Current collector of bipolar stacked battery

Abstract

A method of forming a bipolar battery may form a mixture of a conductive material and a non-conductive material. The method may compress a region of the mixture such that conductive materials of the mixture contact to form a conductive region, and the uncompressed mixture forms an insulating region of a bipolar battery current collector.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to batteries, and more particularly to current collectors for bipolar stacked batteries. BACKGROUND

[0002] Electric vehicles (EVs) are becoming increasingly popular in the market as replacements for traditional internal combustion engine vehicles, primarily due to their environmentally friendly nature and advanced technical features. The operation of electric vehicles relies heavily on their battery systems, which provide the necessary electrical energy to drive the electric motor.

[0003] Conventionally, to generate sufficient voltage to operate high-torque electric motors in vehicles, many batteries are connected in series. However, this design has several inherent drawbacks. First, the series stacking of batteries requires a large number of joining components.

[0004] The joining components not only result in a loss of energy and power density due to volume loss, but they also introduce additional resistance, leading to a reduction in power density. Furthermore, the joining components tend to concentrate the current around the joining area, resulting in an uneven temperature and current distribution across the battery. This ultimately leads to premature degradation of the battery system.

[0005] To address these challenges, bipolar batteries have been developed. In these batteries, the positive and negative electrodes are arranged on either side of the current collector, significantly reducing the need for joining components.

[0006] However, these bipolar batteries also have their own set of problems. Specifically, they are at risk of short-circuiting: if the current collectors from different layers come into contact, the battery cell is unable to exhibit the necessary voltage, resulting in a reduction in the total voltage. Similarly, if the electrolytes of different battery layers come into contact, the cell is again unable to generate the required voltage.

[0007] US Patent Publication US2015 / 0255797A1 discloses covering the edges of the battery cell with an insulating polymer to prevent electrical short-circuiting. Similarly, Japanese Patent JP2011151016A discloses covering the edges of a bipolar all-solid-state battery with a resin to prevent short-circuiting. The current collectors need to be physically separated. The current collectors used in the existing solutions conduct electrons throughout the current collector. This is why the edges of the battery cell must be covered with additional insulating components to prevent short-circuiting caused by contact of the current collectors.

[0008] Existing solutions include two components: an insulating component and a current collector. The current collector in current solutions conducts electrons through its own overall structure. This creates a risk of shorting with other current collectors within the battery cell, and therefore, an insulating component is inserted into the battery cell to physically keep the current collectors separated.

[0009] Accordingly, it is desirable to provide a system and method that overcomes the above problems. SUMMARY

[0010] This Summary is provided to introduce some concepts in a simplified form that are further described below in the DETAILED DESCRIPTION. This Summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used to determine the scope of the claimed subject matter.

[0011] According to one embodiment of the present application, a method of forming a bipolar battery is disclosed. The method can form a mixture of conductive material and non-conductive material. The method can compress a region of the mixture such that the conductive material of the mixture contacts to form a conductive region, and the uncompressed mixture forms an insulating region of a bipolar battery current collector.

[0012] According to one embodiment of the present application, a method of forming a bipolar battery is disclosed. The method can form a current collector. The current collector can be formed from a mixture of conductive material and non-conductive material. The method can compress an inner region of the mixture to form a conductive region, and an outer periphery of the mixture is not compressed to form an insulating region around an outer periphery of the current collector.

[0013] According to one embodiment of the present application, a method of forming a bipolar battery is disclosed. The method can form a current collector formed from a mixture of conductive material and non-conductive material. The method can compress an inner region of the mixture to form a conductive region, and an outer periphery of the mixture is not compressed to form an insulating region around an outer periphery of the current collector. The method can attach a cathode layer to a first side of the conductive region. The method can attach an anode layer to a second side of the conductive region, wherein the insulating region formed around the outer periphery of the current collector is insulating and not connected with the cathode layer and the anode layer, and wherein the mixture includes a porous material to reduce swelling during compression of the mixture.

[0014] RELATED APPLICATIONS

[0015] This patent application is related to U.S. Provisional Application 63 / 632,086, entitled “CURRENT COLLECTOR FOR BIPOLAR STACKED BATTERIES,” filed April 10, 2024, by the same inventors, the entire contents of which are incorporated herein by reference. This patent application claims the benefit of the above-identified provisional application under 35 U.S.C. § 119(e). BRIEF DESCRIPTION OF DRAWINGS

[0016] The present application is described in further detail with reference to the following drawings. These drawings are not intended to limit the scope of the present application but rather are meant to illustrate certain properties thereof. In all the drawings, like reference numbers will be used to refer to like or similar components.

[0017] Figure 1 A side view of an exemplary current collector for use in a bipolar stacked battery according to embodiments of the present disclosure is shown;

[0018] Figure 2 A side view of an exemplary current collector for use in a bipolar stacked battery according to embodiments of the present disclosure is shown;

[0019] Figure 3a A top view of an exemplary current collector for use in a bipolar stacked battery according to embodiments of the present disclosure is shown having compressed and uncompressed regions;

[0020] Figure 3b An enlarged side view of an uncompressed region of an exemplary current collector for use in a bipolar stack according to embodiments of the present disclosure is shown; Figure 3a

[0021] Figure 3c An enlarged side view of a compressed region of an exemplary current collector for use in a bipolar stack according to embodiments of the present disclosure is shown; Figure 3a

[0022] Figure 4a A top view of an exemplary current collector for use in a bipolar stacked battery according to embodiments of the present disclosure is shown before being compressed;

[0023] Figure 4b A top view of an exemplary current collector for use in a bipolar stacked battery according to embodiments of the present disclosure is shown after being compressed;

[0024] Figure 5 A side view of an exemplary bipolar stacked battery melting a current collector in a compressed state according to embodiments of the present disclosure is shown;

[0025] Figure 6 ​​A side view of a portion of a bipolar stacked battery is shown according to embodiments of the present disclosure Figure 5 A side view of a portion of a bipolar stacked battery is shown according to embodiments of the present disclosure

[0026] Figure 7 A side view of a portion of a bipolar stacked battery is shown according to embodiments of the present disclosure

[0027] Figure 8 A side view of a portion of a bipolar stacked battery is shown according to embodiments of the present disclosure DETAILED DESCRIPTION

[0028] The description set forth below is intended as a description of the currently preferred embodiments of the present disclosure and is not intended to represent the only forms in which the present disclosure can be constructed and / or utilized. The description sets forth functions and sequences of steps that can be implemented in various embodiments of the present disclosure. However, the description is not intended to limit the embodiments to the form disclosed herein. Rather, the description is intended to cover all possible modifications and forms, such as modifications, adaptations, and equivalents of the functions and steps described.

[0029] In the present disclosure, a bipolar battery can be disclosed in which only one component is required to achieve the functions of an insulating component and a current collector. The proposed current collector can be compressed by pressure, and only the compressed region can maintain electronic conductivity. When assembling a bipolar battery, the proposed current collector can be compressed in a region in contact with an electrode and a separator. Thus, at the edges of the bipolar battery, the current collector that can not be in contact with the electrode or the separator can remain uncompressed, and thus, the edges of the bipolar battery can maintain insulation at the edges.

[0030] The present disclosure can allow a user to limit the electronically conductive region within the current collector, thereby allowing the current collector to have both a conductive region and an insulating region. In other words, the current collector can function as both a current collector and an insulating component. This can help to reduce the number of components, helping to improve yield. In addition, by eliminating the need for additional insulating material, the side of the battery can be an open-ended edge. This can also enable one to prevent air bubbles from being trapped in the battery stack, which can help to improve the performance and yield of the battery.

[0031] As Figure 1As shown, the current collector 10 can be a composite material 12 made of a mixture of electronically conductive materials and non-conductive materials to provide unique electrical properties and structural advantages. The conductive materials can include, but are not limited to, copper, nickel, chromium, gold, platinum, silver, aluminum, iron, titanium, zinc, cobalt, and stainless steel or carbon. These conductive materials can be in different forms, such as spherical, needle-like, fibrous, or other forms. In addition, combinations of different conductive materials and forms are also possible. The non-conductive materials can include, but are not limited to, plastic materials such as Polyacrylic acids (PAA), Poly(methylmethacrylate) (PMMA); Acrylonitrile butadiene styrene (ABS); Polyamide (PA); Polyimide (PI); Polyamide-imide (PAI); Polycarbonate (PC); Polyoxymethylene (POM); Polyether ether ketone (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). These materials can be enhanced by functional group-modified characteristic side chains to improve performance. In addition, the non-conductive components can be composed of inorganic materials such as silicon dioxide (SiO2), aluminum oxide (Al2O3), zirconium dioxide (ZrO2), zinc oxide (ZnO), titanium dioxide (TiO2), iron oxide (Fe2O3), sodium carbonate (Na2CO3), sodium sulfate (Na2SO4), magnesium carbonate (MgCO3), magnesium sulfate (MgSO4), calcium carbonate (CaCO3), calcium sulfate (CaSO4), sulfur (S), phosphorus sulfide (P2S5), titanium sulfide (TiS2), and zinc sulfide (ZnS).

[0032] According to an embodiment, the conductive material may include non-conductive material particles. The non-conductive material may be polyacrylic acid (PAA), polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamideimide (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), SiO2, Al2O3, ZrO2, ZnO, TiO2, Fe2O3, Na2CO3, Na2SO4, MgCO3, MgSO4, CaCO3, CaSO4, S, P2S5, TiS2, ZnS, and a combination thereof. The non-conductive material may be coated with a conductive material. The conductive material may be one of copper, nickel, chromium, gold, platinum, silver, aluminum, iron, titanium, zinc, cobalt, stainless steel, carbon, or a combination thereof, thereby forming a conductive material.

[0033] The composition of the composite material 12 made of conductive and non-conductive materials within the conductive region can be varied. The volume occupied by the conductive and non-conductive materials can be varied, and voids (air pockets) can be included within the matrix. Furthermore, the distribution of voids, conductive materials, and non-conductive materials can be varied to optimize and customize the current collector 10 for specific application requirements.

[0034] like Figure 2 As shown, the current collector 10 can be compressible. When the thickness of the current collector 10 is reduced due to compression, the embedded conductive materials contact each other to form a network of conductive paths. The formed conductive network can make the current collector 10 have anisotropic conductivity or isotropic conductivity, which means that the conductivity of the current collector can be limited in different directions or different in different directions, or can be conductive in all directions. It is worth noting that the current collector 10 can conduct electrons but not ions.

[0035] Since anisotropy and conductivity can be adjusted by the degree of compression, the thickness of the current collector 10 before and after compression (T) can be unspecified. This design flexibility allows customization based on specific application requirements.

[0036] Although the compressed area can become the conductive area 12 c , but the uncompressed region of the current collector 10 may remain as the insulating region 12 i (See Figure 2 and Figure 3a 、 Figure 3b 、 Figure 3c). This can allow the current collector 10 to be compressed from the conductive regions 12 c Seamless transition to insulating regions 12 i . According to embodiments, the inner regions can form compression regions, and can become conductive regions 12 c . The outer peripheral regions in the current collector 10 can not be compressed, and can remain as insulating regions 12 i .

[0037] As shown in Figure 4a and Figure 4b , the area of the current collector 10 can or can not change before and after compression. In cases where the current collector 10 is subjected to pressure in the thickness direction of the current collector 10, the current collector 10 can be subjected to expansion in the planar direction. Generally, the more expansion in the planar direction that the current collector 10 can be subjected to, the thinner the current collector 10 can become. This can help to reduce the thickness of the battery stack. However, in cases where the current collector 10 is composed of voids (porous matrix), the planar expansion can be suppressed. This means that in Figure 4a and Figure 4b , the area before compression (a i ) can be the same as the area after compression (A i ).

[0038] Figure 5 A bipolar solid-state battery 16 is shown that uses the pressure-activated current collector 10 described above in the compressed state. In the direction from the high voltage side to the low voltage side, the bipolar battery 16 stack of cells can be composed of the current collector 10, cathode layer 2, separator 4, anode layer 3, and another current collector 10 in the repeating order, i.e., 10, 2, 4, 3, 10, 2, 4, 3, 10…10, 2, 4, 3, 10.

[0039] Referring to Figure 6 , an exploded view of a portion of the bipolar solid-state battery 16 can be seen. Here, the current collector 10 can have electron-conductive regions 12 c and non-conductive insulating regions 12 i . The electron-conductive regions 12 c may be the regions that are compressed, and these regions can be the regions that are in contact with or close to the cathode layer 2 or anode layer 3. The outer edges of the current collector 10 that can not be in contact or close to the cathode layer 2 or anode layer 3 can remain non-conductive and form insulating regions 12 i . This insulation of the edges of the current collector 10 can eliminate the need for an insulating frame that can be used in conventional bipolar batteries. For example, existing bipolar battery designs suggest the use of resin to physically isolate the current collector from shorting around the edges. However, by utilizing this pressure-activated current collector 10, shorting can be prevented without the need for additional insulation within the bipolar battery 16. Furthermore, as Figure 7As shown, the spacing (S) between the current collectors 10 can be 0 or greater than 0, as shorting does not occur even if the insulating edges of the current collectors 10 are in contact.

[0040] Referring to Figure 8 , a side view of the current collector 10 is shown. In Figure 8 , the thickness between the compressed and uncompressed regions of the current collector 10 can be seen. The current collector 10 can have a total thickness T. The electronically conductive regions 12 c that can be compressed can have a thickness t. The electronically conductive regions 12 c that can be compressed can have a thickness t. The electronically conductive regions 12 c that can be compressed can have a thickness t. The electronically conductive regions 12 c1 that can be compressed can have a thickness t. The electronically conductive regions 12 i that can be compressed can have a thickness t. The electronically conductive regions 12 i1 that can be compressed can have a thickness t. The electronically conductive regions 12 c that can be compressed can have a thickness t. The electronically conductive regions 12 c2 that can be compressed can have a thickness t. The electronically conductive regions 12 i that can be compressed can have a thickness t. The electronically conductive regions 12 i2 that can be compressed can have a thickness t. The electronically conductive regions 12

[0041] Referring to Figures 5-8 , the cathode layer 2 can be a layer containing at least a cathode active material (CAM). Examples of the CAM can include, but are not limited to, 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, etc.), lithium-containing phosphates of olivine structure (such as LiFePO4, LiFe x Mn 1-x PO4, LiMnPO4, LiFe x Co 1-x PO4, LiCoPO4, etc.), lithium-containing oxide materials of spinel structure (such as LiNi 0.5 Mn 1.5 O4, LiMn2O4), lithium-excess layered structure oxides (such as Li2MnO3, Li2RuO3, Li2Ru x Ti 1- x O3, Li2Ru x Sn 1-x O3, Li2Mn x Ti 1-x O3, Li2Mnx Sn 1-x O3, etc.), layered lithium-containing sulfide materials (such as TiS2, MoS2, NbS2, TaS2, sulfur, etc.), or lithium-containing sulfides of Chevrel structure (such as LiCu x MoS 1-z , etc.).

[0042] The surface of the CAM can be coated with a thin layer of material (coating). Examples of the coating can include, but are not limited to, crystalline phases (such as Li2ZrO3, LiNbO3, LiPO3, Li3PO4, LiTi2(PO4)3, LiZr(PO4)3, ZrO2, Al2O3, EtOLi, MtOLi, LiOH, Li2CO3, etc.) and / or amorphous phases (such as metal alkoxides or metal phosphates, etc.).

[0043] In addition to the CAM, the cathode layer 2 can also include a solid electrolyte, a binder, an electron conductive additive.

[0044] Examples of the electrolyte can include, but are not limited to, organic liquids, organic polymers, and inorganic solids. Generally, the electrolyte can be an inorganic solid because the number of lithium migration is higher than that of the liquid, and the ionic conductivity is higher than that of the organic polymer. This is also because the inorganic solid is generally rigid and does not exhibit flowability, while flowability can be more suitable for the composition of a stacked battery in which no ionic short circuit occurs.

[0045] In general, examples of electrolytes can include, but are not limited to, materials that can have materials composed of lithium-phosphorus-oxygen-nitrogen (Li-P-O-N), lithium-silicon-oxygen (Li-Si-O), lithium-boron-silicon-oxygen (Li-B-Si-O), lithium-boron-oxygen (Li-B-O), lithium-carbon-boron-oxygen (Li-C-B-O), lithium-aluminum-silicon-oxygen (Li-Al-Si-O), lithium-titanium-aluminum-phosphorus-oxygen (Li-Ti-Al-P-O), lithium-zirconium-aluminum-phosphorus-oxygen (Li-Zr-Al-P-O), lithium-lanthanum-zirconium-oxygen (Li-La-Zr-O), lithium-lanthanum-tantalum-zirconium-oxygen (Li-La-Ta-Zr-O), lithium-lanthanum-niobium-zirconium-oxygen (Li-La-Nb-Zr-O), lithium-M-sulfur (Li-M-S, M is B, Al, Si, P, Zn, Ge, Zr, Sn, or combinations thereof), lithium-M'-sulfur-oxygen (Li-M'-S-O, M' is B, Al, Si, P, Zn, Ge, Zr, Sn, or combinations thereof), lithium-phosphorus-sulfur-X (Li-P-S-X, X is F, Cl, Br, or combinations thereof), lithium-phosphorus-sulfur-oxygen-X' (Li-P-S-O-X', X' is F, Cl, Br, or combinations thereof), lithium-boron-hydrogen (Li-B-H), lithium-boron-nitrogen-hydrogen (Li-B-N-H), lithium-boron-hydrogen-oxygen (Li-B-H-O), lithium-boron-nitrogen-hydrogen-oxygen (Li-B-N-H-O), lithium-M"-X" (Li-M"-X", M" is In, Zr, Sc, Ga, Nb, Ta, or combinations thereof, X" is F, Cl, Br, or combinations thereof), lithium-M"-X"-oxygen (Li-M"-X"-O, M" is In, Zr, Sc, Ga, Nb, Ta, or combinations thereof, X" is F, Cl, Br, or combinations thereof).

[0046] Examples of binders that can be included in the cathode layer 2 can include, but are not limited to, butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binders can be modified by functional groups.

[0047] In addition, the cathode layer 2 can contain an electron conductive additive. For example, various types of carbon can include, but are not limited to, acetylene black (AB), Ketjen black (KB), Vapor Grown Carbon Fiber (VGCF), carbon nanotubes, carbon nanohorns, graphite, needle / fiber-like graphite, and fullerenes.

[0048] The thickness of the cathode layer 2 is not particularly limited, but a thicker layer can be preferred when a higher capacity is required. For example, the thickness of the cathode layer 2 can be about 0.1 um to 1 mm, and can be preferably about 60 um to 500 um.

[0049] The anode layer 3 can be a layer containing at least an anode active material (AAM). Examples of the AAM can include, but are not limited to, layered lithium-containing sulfide materials (such as TiS2, MoS2, NbS2, TaS2, etc.), titanium-containing oxides (such as Li4Ti5O12, Ti4O9, Ti2(PO4)3, etc.), tungsten-containing oxides (such as NbWO4, Nb2W4O13, etc.), vanadium-containing oxides (such as LiVO2, etc.), artificial carbon (or hard carbon), graphite, lithium metal alloys (such as LiIn, LiSn, LiSi, LiGe, LiAl, etc.), or metallic lithium. 12 x y z x 16 55 18 16 93 x x x x x

[0050] In addition to the AAM, the anode layer 3 can contain a solid electrolyte, a binder, an electron conductive additive.

[0051] Examples of the electrolyte can include, but are not limited to, organic liquids, organic polymers, and inorganic solids. In general, the electrolyte can be an inorganic solid because the number of lithium migration is higher than that of the liquid, and the ionic conductivity is higher than that of the organic polymer. This is also because the inorganic solid is generally rigid and does not exhibit fluidity, while fluidity can be more suitable for the composition of a stacked battery in which no ion short circuit occurs.

[0052] ​​​​​​​​​​​​​​​In general, examples of electrolytes can include, but are not limited to, materials having the following compositions: Li-P-O-N, Li-Si-O, Li-B-Si-O, Li-B-O, Li-C-B-O, Li-Al-Si-O, Li-Ti-Al-P-O, Li-Zr-Al-P-O, Li-La-Zr-O, Li-La-Ta-Zr-O, Li-La-Nb-Zr-O, Li-M-S (M is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-M'-S-O (M' is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-P-S-X (X is F, Cl, Br, or a combination thereof), Li-P-S-O-X' (X' is F, Cl, Br, or a combination thereof), Li-B-H, Li-B-N-H, Li-B-H-O, Li-B-N-H-O, 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).

[0053] Examples of binders that can be included in the anode layer 3 can include, but are not limited to, butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binders can be modified with functional groups.

[0054] Further, the anode layer 3 can include an electronically conductive additive. For example, various types of carbon can include acetylene black (AB), ketjen black (KB), VGCF, carbon nanotube, carbon nanohorn, graphite, needle / fiber-like graphite, and fullerene.

[0055] The thickness of the anode layer 3 is not particularly limited, but a thicker layer can be preferred when a higher capacity is required. For example, the thickness of the anode layer 3 can be about 0.1 um to 1 mm, and can be preferably about 60 um to 500 um.

[0056] The separator 4 can be an electronic insulator and an ionic 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 composed of a polymer such as polyethylene (PE), polypropylene (PP), and combinations thereof, and the like. The membrane can be immersed with an organic-based electrolyte.

[0057] Generally, the separator 4 can be composed of inorganic solids because the migration amount of lithium is higher than that of liquid, and the ionic conductivity is higher than that of organic polymers. This is also because inorganic solids are generally rigid and do not exhibit fluidity, and fluidity can be more suitable for composing a stacked battery in which ion short-circuiting does not occur.

[0058] Examples of the electrolyte can include, but are not limited to, organic liquids, organic polymers, and inorganic solids. Generally, the electrolyte can be an inorganic solid because the migration amount of lithium is higher than that of liquid, and the ionic conductivity is higher than that of organic polymers. This is also because inorganic solids are generally rigid and do not exhibit fluidity, and fluidity can be more suitable for composing a stacked battery in which ion short-circuiting does not occur.

[0059] Some examples of the electrolyte can include materials having the following compositions: Li-P-O-N, Li-Si-O, Li-B-Si-O, Li-B-O, Li-C-B-O, Li-Al-Si-O, Li-Ti-Al-P-O, Li-Zr-Al-P-O, Li-La-Zr-O, Li-La-Ta-Zr-O, Li-La-Nb-Zr-O, Li-M-S (M is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-M’-S-O (M’ is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-P-S-X (X is F, Cl, Br, or a combination thereof), Li-P-S-O-X’ (X’ is F, Cl, Br, or a combination thereof), Li-B-H, Li-B-N-H, Li-B-H-O, Li-B-N-H-O, 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).

[0060] In addition to the solid electrolyte material described above, the solid electrolyte layer can include a binder. Examples of the binder that can be included in the cathode layer 2 can include, but are not limited to, butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binder can be modified by a functional group.

[0061] The thickness of the separator 4 is not particularly limited, but a thinner layer can be preferred when a higher capacity is required. For example, the thickness of the separator 4 can be between 0.1 pm and 1 mm, and can be preferably about 0.1 pm to 50 pm.

[0062] The present invention provides a system and method for forming a current collector 10. The current collector 10 can be formed of an electrically conductive material and a non-conductive material. The current collector 10 can acquire electronic conductivity only in a compressed region. However, the current collector 10 can remain ionically insulating throughout its structure. The current collector 10 can have both an electronically conductive region and an insulating region. The insulating region can be both electronically and ionically insulating. Upon compression of the current collector 10, the conductive particles therein can form a network of conductive pathways that can render the current collector anisotropically conductive or isotropically conductive. For example, the conductivity of the current collector can be restricted in different directions or different in different directions, or can be conductive in all directions. The thickness (t) after compression must be less than the thickness (T) before compression. That is, t < T. The separation (S) between edges of the current collector after compression can be 0 or greater, i.e., S > 0. For example, the edges of the current collector that are not subjected to compression can be in contact without causing a short circuit because it remains insulating. However, the edges of the current collector 10 can also be physically separated. For example, increasing the thickness of the electrodes or separators sandwiched between the current collectors 10 can create a gap between the edges of the current collectors 10.

[0063] The previous description is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown and described herein, but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular is not intended to mean "one and only one" unless specifically so stated, but rather "one or more." Unless specifically stated otherwise, the term "some" refers to one or more. All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether these embodiments are ultimately claimed.

Claims

1. A method of forming a bipolar battery, comprising: forming a mixture of conductive and non-conductive materials; Regions of the mixture are compressed so that the conductive materials of the mixture are in contact to form conductive regions, and the uncompressed mixture forms insulating regions of a bipolar battery current collector.

2. The method according to claim 1, comprising: The conductive material of the mixture is compressed so that the conductive region has one of anisotropic conductivity or isotropic conductivity.

3. The method according to claim 1, wherein The conductive material includes at least one of copper, nickel, chromium, gold, platinum, silver, aluminum, iron, titanium, zinc, cobalt, stainless steel, carbon, or a combination thereof.

4. The method of claim 1 , comprising coating particles of non-conductive material with a conductive material, wherein The conductive material is one of the following: copper, nickel, chromium, gold, platinum, silver, aluminum, iron, titanium, zinc, cobalt, stainless steel, carbon, or a combination thereof.

5. The method according to claim 4, wherein The non-conductive material is one of the following materials: polyacrylic acid PAA, polymethyl methacrylate PMMA, acrylonitrile butadiene styrene ABS, polyamide PA, polyimide PI, polyamideimide PAI, polycarbonate PC, polyoxymethylene POM, polyetheretherketone PEEK, polyetherimide PEI, polyethylene PE, polyethylene terephthalate PET, polyphenylene ether PPO, polyphenylene sulfide PPS, polypropylene PP, polyvinyl chloride PVC, polyvinylidene fluoride PVDF, polytetrafluoroethylene PTFE, silicon dioxide, aluminum oxide, zirconium dioxide, zinc oxide, titanium dioxide, iron oxide, sodium carbonate, sodium sulfate, magnesium carbonate, magnesium sulfate, calcium carbonate, calcium sulfate, sulfur, phosphorus sulfide, titanium sulfide, zinc sulfide and combinations thereof.

6. The method according to claim 1, wherein The non-conductive material includes at least one of the following materials: polyacrylic acid PAA, polymethyl methacrylate PMMA, acrylonitrile butadiene styrene ABS, polyamide PA, polyimide PI, polyamideimide PAI, polycarbonate PC, polyoxymethylene POM, polyetheretherketone PEEK, polyetherimide PEI, polyethylene PE, polyethylene terephthalate PET, polyphenylene ether PPO, polyphenylene sulfide PPS, polypropylene PP, polyvinyl chloride PVC, polyvinylidene fluoride PVDF, polytetrafluoroethylene PTFE and combinations thereof.

7. The method according to claim 1, wherein The non-conductive material includes at least one of the following materials: silicon dioxide, aluminum oxide, zirconium dioxide, zinc oxide, titanium dioxide, iron oxide, sodium carbonate, sodium sulfate, magnesium carbonate, magnesium sulfate, calcium carbonate, calcium sulfate, sulfur, phosphorus sulfide, titanium sulfide, zinc sulfide, and combinations thereof.

8. The method according to claim 1, wherein The mixture includes a porous material to reduce expansion of the mixture during compression.

9. The method of claim 1, comprising compressing an interior region of the mixture to form the conductive region, and an outer periphery of the mixture being uncompressed to form the insulating region around an outer periphery of the current collector.

10. The method according to claim 1, comprising: An inner region of the mixture is compressed to form the conductive region, and an outer periphery of the mixture is not compressed to form the insulating region around an outer periphery of the current collector, wherein a first gap is formed between a first surface of the conductive region and a first surface of the insulating region, and a second gap is formed between a second surface of the conductive region and a second surface of the insulating region.

11. The method according to claim 1 , comprising: attaching a cathode layer to the first side of the conductive region; as well as An anode layer is attached to the second side of the conductive region.

12. The method according to claim 1, comprising: attaching a cathode layer to the first side of the conductive region; as well as attaching an anode layer to the second side of the conductive region; The insulating region formed around the outer periphery of the current collector is insulating and is not connected to the cathode layer and the anode layer.

13. A method of forming a bipolar battery, comprising: forming a current collector, wherein the current collector is formed of a mixture of a conductive material and a non-conductive material; as well as An interior region of the mixture is compressed to form a conductive region, and an outer periphery of the mixture is uncompressed to form an insulating region around the periphery of the current collector.

14. The method according to claim 13, comprising: The inner region of the mixture is compressed to form the conductive region, and a first gap is formed between a first surface of the conductive region and a first surface of the insulating region, and a second gap is formed between a second surface of the conductive region and a second surface of the insulating region.

15. The method according to claim 13, comprising: attaching a cathode layer to the first side of the conductive region; as well as An anode layer is attached to the second side of the conductive region.

16. The method according to claim 13, wherein: The conductive material includes non-conductive material particles coated with a conductive material, wherein the non-conductive material includes at least one of the following materials: polyacrylic acid PAA, polymethyl methacrylate PMMA, acrylonitrile butadiene styrene ABS, polyamide PA, polyimide PI, polyamideimide PAI, polycarbonate PC, polyoxymethylene POM, polyetheretherketone PEEK, polyetherimide PEI, polyethylene PE, polyethylene terephthalate PET, polyphenylene ether PPO, polyphenylene sulfide PPS, polypropylene PP, polyvinyl chloride PVC, polyvinylidene fluoride PVDF, polytetrafluoroethylene PTFE, silicon dioxide, aluminum oxide, zirconium dioxide, zinc oxide, titanium dioxide, iron oxide, sodium carbonate, sodium sulfate, magnesium carbonate, magnesium sulfate, calcium carbonate, calcium sulfate, sulfur, phosphorus sulfide, titanium sulfide, zinc sulfide, and combinations thereof; and the conductive material includes at least one of the following: copper, nickel, chromium, gold, platinum, silver, aluminum, iron, titanium, zinc, cobalt, stainless steel, carbon, and combinations thereof.

17. The method according to claim 13, wherein: The conductive material includes at least one of copper, nickel, chromium, gold, platinum, silver, aluminum, iron, titanium, zinc, cobalt, stainless steel, carbon, or a combination thereof.

18. The method according to claim 13, wherein The non-conductive material includes at least one of the following materials: polyacrylic acid PAA, polymethyl methacrylate PMMA, acrylonitrile butadiene styrene ABS, polyamide PA, polyimide PI, polyamideimide PAI, polycarbonate PC, polyoxymethylene POM, polyetheretherketone PEEK, polyetherimide PEI, polyethylene PE, polyethylene terephthalate PET, polyphenylene ether PPO, polyphenylene sulfide PPS, polypropylene PP, polyvinyl chloride PVC, polyvinylidene fluoride PVDF, polytetrafluoroethylene PTFE, silicon dioxide, aluminum oxide, zirconium dioxide, zinc oxide, titanium dioxide, iron oxide, sodium carbonate, sodium sulfate, magnesium carbonate, magnesium sulfate, calcium carbonate, calcium sulfate, sulfur, phosphorus sulfide, titanium sulfide, zinc sulfide and combinations thereof.

19. The method according to claim 13, wherein The mixture includes a porous material to reduce expansion of the mixture during compression.

20. A method of forming a bipolar battery, comprising: forming a current collector, wherein the current collector is formed of a mixture of a conductive material and a non-conductive material; Compressing an inner region of the mixture to form a conductive region, and leaving an outer periphery of the mixture uncompressed to form an insulating region around an outer periphery of the current collector; attaching a cathode layer to the first side of the conductive region; as well as attaching an anode layer to the second side of the conductive region; wherein the insulating region formed around the periphery of the current collector is insulating and not connected to the cathode layer and the anode layer; The mixture comprises a porous material to reduce expansion of the mixture during compression.

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