Li x Si、Li x Ge, Li x Al or metallic lithium.

[0060] In addition to the AAM, the anode layer 3 may also include a solid electrolyte, a binder, an electronically conductive additive. Examples of electrolytes include organic liquids, organic polymers, inorganic solids. Preferably, the electrolyte includes an inorganic solid because its lithium transfer number is higher than that of a liquid and its ionic conductivity is higher than that of an organic polymer. In addition, because inorganic solids are generally rigid and do not show fluidity, this is preferred for constructing a stacked battery 13 without ionic short circuits.

[0061] Preferred examples of the electrolyte include materials having the following compositions: Li-PON, Li-Si-O, Li-B-Si-O, Li-BO, Li-CBO, Li-Al-Si-O, Li-Ti-Al-PO, Li-Zr-Al-PO, Li-La-Zr-O, Li-La-Ta-Zr-O, Li-La-Nb-Zr-O, Li-MS (M is B, Al, Si, P, Zn, Ge, Zr, Sn or any combination thereof), Li-M'-SO (M' is B, Al, Si, P, Zn, Ge, Zr, Sn or any combination thereof), Li-PSX (X is F, Cl, Br or any combination thereof), Li-PSO-X' (X' is F, Cl, Br or any combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M" is In, Zr, Sc, Ga, Nb, Ta or any combination thereof; X" is F, Cl, Br or any combination thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta or any combination thereof; X" is F, Cl, Br or any combination thereof).

[0062] Examples of the binder that may be contained in the anode layer 3 include butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE). The side chain of the binder may be modified with a functional group.

[0063] In addition, the anode layer 3 may contain an electron conductive additive, such as various types of carbon, including acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns, and fullerene carbon.

[0064] The thickness of the anode layer 3 is not particularly limited, but when a higher capacity is required, a thicker layer may be preferred. For example, the thickness of the anode layer 3 is preferably 0.1 μm to 1 mm, more preferably 60 μm to 500 μm.

[0065] The separator 4 is an electronic insulator but also an ion conductor. The electrolyte can be an organic liquid, an organic polymer or an inorganic solid. If an organic-based electrolyte (liquid or polymer) is selected, the separator 4 can be a porous membrane comprising a polymer (e.g., polyethylene (PE), polypropylene (PP) and any combination thereof); the membrane is immersed in the organic-based electrolyte.

[0066] Preferably, the separator 4 is composed of an inorganic solid because its lithium transfer number is higher than that of a liquid and its ionic conductivity is higher than that of an organic polymer. This is also because inorganic solids are generally rigid and do not show fluidity, which is preferred for constructing a stacked battery 13 without ionic short circuits.

[0067] Examples of electrolytes include organic liquids, organic polymers, inorganic solids. Preferably, the electrolyte is an inorganic solid because its lithium transfer number is higher than that of a liquid and its ionic conductivity is higher than that of an organic polymer. This is also because inorganic solids are generally rigid and do not show fluidity, which is preferred for constructing a stacked battery 13 without ionic short circuits. Preferred examples of electrolytes include materials having the following compositions: Li-PON, Li-Si-O, Li-B-Si-O, Li-BO, Li-CBO, Li-Al-Si-O, Li-Ti-Al-PO, Li-Zr-Al-PO, Li-La-Zr-O, Li-La-Ta-Zr-O, Li-La-Nb-Zr-O, Li-MS (M is B, Al, Si, P, Zn, Ge, Zr, Sn or a combination thereof), Li-M'-SO (M' is B, Al, Si, P, Zn, Ge, Zr, Sn or a combination thereof), Li-PSX (X is F, Cl, Br or a combination thereof), Li-PSO-X' (X' is F, Cl, Br or a combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M" is In, Zr, Sc, Ga, Nb, Ta or a combination thereof; X" is F, Cl, Br or a combination thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta or a combination thereof; X" is F, Cl, Br or a combination thereof).

[0068] In addition to the above-mentioned solid electrolyte material, the solid electrolyte layer may contain a binder. Examples of binders may include butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE). The side chain of the binder may be modified by a functional group.

[0069] The thickness of the separator 4 is not particularly limited, but when a higher capacity is required, a thinner layer may be preferred. For example, the thickness of the separator 4 is preferably 0.1 μm to 1 mm, more preferably 0.1 μm to 50 μm.

[0070] The electronic and ionic insulator 5 is to enhance the insulation between the layers so that the stacked battery 13 can present a high voltage. It is finely formed on the current collector 1, carefully wrapping the long and short sides of the current collector 1. It exists to ensure that any surface area on the current collector 1 that is not occupied by the cathode layer 2 or the anode layer 3 is completely shielded.

[0071] In terms of electrical properties, the electronic and ionic insulator 5 is designed to be an excellent insulator. Its conductivity must be less than 10 -8 S / cm, a more stringent and ideal threshold is less than 10 -10 S / cm. This ensures that the insulator is working at its optimum, providing maximum protection against any unwanted current flow.

[0072] The location of the electronic and ionic insulator 5 is not strictly limited. The guiding principle is that the current collector 1 should be fully shielded. In practice, this can mean that the insulator 5 can be located on both sides of the current collector - one side facing the cathode layer 2 and the other side facing the anode layer 3.

[0073] While the exact area of ​​the insulator 5 on the surface of the current collector 1 is not strictly defined, it is critical that it fully covers any exposed area left at the edge of the electrode active material layer. The key is that it electronically insulates the surface of the current collector 1. However, it is critical to avoid forming the insulator 5 on the cathode layer 2 or the anode layer 3. When manufacturing stacked batteries 13, this placement may cause problems during the bonding process. The overlap between the electrode layer and the insulator layer may produce areas of uneven pressure. This pressure difference can damage the current collector 1 and even the diaphragm layer. In addition, the overlapping area will naturally be thicker than the edge of the electrode alone, thereby compromising the sealing ability of the insulator. Any slack in the seal may cause ionic short circuits, and the ionic conductor may seep out or slip out of the diaphragm. In the most serious cases, direct contact between the diaphragm layers can cause ionic short circuits, seriously affecting the function of the battery pack.

[0074] The gap or distance between the cathode layer 2 and the insulator 5, expressed as the width (r) of the exposed surface of the current collector 1, should be carefully calibrated to ensure interlayer insulation. It is not limited by the stiffness parameter, but ideally the width r should be between 0.0001% and 10% of the square root of S, where S represents the area of ​​the cathode layer 2 in cm 2 This ensures a balanced design that provides optimal insulation while maintaining the structural integrity and performance of the battery pack. The gap or distance criteria between the cathode layer 2 and the insulator 5 apply to the gap or distance criteria between the anode layer 3 and the insulator 5.

[0075] The material for the electronic and ionic insulator 5 is not limited to a specific material as long as the material has the required insulating ability. Thermoplastics may be preferred because the softened plastic can fill the gaps or voids generated during the lamination process, and due to fluidity or plastic deformation, it can also cover the edges of the current collector 1 and the separator 4 after the lamination process. Examples of materials for the electronic and ionic insulator 5 include acrylic acid, such as polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamide-imide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE).

[0076] The insulator 5 can be made of a variety of different materials. Figure 1 As shown, the vertical edge 5a need not be of the same material as the horizontal edge 5b.

[0077] The bipolar battery pack of the present invention is an improvement over the existing bipolar battery packs because in the stacked battery 13, only the top and bottom current collectors 1 are exposed to the external environment. In the stacked battery 13, the edge of the stack is completely covered by a reinforcement made of an insulator 5, and the current collector 1, the cathode layer 2, the anode layer 3, and the separator 4 are not exposed. In addition, in the stacked battery 13, the area of ​​the separator 4 is larger than the cathode layer 2 and the anode layer 3, but smaller than the current collector 1. With this configuration, short circuits caused by ions contacting another layer can be avoided, while internal short circuits (cathode and anode) can be avoided. Finally, in the stacked battery 13, the current collectors 1 and separators 4 of different layers are not in contact.

[0078] Airtight bags

[0079] Figures 15 to 18The airtight bag 23 shown in FIG. 1 plays multiple roles in the overall architecture of the proposed battery pack system. The airtight bag 23 includes a current collector 21 and an insulator 20 , and has multiple functions.

[0080] One of the main functions of the airtight bag 23 is its strong protection against moisture intrusion. By being airtight, it forms an impermeable barrier, ensuring that no moisture can enter the stacked cells 13 inside it. The importance of this feature cannot be underestimated, as moisture intrusion can damage the overall health, efficiency and life of the battery cells.

[0081] In addition to being moisture-proof, the bag 23 has a notable feature that creates a vacuum environment for the stacked battery 13. By doing so, the environment within the bag 23 remains inert, which is critical to maintaining the chemical and physical integrity of the stacked battery 13. The inert environment ensures that there are no undesirable chemical reactions that would otherwise compromise the performance or safety of the battery. In addition, the airtight bag 23 provides atmospheric pressure for the stacked battery 13. This feature is cleverly designed without the need to add any mechanical parts. Applying moderate pressure to the battery pack has many benefits. It can help reduce the internal resistance inside the battery pack, thereby enhancing the cycle capacity and overall efficiency of the battery pack.

[0082] After the vacuum lamination process, the airtight bag 23 is suitable for further densification of the stacked cells 13 using an isostatic press. This ensures that the battery assembly is evenly compacted, thereby ensuring optimal performance and service life.

[0083] The airtight bag 23 plays a role in achieving the vacuum operation of the system. Since the current collector 21 of the airtight bag 23 establishes an electrical connection with the stacked battery 13, it ensures that the battery operates seamlessly under vacuum conditions.

[0084] The insulator 20 may be the same material as the electronic and ionic insulator 5 used in the stacked cell 13, or it may be a different material. Any suitable material may be used, provided it is not electronically and ionically conductive. It may be a ceramic or a plastic, particularly if it has a low permeability to moisture and oxygen. Plastics are particularly desirable if the process requires pressurizing the stacked cell 13 using an airtight bag 23. This is because plastics are generally more flexible than ceramics, some plastic deformation is expected during pressurization, and the risk of cracking is expected to be less than for brittle ceramics.

[0085] Plastic materials used for the insulator 20 include acrylics, such as polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamide-imide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE).

[0086] There may also be other different thermoplastic materials 22 in the insulator 20. This is expected to improve the thermal weldability of the insulator 20 and reduce moisture permeability, thereby maintaining a high vacuum. If a thermoplastic material 22 is used, its welding temperature should be lower than the welding temperature of the insulator 20. This will improve the airtightness of the airtight bag 23 while maintaining the mechanical strength of the insulator 20.

[0087] The thermoplastic layer 22 may be composed of a single material or may be multi-layered and composed of a variety of materials. For example, if it is a single material, acrylic acid, such as polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamide-imide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE) are candidate materials. In the case of multiple layers, it is a combination of the above materials. For example, but not limited to, PP / PE double-layer structure, PP / PE / PP three-layer structure, PE / PP / PE three-layer structure, etc. are all possible.

[0088] There is no clear regulation on the position of the thermoplastic plastic layer 22, as long as it can ensure that the joints between one insulator 20 and another insulator 20 and the joints between the insulator 20 and the current collector 21 are fully sealed. For example, it can cover the entire surface of the insulator 20, or only cover the joint between two insulators 20, or only cover the joint between the current collector 21 and the insulator 20.

[0089] The thickness of the insulator 20 is not particularly limited, but when a higher capacity is required, a thinner layer may be preferred. For example, the thickness of the insulator 20 is preferably 1 μm to 2 mm, more preferably 10 μm to 1000 μm.

[0090] The current collector 21 of the airtight bag 23 can be made of metal foil, metal mesh, etc., and metal foil is particularly preferred. Examples of metals constituting the current collector 1 include Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co and stainless steel. It can be a pure metal element, an admixture, an alloy or a coating. The metal surface can also be covered with carbon or other materials. This will ensure good adhesion to the cathode layer 2 and the anode layer 3. In addition to metals, carbon can also be used for the current collector 21. Resin composites with electronic conductors (metals or carbon) as fillers can also be used for the current collector 1. Possible carbon filler materials include acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns and fullerene carbon.

[0091] Possible filler metals include stainless steel, Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co. The shape of the filler can be spherical, fibrous, needle-like or hollow. When using needle-like or fibrous fillers, it may be effective to orient them. This is because orientation controls the flow of electrons, making it easier to interrupt the current when an abnormality occurs.

[0092] The thickness of the current collector 21 is not particularly limited, and is, for example, preferably 0.1 μm to 2 mm, and more preferably 10 μm to 1000 μm.

[0093] The bipolar battery of the present invention is an improvement over the existing bipolar batteries because the airtight bag 23 is provided with the current collector 21 and the insulating surface 20. In addition, the airtight bag 23 allows the densification process of the stacking, and the airtight bag 23 is located inside the vacuum.

[0094] Battery Pack Housing

[0095] like Figure 19 to Figure 20 As shown, the bipolar battery pack is preferably contained in a battery pack housing as an integral stack of cells 13 to prevent external impact and environmental degradation during use. In addition, the housing enables people to handle the high-voltage battery pack system during operation, installation to equipment, disassembly or maintenance.

[0096] The battery housing includes a shell 37, which protects the stacked cells 13 (which may or may not be in the airtight bag 23) from external air and impact during actual use. In addition to the mechanical strength required of ordinary battery cells, the shell 37 should have a more insulating structure because the voltage of the stacked cells 13 is higher than that of ordinary electrochemical cells. The material should be composed entirely of electrically insulating materials. For example, metal shells commonly used for lithium-ion batteries or nickel metal hydride batteries are not ideal because of concerns that insulation breakdown may impair battery performance.

[0097] Ceramics, rubber or plastics are possible materials for the housing 37. For ceramics, aluminum oxide, silicon dioxide or zirconium oxide may be considered. For plastics, examples include acrylics, such as polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamide-imide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF) and polytetrafluoroethylene (PTFE).

[0098] In order to ensure the performance of the stacked battery 13, the housing 37 is preferably a sealed structure. For example, O-rings, welding, adhesives, etc. can be used to create a sealed structure. When sealing the housing 37, the internal atmosphere should be considered from two perspectives. First, from the perspective of the chemical stability of the battery pack itself, the concentrations of moisture and oxygen should preferably be lower. In addition, considering that there may be high voltages in the stacked battery 13, rare gases such as He, Ar, and Xe should be avoided because these gases easily cause dielectric breakdown under high voltage conditions. Taking the above into account, the atmosphere inside the stacked battery 13 should be vacuum, N2, SF6, etc.

[0099] The housing 37 is equipped with an electrical connector 36 for making an electrical connection with the stacked battery 13, characterized in that the electrical connector 36 is located at a height h below the top surface of the housing 37. To this end, the housing 37 has a recess 38 in which the electrical connector 36 is placed. This structure reduces the risk of accidental external short circuits of the stacked battery 13 during installation, transportation and maintenance of the battery pack. Due to the distance of the electrical connectors 36a and 36b along the housing 37, the risk of external short circuits due to leakage discharge is also reduced.

[0100] The recess 38 has a depth h and has an electrical connector 36 therein. The shape of the recess may be cylindrical, square, polygonal, hemispherical, or any other shape. Its lower area should be as small as possible to reduce the risk of accidental external short circuits. In other words, the recess 38 should be larger than the electrical connector 36, the connectors and wiring of the external circuit, and should be large enough to facilitate maintenance, etc., but it does not have to be larger than this. The depth h of the recess 38 is not specified, and in terms of energy density, h should be as small as possible, but in terms of insulation resistance and external short circuit risk, a larger h is preferred. It can be designed accordingly according to the battery pack voltage. For example, h can be from 2 mm to 100 mm, although it is not limited to this value. The depth h1 on the positive electrode side and the depth h2 on the negative electrode side do not have to be the same. For example, one of them can be set to zero.

[0101] The electrical connector 36 may be in the shape of, for example, a screw (external or internal thread), a pin, a foil, a plate, a needle, etc. Preferred materials are metals, such as copper, aluminum, and stainless steel.

[0102] The bipolar battery pack of the present invention is an improvement over the existing bipolar battery packs because the battery pack housing is made of an electronic / ionic insulator. The battery pack housing has an electrical connector 36, which is placed in a recess 38 to avoid short circuits during handling / installation / removal / connection. In addition, the battery pack housing is sealed and filled with an inert substance such as vacuum, N2, SF6, etc., but not a rare gas.

[0103] The method for manufacturing a high voltage electrochemical cell includes the following steps.

[0104] The method for manufacturing a high-voltage electrochemical battery includes the following steps: a process of protecting the edge of the current collector 1 by placing an insulator 5 at the edge of the current collector 1; a process of manufacturing an electrode layer by preparing a self-supporting film of the cathode layer 2 and the anode layer 3; a process of placing the self-supporting film prepared by the above process at a position r inside the current collector 1 where the insulator 5 is formed on the edge of the current collector 1; and a process of manufacturing the cathode layer 2 and the anode layer 3. The process includes an electrode bonding process, wherein the self-supporting film prepared by the above process is placed at a position r inside the current collector 1 where the insulator 5 is formed on the edge of the current collector 1, the cathode layer 2 and the anode layer 3 are bonded to the current collector 1, and the anode layer 3 / current collector 1 / cathode layer 2 / anode layer 3 prepared by the above process are bonded to both sides or one side of the cathode layer 2. The cathode layer 2 is formed on both sides or one side of the cathode layer 2, and a stack 6 or 7 or 8 is formed.

[0105] A cathode terminal stack 9 or 10 in which only a cathode layer 2 is formed on a current collector 1, and an anode terminal stack 11 or 12 in which only an anode layer 3 is formed on a current collector 1 are prepared. A stack 11 or 12 in which only an anode layer 3 is formed on a current collector 1 is prepared. Each process is the same as the bipolar stacking process, so the description is omitted here.

[0106] The stacks and terminal stacks prepared in the above process are stacked by compaction under high pressure to obtain a stacked battery 13. At this time, the airtight bag 23 may or may not be provided.

[0107] The stacked battery 13 produced by the above process is inserted into the housing 30 and sealed. This process produces a high voltage electrochemical battery.

[0108] refer to Figure 21 to Figure 24, another embodiment of a stacked battery 13' is shown. Similar to the stacked battery group 13, in the direction from the high voltage side to the low voltage side, the stacked battery 13' can be composed of a current collector 1, a cathode layer 2, a separator 4, an anode layer 3 and another current collector 1. This configuration of elements 1, 2, 4, 3, 1, 2, ... 2, 4, 3, 1 can be repeated in this repetitive order to form a stacked battery 13'. Each layer is formed in such a way that no layer contacts any other layer inside / between the stack.

[0109] The stacked battery 13' may have an insulator 5. The insulator 5 may be used to enhance interlayer insulation, thereby allowing the stacked battery 13' to present a high voltage. The insulator 5 may be finely formed on the current collector 1. The insulator 5 may be configured to ensure that any surface area on the current collector 1 that is not occupied by the cathode layer 2 or the anode layer 3 is completely shielded.

[0110] In terms of its electrical properties, the insulator 5 can be designed to be an excellent insulator. The insulator 5 can be formed of a material that does not have electronic or ionic conductivity. The electrical conductivity of the insulator 5 can be less than 10 -8 S / cm, a more stringent and ideal threshold is less than 10 -10 S / cm. This ensures that the insulator 5 can work at its optimum, providing maximum protection against any undesired current flow.

[0111] The position of the insulator 5 is not strictly limited. The guiding principle is that at least one exposed side of the current collector 1 should be fully shielded. For example, the insulator 5 can cover a portion of the exposed edge of one side of the current collector 1. Fig.21 and Fig. 22 In the embodiment shown, the insulator 5 may be formed on each surface 1A of the current collector 1 adjacent to the anode layer 3. Fig. 22 As shown, the height of the insulator 5 can be less than the height of the anode layer 3. Alternatively, as Fig.23 As shown, the insulator 5 may be formed on the surface 1B of each current collector 1 adjacent to the cathode layer 2. Fig.23 As shown, the height of the insulator 5 may be smaller than the height of the cathode layer 2. Alternatively, the insulator 5 may be formed on both surfaces 1A and 1B of the current collector 1 attached to each of the cathode layer 2 and the anode layer 3, as shown in FIG. Fig.24 As shown. Fig.24 As shown, the height of the insulator 5 may be smaller than the height of the anode layer 3 and the height of the cathode layer 2 .

[0112] The insulator 5 may be laminated onto the current collector 1, but this is not necessary. Laminating the insulator 5 onto the current collector 1 can simplify the production process.

[0113] The insulator 5 may not completely seal the edges of the current collector 1. This configuration may allow gas to escape. During the densification process, completely sealing the edges of the current collector 1 may cause gas to be trapped, forming bubbles. These bubbles may increase the impedance of the stacked battery 13' and may accelerate degradation. In addition, during long-term cycling, completely sealing the gas may trap the gas, which may cause the impedance of the stacked battery 13' to increase and further degradation.

[0114] Furthermore, during the pressurization step in the manufacturing process of the stacked battery 13 ′, not sealing the edges can be beneficial for relieving stress, thereby avoiding cracking of the current collector 1 or the insulator 5 .

[0115] While the exact area of ​​the insulator 5 on the exposed surface of the current collector 1 may not be strictly defined, it may be critical that the insulator 5 adequately covers any exposed areas left at the edges of the electrode active material layers. The key may be that the insulator 5 electronically insulates the surface of the current collector 1. However, it may be important to avoid forming the insulator 5 on exposed areas of the cathode layer 2 or anode layer 3. Such placement may be problematic during the bonding process when preparing stacked cells 13'. The overlap between the electrode and the insulator 5 can create areas of uneven pressure. This pressure difference may damage the current collector 1 and even the separator 4. In addition, the overlapping area will naturally be thicker than the edges of the electrodes alone, thereby compromising the insulating properties.

[0116] When the insulator 5 is applied, a gap T may be formed on the current collector 1. The distance of the gap T on the current collector 1 should be carefully calibrated to ensure interlayer insulation. It is not limited by the rigidity parameter, but the distance should be between 0.0001% and 10% of the square root of S6, where S6 can represent the area of ​​the anode layer 3 in cm 2 This can ensure a balanced design that provides optimal insulation while maintaining the structural integrity and performance of the stacked cell 13'. The gap or distance criteria between the anode layer 3 and the insulator 5 can also be applied to the gap or distance criteria between the cathode layer 2 and the insulator 5.

[0117] The material used for the insulator 5 is not limited to a specific material, as long as the material has the required insulating ability. The materials used may have been listed above. Thermoplastics may be preferred because the softened plastic can fill the gaps or voids that may be generated during the lamination process, and due to fluidity and plastic deformation, it can also cover the edges of the current collector 1 and the separator 4 after the lamination process. Examples of insulators 5 may include, but are not limited to: acrylic acid, such as polyacrylic acid (PAA), poly (methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamide-imide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE). The insulator 5 can be composed of a variety of different materials, such as a combination of the above materials.

[0118] refer to Figures 25 to 30 , showing another embodiment of the stacked battery 13". Similar to the stacked batteries 13 and 13', in the direction from the high voltage side to the low voltage side, the stacked battery 13' can be composed of a current collector 1, a cathode layer 2, a separator 4, an anode layer 3 and another current collector 1. This configuration of elements 1, 2, 4, 3, 1, 2, ... 2, 4, 3, 1 can be repeated in this repeating order to form a stacked battery 13". Each layer is formed in such a way that no layer is in contact with any other layer inside / between the battery stack.

[0119] The exposed edge of the current collector 1 may be covered by an insulator 5. The insulator 5 does not have electronic or ionic conductivity. The insulator 5 may cover a portion of the exposed edge of one side of the current collector 1. Figure 25 to Figure 26 and Figures 28 to 29 In the embodiment shown, the insulator 5 may be formed on each surface 1A of the current collector 1 adjacent to the anode layer 3. Alternatively, as Fig. 27 As shown, the insulator 5 may be formed on the surface 1B of each current collector 1 adjacent to the cathode layer 2. Alternatively, the insulator 5 may be formed on both surfaces 1A and 1B of each current collector 1 attached to the cathode layer 2 and the anode layer 3, as shown in FIG. Fig.30 shown.

[0120] like Figures 25 to 26As shown, when the insulator 5 is attached to the exposed surface of the current collector 1 adjacent to the anode layer 3, the current collector 1 can be designed to bend upward at the edge of the anode layer 3 to create a sloped edge 1A for the stacked battery 13". The sloped edge 1A can enhance the structural integrity and ionic insulation of the battery by covering the separator 4 upward from the outside of the battery. The insulator 5 can be laminated to the current collector 1 and bent upward with the current collector 1, thereby ensuring proper insulation and alignment inside the stacked battery 13" configuration.

[0121] The separator 4 can also be bent upward with the current collector 1. It is worth noting that the separator 4 can be smaller than the current collector 1 and the insulator 5, thereby ensuring that the separator 4 is not exposed to the external surface. This design can minimize the risk of damage to the separator 4 and can maintain the insulation integrity.

[0122] The angle X of the inclined edge 1A relative to the bottom of the current collector 1 that can be laminated to the anode layer 3 can be 3 degrees to 90 degrees. More specifically, the angle X can be 5 degrees to 80 degrees. The inclined edge 1A may be beneficial to improve the insulation between the layers and prevent electrical short circuits.

[0123] like Fig. 27 As shown, if the insulator 5 is attached to the cathode side of the current collector 1 surface, the same criteria used between the anode layer 3 and the insulator 5 also apply to the criteria used between the cathode layer 2 and the insulator 5. In addition, as Fig.30 As shown, if the insulator 5 is laminated on both sides of the current collector 1, the angle X may be 3 degrees to 90 degrees. More specifically, the angle X may be 5 degrees to 80 degrees.

[0124] In the stacked battery 13 ″, similar to the stacked battery 13 ′, a gap T may be formed on the current collector 1. Fig.30 As shown, when forming the inclined edge 1A, the separator 4 can be applied and squeezed in the gap T between the cathode layer 2 or the anode layer 3. Since the anode layer 3 (or the cathode layer 2 or both) can be covered by the separator 4, the squeezed separator 4 can improve the electrical insulation of the stacked battery 13".

[0125] As described below, stacked batteries 13" have been prepared and tested. The resulting stacked battery group 13" can satisfy the following area relationship:

[0126] S1>S3>S4>S2>S5≥S6 or S1>S3>S4>S2>S6≥S5, where:

[0128] S1 = area created by the outer edge of the insulator 5

[0129] S2 = area created by the inner edge of the insulator 5

[0130] S3 = Area of ​​current collector 1

[0131] S4 = Area of ​​diaphragm 4

[0132] S5 = Area of ​​cathode layer 2

[0133] S6 = area of ​​anode layer 3

[0134] A carbon-coated aluminum foil (area S3) with a thickness of 40 μm is prepared as the current collector 1, and a polyetherimide (PEI) film with a thickness of 25 μm, which may be provided with an adhesive polyisobutylene (PIB), is attached to one side of the carbon-coated aluminum foil as the insulator 5. The outer and inner edges of the insulator 5 generate areas S1 and S2, respectively.

[0135] The cathode layer 2 may be made of a cathode active material (LiNi 1 / 3 Co 1 / 3 Mn 1 / 3 The powders of O2, MTI), solid electrolyte (SSE-10, NEI) and PTFE (Daikin America) were mixed in a ratio of 87:12:1 (wt%). The mixture was then stretched into a sheet with a thickness of 120 μm to form the cathode layer 2. The area of ​​the cathode layer 2 is S5.

[0136] The anode layer 3 may be made of an anode active material (Li4Ti5O 12 , MSE Supply LLC), solid electrolyte (SSE-10, NEI), carbon black (Imerys) and PTFE (Daikin America) powders were mixed in a ratio of 80:15:1:4 (wt%). The mixture was then stretched into a sheet with a thickness of 300 μm to form an anode layer 3. The area of ​​the anode layer 3 was S6.

[0137] The separator 4 may be made by mixing powders of a solid electrolyte (SSE-10, NEI) and PTFE (Daikin America) at a ratio of 97:3 (wt%). The mixture is then rolled into a sheet with a thickness of 120 μm to form the separator 4. The area of ​​the separator 4 is S4.

[0138] A stacked battery 13" can be manufactured by stacking unit cells consisting of a current collector 1, an anode layer 3, a separator 4 and a cathode layer 2. These layers can be stacked in the order of current collector 1, anode layer 3, separator 4, cathode layer 2, current collector 1. This configuration of elements 1, 2, 4, 3, 1, 2, ... 2, 4, 3, 1 can be repeated in this repetitive order. A total of 10 electrochemical cells can be stacked to form a bipolar stacked battery 13". Only the surface of the last current collector 1 that is in contact with the cathode layer 2 can be free of an insulator. The areas of S1, S2, S3, S4, S5 and S6 are listed in Table 1 below. The area satisfies S1>S3>S4>S2>S6≥S5.

[0139] The edge of the inclined edge 1A of the stacked battery 13" may be bent at an angle (X) of 80 degrees.

[0140] Table 1

[0141] <![CDATA[S1 / cm 2 ]]> <![CDATA[S2 / cm 2 ]]> <![CDATA[S3 / cm 2 ]]> <![CDATA[S4 / cm 2 ]]> <![CDATA[S5 / cm 2 ]]> <![CDATA[S6 / cm 2 ]]> 9.07 6.15 8.04 7.07 3.80 4.91

[0142] The bipolar stacked battery 13" can deliver 1.0 mA / cm2 of current in the voltage range of 15 V to 27 V. 2 The bipolar stack battery 13" can be charged and discharged without any ionic or electronic short circuit. The charge and discharge curves are shown in FIG. Fig.31 shown.

[0143] As a comparison with the above-mentioned embodiments, the stacked battery 13" is again prepared and tested as described below. In this embodiment, the stacked battery 13" satisfies the same area relationship as described above. The current collector 1 is formed in the same manner as in the previous test embodiment, except that the thickness of the polyetherimide (PEI) film is different. In this test embodiment, a PEI film with a thickness of 250 μm and provided with an adhesive polyisobutylene (PIB) is attached to one side of a carbon-coated aluminum foil as an insulating frame. The remaining structure of the stacked battery 13" remains unchanged. Therefore, the manufacture of the cathode layer 2, the anode layer 3, the separator 4, and the manufacture of the stacked battery 13" are the same as in the previous test embodiment.

[0144] In this test embodiment, the edges of the stacked cells 13" are not bent. Therefore, the angle X is 0°.

[0145] Table 2

[0146] <![CDATA[S1 / cm 2 ]]> <![CDATA[S2 / cm 2 ]]> <![CDATA[S3 / cm 2 ]]> <![CDATA[S4 / cm 2 ]]> <![CDATA[S5 / cm 2 ]]> <![CDATA[S6 / cm 2 ]]> 9.07 6.15 8.04 7.07 3.80 4.91

[0147] Table 3

[0148] X(degrees) Coulombic efficiency of the second cycle (%) Example 80 94.4 Comparative Example 0 64.9

[0149] The bipolar stack cell 13" has a voltage range of 15V to 27V at 1.0mA / cm2 However, at the second cycle, it showed a low Coulombic efficiency (64.9%). In addition, despite the same number of stacks, the voltage curve was lower than the previous tested embodiment. The low Coulombic efficiency and overall low voltage curve indicate that a short circuit has occurred in the battery. The charge and discharge curves can be seen as Fig.32 shown.

[0150] The above description is to enable those skilled in the art to implement the various embodiments described herein. It will be apparent to those skilled in the art that various modifications to these embodiments will be apparent, and the general principles defined herein may be applied to other embodiments. Therefore, the claims are not intended to be limited to the embodiments shown and described herein, but should be given the full scope consistent with the language of the claims, wherein unless otherwise specified, singular references to elements do not mean "one (kind) and only one (kind)", but "one (kind) or more (kinds)". The elements of each embodiment described in the present disclosure are structural and functional equivalents known to those skilled in the art or later, are expressly incorporated herein by reference, and are intended to be included in the claims. In addition, nothing disclosed herein is intended to be dedicated to the public.

Claims

1. A bipolar stacked battery pack comprising: A plurality of bipolar electrodes, wherein each bipolar electrode comprises: current collector; a cathode layer comprising a cathode active material formed on a first surface of the current collector; an anode layer comprising an anode active material formed on the second surface of the current collector; a separator layer formed on the cathode layer and the anode layer, wherein the separator layer extends beyond opposite side edges of the cathode layer and the anode layer; and an insulator formed on an exposed side edge of at least one side of the current collector, the insulator extending beyond the current collector; A pair of terminal stacks, wherein one of the pair of terminal stacks is formed on a higher voltage side of the bipolar stack battery and a second of the pair of terminal stacks is formed on a lower voltage side of the bipolar stack battery. 2 . The bipolar stacked battery of claim 1 , wherein the insulator covers all exposed surfaces of current collectors, cathode layers, anode layers, and separators of the plurality of bipolar electrodes.

3. The bipolar stacked battery pack according to claim 1, wherein the pair of terminal stacks comprises: a cathode terminal stack formed on the higher voltage side of the bipolar stack battery, the cathode terminal stack comprising: a cathode terminal current collector; and a cathode terminal layer including a cathode terminal active material formed on a first surface of the cathode terminal current collector; and an anode terminal stack formed on a lower voltage side of the bipolar stack battery, the anode terminal stack comprising: an anode terminal current collector; and An anode terminal layer including an anode terminal active material is formed on a first surface of the anode terminal current collector.

4. The bipolar stacked battery pack according to claim 3, wherein the insulator covers all exposed surfaces of the current collectors, cathode layers, anode layers and separators of the multiple bipolar electrodes, the exposed surface of the cathode terminal layer and the exposed area on the first surface of the cathode terminal current collector, and the exposed surface of the anode terminal layer and the exposed area on the first surface of the anode terminal current collector.

5. The bipolar stack battery of claim 1, comprising an airtight bag surrounding the plurality of bipolar electrodes.

6. The bipolar stack battery of claim 5, comprising a battery housing surrounding the plurality of bipolar electrodes and the airtight bag, wherein the electrical connector is located within a recess of the battery housing. 7 . The bipolar stacked battery pack according to claim 1 , wherein opposite side edges of current collectors of the plurality of bipolar electrodes are bent upward or downward relative to a plane of the current collectors. 8 . The bipolar stacked battery assembly according to claim 7 , wherein the angle at which the opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward is 5° to 85°.

9. The bipolar stacked battery according to claim 1, comprising a gap formed between the anode layer and the insulator, the insulator being formed on an exposed area on the second surface of the current collector forming the anode layer, wherein a portion of the separator is located within the gap.

10. The bipolar stacked battery according to claim 1, comprising a gap formed between the cathode layer and the insulator formed on an exposed area on a first surface of a current collector forming the cathode layer, wherein a portion of a separator is located within the gap.

11. The bipolar stacked battery pack according to claim 1, comprising: a first gap formed between the anode layer and the insulator, the insulator being formed on an exposed area on a first surface of a current collector forming the anode layer; and A second gap is formed between the cathode layer and the insulator, the insulator is formed on an exposed area on a second surface of a current collector forming the cathode layer, wherein a separator is located in the second gap.

12. The bipolar stacked battery according to claim 9, wherein the distance of the gap is in cm 2 0.0001% to 10% of the square root of the anode layer area measured. 13 . The bipolar stacked battery pack according to claim 9 , wherein opposite side edges of current collectors of the plurality of bipolar electrodes are bent upward or downward relative to a plane of the current collectors. 14 . The bipolar stacked battery pack according to claim 10 , wherein opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward or downward relative to a plane of the current collectors. 15 . The bipolar stacked battery pack according to claim 11 , wherein opposite side edges of current collectors of the plurality of bipolar electrodes are bent upward or downward relative to a plane of the current collectors. 16 . The bipolar stacked battery assembly according to claim 13 , wherein the angle at which the opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward is 5° to 85°.

17. A bipolar stacked battery comprising: A plurality of bipolar electrodes, wherein each bipolar electrode comprises: current collector; a cathode layer comprising a cathode active material formed on a first surface of the current collector; an anode layer comprising an anode active material formed on the second surface of the current collector; a separator layer formed on the cathode layer and the anode layer, wherein the separator layer extends beyond opposite side edges of the cathode layer and the anode layer; an insulator formed on an exposed side edge of at least one side of the current collector, the insulator extending beyond the current collector; A gap is formed between at least one of the anode layer and the insulator or between the cathode layer and the insulator; the insulator is formed on an exposed area on a first surface of a current collector forming the anode layer, and the diaphragm is located in the gap between the anode layer and the insulator; the insulator is formed on an exposed area on a second surface of a current collector forming the cathode layer, wherein the diaphragm is located in the gap between the cathode layer and the insulator.

18. The bipolar stack battery according to claim 17, wherein the distance of the gap is in cm 2 0.0001% to 10% of the square root of the anode layer area measured. 19 . The bipolar stacked battery pack according to claim 17 , wherein opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward or downward relative to a plane of the current collectors. 20 . The bipolar stacked battery assembly according to claim 19 , wherein the angle at which the opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward is 5° to 85°.

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