Multilayer bipolar battery and method thereof

Abstract

A method of forming a stacked bipolar battery laminates a plurality of layered cells of the stacked bipolar battery together at a time.

Description

[0001] Related applications

[0002] This patent application relates to U.S. Provisional Application No. 63 / 666,512, filed on July 1, 2024, entitled “MULTI-LAYERBIPOLAR BATTERY CURRENT COLLECTOR AND METHOD THEREFOR,” the entire contents of which are incorporated herein by reference. This patent application claims the benefit of the aforementioned provisional application pursuant to 35 U.S.SC §119(e). Technical Field

[0003] This application generally relates to high-voltage electrochemical cells including bipolar cells / battery systems, and more specifically, to multilayer bipolar cell stacks with current collectors having specific yield strength and high ductility, which prevent the current collectors from cracking during multilayer lamination processes. Background Technology

[0004] Batteries are ubiquitous devices in modern daily life. Over time, different types of batteries have been developed for various purposes, from simple single batteries to power relatively low-tech devices such as flashlights to complex multi-cell batteries to power more sophisticated devices used in industrial environments, including computers. Recently, multilayer bipolar batteries have been developed. In a multilayer bipolar battery, multiple cell layers make up the entire battery. The basic components that comprise such layers typically include electrodes, current collectors, and separators.

[0005] A common problem with multilayer bipolar cells is the risk of ion short circuits. In this regard, if electrodes from different layers come into contact due to current collector breakage caused by the manufacturing process, especially during multilayer lamination, the cell cannot exhibit the necessary voltage, resulting in lower overall voltage and poorer cycle performance.

[0006] In the past, one solution to prevent the aforementioned risk of ion short circuits involved fabricating individual monolayers in a bipolar cell to avoid current collector breakage, and then stacking the individual cell layers together to achieve high voltage. However, this solution can be problematic because it requires a significant amount of processing time to fabricate each layer individually and stack them together. For example, laminating and stacking ten layers requires ten pressurizations, while achieving ten-layer lamination requires only one pressurization to achieve ten-layer stacking. Furthermore, the contact between each layer in a stacked monolayer is looser compared to the contact between each layer in a laminated multilayer stack. This loose connection between stacked monolayers can be unstable, leading to premature battery breakdown and consequently shortened battery life.

[0007] Therefore, there is a need for a current collector for multilayer bipolar cells, possessing specific yield strength and high ductility to prevent cracking during multilayer lamination processes. Multilayer bipolar stacked cells with such a current collector are also required. This disclosure addresses these needs and provides other related advantages. Summary of the Invention

[0008] According to an embodiment of this disclosure, a method for forming a stacked bipolar battery is disclosed. This method laminates multiple layered cells of the stacked bipolar battery together in a single step.

[0009] According to embodiments of this disclosure, a method for forming a stacked bipolar battery is disclosed. The method forms a plurality of layered units. Each of the plurality of layered units includes: a first current collector having a first side and a second side, wherein each of the first current collectors has a yield strength greater than or equal to 50 MPa to prevent overexpansion and less than or equal to 1000 MPa to prevent delamination due to elastic deformation; a positive electrode layer having a first side and a second side, wherein the first side of the positive electrode layer is formed on the second side of the first current collector; a separator layer having a first side and a second side, wherein the first side of the separator layer is formed on the second side of the positive electrode layer; and a negative electrode layer having a first side and a second side, wherein the first side of the negative electrode layer is formed on the second side of the separator layer. This method laminates a plurality of layered units of a stacked bipolar battery together at a time.

[0010] According to embodiments of this disclosure, a method for forming a stacked bipolar battery is disclosed. The method includes forming a plurality of layered units, each of the plurality of layered units comprising: a first current collector having a first side and a second side, wherein each of the first current collectors has a yield strength greater than or equal to 50 MPa to prevent overexpansion and less than or equal to 1000 MPa to prevent delamination due to elastic deformation, each of the first current collectors allowing for 5% to 15% deformation; a positive electrode layer having a first side and a second side, wherein the first side of the positive electrode layer is formed on the second side of the first current collector; a separator layer having a first side and a second side, wherein the first side of the separator layer is formed on the second side of the positive electrode layer; and a negative electrode layer having a first side and a second side, wherein the first side of the negative electrode layer is formed on the second side of the separator layer. This method laminates a plurality of layered units of the stacked bipolar battery together at a time. Attached Figure Description

[0011] This application is further described in detail with reference to the following accompanying drawings. These drawings are not intended to limit the scope of this application, but rather to illustrate certain attributes. In the following description, the same parts are labeled with the same numerals throughout the specification and drawings. The drawings are not necessarily drawn to scale, and some drawings may be shown in exaggerated or generalized form for clarity and brevity. However, the disclosure itself, as well as the preferred modes of use and their further purposes and advantages, can be best understood by referring to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:

[0012] Figure 1 A side view of a multilayer bipolar battery stack apparatus according to one aspect of this disclosure shows an exemplary arrangement of battery cell components that may occur prior to a multilayer lamination process.

[0013] Figure 2 A side view of a multilayer bipolar battery stack apparatus according to one aspect of the present disclosure shows an exemplary arrangement of battery cell components that may appear after a multilayer lamination process.

[0014] Figure 3 An exploded view of a single layer of a multilayer bipolar battery stack device according to one aspect of this disclosure;

[0015] Figure 4 A side view of a single layer of a multilayer bipolar battery stack apparatus according to one aspect of this disclosure shows an exemplary arrangement of the battery cell components that may occur prior to the multilayer lamination process; and

[0016] Figure 5 The side view of a single layer of a multilayer bipolar battery stack apparatus according to one aspect of this disclosure shows an exemplary arrangement of battery cell components that may appear after a multilayer lamination process. Detailed Implementation

[0017] The following description, set forth in conjunction with the accompanying drawings, is intended as a description of the currently preferred embodiment of this disclosure and is not intended to represent the only form in which this disclosure can be constructed and / or utilized. This description, in conjunction with the illustrated embodiments, sets forth the functions and sequence of steps for constructing and operating this disclosure. However, it should be understood that the same or equivalent functions and sequence can be implemented through different embodiments that are also intended to be included within the spirit and scope of this disclosure.

[0018] Figures 1 to 5An embodiment of the multilayer bipolar battery stack apparatus 50 of the present invention is also disclosed. The multilayer bipolar battery stack apparatus 50 is characterized by a current collector with specific strength and high ductility, which prevents the current collector from breaking during the multilayer lamination process. Typically, the multilayer bipolar battery stack apparatus 50 utilizes specific mechanical properties to enable multilayer lamination of bipolar battery cells without damaging the current collectors in the multilayer stack. This significantly improves production throughput and yield, as well as potential electrical performance, while minimizing the possibility of battery short circuits due to bipolar current collector breakage.

[0019] First refer to Figure 1 This illustration shows an embodiment of the multilayer bipolar battery stack device 50 of the present invention. The multilayer bipolar battery stack device 50 typically has a layered structure comprising a plurality of individual layered units 10. Although a total of ten layered units 10 are shown in this embodiment, it should generally be understood that the number of layered units 10 used in the multilayer bipolar battery stack device 50 may deviate from this number, depending on the intended use of the multilayer bipolar battery stack device 50 and the possible needs of the corresponding configuration.

[0020] Turn now Figures 3 to 5 This paper describes an embodiment of a single-layer layered unit 10 of a multilayer bipolar battery stack device 50. Each layered unit 10 can be composed of various shapes. For example, the layered unit 10 can be circular, square, rectangular, hexagonal, trapezoidal, or some other suitable shape, depending on the desired use of the multilayer bipolar battery stack device 50 and the possible configurations that may be required. Figures 3 to 5 As shown, the layered unit 10 typically includes the following components: at least one current collector 12, a positive electrode layer 14, a separator 16, and a negative electrode layer 18. As illustrated, each layered unit 10 may include a pair of current collectors 12, comprising a first current collector 12A and a second current collector 12B (collectively referred to as current collectors 12). For each layered unit 10, the first current collector 12A may be positioned near the upper region 36 of the layered unit 10, while the second current collector 12B may be positioned near the lower region 38 of the layered unit 10, wherein the positive electrode layer 14, the separator 16, and the negative electrode layer 18 are arranged side-by-side between the current collectors 12. Figures 1 to 2 As shown, adjacent layered units 10 in the multilayer bipolar battery stack device 50 share a current collector 12, such that the second current collector 12B of the upper layered unit 10 is also used as the first current collector 12A of the lower adjacent layered unit 10.

[0021] refer to Figures 1 to 5The current collector 12 will be discussed in further detail. The current collector 12 can be made of metal foil, metal mesh, etc. Preferably, the current collector 12 is made of metal foil. Exemplary metals that can be included in the current collector 12 include Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, or stainless steel. These metals can be in pure, doped, alloyed, or cladding form. The surface of the metal can also be covered with carbon or some other suitable material. This will ensure good adhesion to the positive electrode layer 14 and the negative electrode layer 18. In addition to metals, carbon can also be used in the current collector 12. Resin composite materials with electronic conductors (metal or carbon or metal-coated plastic) as fillers can also be used in the current collector 12. Possible carbon filler materials include acetylene black (AB), ketene black (KB), VGCF, carbon nanotubes, carbon nanoparticles, graphite, needle graphite, or fullerene. Possible filler metals include stainless steel, Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, or Co. The overall shape of the packing material can vary and can be spherical, fibrous, needle-like, hollow, or some other suitable shape. When using needle-like or fibrous packing materials, orienting them can be effective. This is because orientation controls the flow of electrons and makes it easier to interrupt the current in the event of an anomaly.

[0022] It should be noted that the composition, configuration, and conductivity conditions of the current collector 12 can vary. For example, the current collector can be composed of various materials, such as metal foil (as described above), conductive film or conductive paper, or single-layer or sandwich composite materials having various conductive agents treated using different methods. The current collector 12 can also conduct electricity continuously, for example by using metal foil, or only conduct electricity after the battery is manufactured, for example by using a composite material whose conductivity is activated only after compression. In addition, the conductivity of the current collector 12 can be isotropic or anisotropic.

[0023] Regarding the dimensions of the current collector 12, the thickness of the current collector 12 is generally not particularly limited, but is preferably from 0.1 μm to 1 mm, more preferably from 1 μm to 50 mm. Furthermore, the area of ​​the current collector 12 can vary. For example, the area of ​​the current collector 12 can be relatively larger or smaller than the positive electrode layer 14, the negative electrode layer 18, or the separator layer 16, or have an area size falling between the dimensions of the different corresponding layers (i.e., the positive electrode layer 14, the separator layer 16, and / or the negative electrode layer 18).

[0024] Regarding the shape, the shape of the current collector 12 can vary. For example, the shape of the current collector 12 can be various shapes, such as circle, square, rectangle, hexagon, trapezoid, etc.

[0025] It should also be noted that the current collector 12 may include an insulating frame or may be independent.

[0026] When subjected to the stresses required for lamination, the current collector 12 needs the ability to plastically deform (as discussed further below), but it must not deform prematurely during the lamination process. The ductility of the current collector 12 should also be high enough that it deforms together with the rest of the multilayer bipolar battery stack 50 without breaking during the manufacturing process. For example, the current collector 12 should have a yield strength of 50 MPa to 1000 MPa and an elongation at break of at least 5% to prevent battery short circuits due to breakage of the current collector 12 during the multilayer lamination process.

[0027] Now turning to the positive electrode layer 14, this component will be discussed in further detail. The positive electrode layer 14 is a layer containing at least a positive electrode active material (CAM). Examples of CAMs include layered lithium oxide materials, such as LiCoO2, LiMnO2, LiNiO2, and LiNi... x Mn y Co 1-x-y O2, LiNi x Co y Al 1-x-y O2, lithium phosphates with an olivine structure, such as LiFePO4 and LiFe x Mn 1-x PO4, LiMnPO4, LiFe x Co 1-x PO4, LiCoPO4, and lithium oxide materials with a spinel structure, 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, Li2Mn x Sn 1-x O3, layered lithium-containing sulfide materials, such as TiS2, MoS2, NbS2, TaS2, sulfur, or lithium-containing sulfides with a Chevrel structure, such as LiCu. x MoS 1-z .

[0028] The surface of a CAM can be coated with a thin layer of material, which together constitute a coating. Examples of coatings include crystalline phases such as Li₂ZrO₃, LiNbO₃, LiPO₃, Li₃PO₄, LiTi₂(PO₄)₃, Liz(PO₄)₃, ZrO₂, Al₂O₃, EtOLi, MtOLi, Lion, Li₂CO₃, and / or amorphous phases such as metal alkoxides and metal phosphates.

[0029] In addition to the CAM, the positive electrode layer 14 may also contain a solid electrolyte, a binder, or an electron-conducting additive. Examples of electrolytes include organic liquids, organic polymers, and inorganic solids. Preferably, the electrolyte used contains an inorganic solid. This is because inorganic solids exhibit a relatively higher lithium transfer number compared to liquids and a relatively higher ionic conductivity compared to organic polymers. It is also because inorganic solids are generally rigid and do not exhibit fluidity, which preferably forms a multilayer bipolar battery stack device 50 without ionic short circuits.

[0030] Preferred examples of electrolytes for the positive electrode layer 14 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-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), and Li-M'-SO (M' is B, Al, Si, P, Zn, Ge). Li-PSX (X is F, Ca, Br or a combination thereof), Li-PSO-X' (X' is F, Ca, 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, Ca, Br or a combination thereof), or Li-M”-X”-O (M” is In, Zr, Sc, Ga, Nb, Ta or a combination thereof; X” is F, Ca, Br or a combination thereof).

[0031] Examples of adhesives that can be included in the positive electrode layer 14 include butadiene rubber (BR), butyl rubber (IIR), acrylic butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the adhesive can be modified with functional groups.

[0032] Additionally, the positive electrode layer 14 may contain electron-conducting additives. For example, various types of carbon may include acetylene black (AB), ketene black (KB), VGCF, carbon nanotubes, carbon nanoparticles, graphite, needle-like graphite, or fullerene.

[0033] There is no particular limitation on the thickness of the positive electrode layer 14, but a relatively thicker layer may be preferred when higher capacity is required. For example, the thickness of the positive electrode layer 14 is preferably 0.1 μm to 1 mm, and more preferably 60 μm to 500 μm.

[0034] Now turning to the negative electrode layer 18, this component will be discussed in further detail. The negative electrode layer 18 is a layer containing at least a negative electrode active material (AAM). Examples of AAMs include: layered lithium-containing sulfide materials such as TiS2, MoS2, NbS2, TaS2; and titanium-containing oxides such as Li4Ti5O12, Ti... x Nb y O z Li x Ti2(PO4)3, containing tungsten oxides, such as Nb 16 W5O 55 、Nb 18 W 16 O 93 Vanadium oxides, such as LiVO2, artificial carbon (or hard carbon), graphite, and Li-metal alloys, such as Li x In, Li x Sn、Le x is、Li e ge、Li x Al, or lithium metal.

[0035] In addition to AAM, the negative electrode layer 18 may also contain a solid electrolyte, a binder, or an electron-conducting additive. Examples of electrolytes include organic liquids, organic polymers, and inorganic solids. Preferably, the electrolyte used contains an inorganic solid. This is because, as mentioned above, inorganic solids exhibit a relatively higher lithium transfer number compared to liquids and a relatively higher ionic conductivity compared to organic polymers. This is also because inorganic solids are generally rigid and do not exhibit fluidity, which preferably constitutes a multilayer bipolar battery stack device 50 without ionic short circuits.

[0036] 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), and Li-M'-SO (M' is B, Al, Si, P, Zn). Li-PSO-X' (X' is F, Ca, 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, Ca, Br or a combination thereof) or Li-M”-X”-O (M” is In, Zr, Sc, Ga, Nb, Ta or a combination thereof; X” is F, Ca, Br or a combination thereof).

[0037] Examples of adhesives that can be included in the negative electrode layer 18 include butadiene rubber (BR), butyl rubber (IIR), acrylic butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the adhesive can be modified with functional groups.

[0038] Additionally, the negative electrode layer 18 may contain electron-conducting additives. For example, various types of carbon may include acetylene black (AB), ketene black (KB), VGCF, carbon nanotubes, carbon nanoparticles, graphite, needle-like graphite, or fullerenes.

[0039] There is no particular limitation on the thickness of the negative electrode layer 18, but a relatively thicker layer may be preferred when higher capacity is required. For example, the thickness of the negative electrode layer 18 is preferably 0.1 μm to 1 mm, and more preferably 60 μm to 500 μm.

[0040] Turning now to diaphragm 16, this component will be discussed in further detail. Diaphragm 16 is an electronic insulator but an ionic conductor. The electrolyte used can be an organic liquid, an organic polymer, or an inorganic solid. If an organic-based electrolyte (liquid or polymer) is chosen, diaphragm 16 can be a porous membrane composed of polymers such as polyethylene (PE), polypropylene (PP), and combinations thereof; the membrane is immersed in the organic-based electrolyte.

[0041] Preferably, the electrolyte used in the separator 16 is composed of an inorganic solid. This is because, as mentioned above, inorganic solids exhibit a relatively high lithium transfer number compared to liquids, and a relatively high ionic conductivity compared to organic polymers. It is also because inorganic solids are generally rigid and do not exhibit fluidity, which preferably constitutes a multilayer bipolar battery stack device 50 without ionic short circuits.

[0042] 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), and Li-M'-SO (M' is B, Al, Si, P, Zn). Li-PSX (where X is F, Ca, Br or a combination thereof), Li-PSO-X' (where X' is F, Ca, Br or a combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M”-X (where M” is In, Zr, Sc, Ga, Nb, Ta or a combination thereof; X” is F, Ca, Br or a combination thereof), or Li-M”-X”-O (where M” is In, Zr, Sc, Ga, Nb, Ta or a combination thereof; X” is F, Ca, Br or a combination thereof).

[0043] In addition to the aforementioned solid electrolyte material, the solid electrolyte layer comprising the separator 16 may also include an adhesive. Examples of adhesives that may be included in the separator 16 include butadiene rubber (BR), butyl rubber (IIR), acrylic butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the adhesive may be modified with functional groups.

[0044] There is no particular limitation on the thickness of the diaphragm 16, but a relatively thinner layer may be preferred when higher capacity is required. For example, the thickness of the diaphragm 16 is preferably from 0.1 μm to 1 mm, more preferably from 0.1 μm to 50 μm.

[0045] Now go to Figure 1, a schematic view of a multi-layer bipolar battery stack device 50 according to an embodiment of the present disclosure is described, which has an exemplary arrangement of multi-layer battery cell components that may occur before a multi-layer lamination process. In the direction from the high voltage region 28 to the low voltage region 30, the multi-layer bipolar battery stack device 50 includes a plurality of layered units 10, and each layered unit 10 includes a current collector 12, a positive electrode layer 14, a separator 16, and a negative electrode layer 18.

[0046] Now turning to Figure 2 , a schematic view of a multi-layer bipolar battery stack device 50 according to an embodiment of the present disclosure is described, which has an exemplary arrangement of multi-layer battery cell components that may occur after a multi-layer lamination process.

[0047] By observing Figure 1 and Figure 2 it can be seen that the height H 26 of the multi-layer bipolar battery stack device 50 after multi-layer lamination (see Figure 2 ) is always at least 20% smaller than the height h 22 of the multi-layer bipolar battery stack device 50 before completing the multi-layer lamination (see Figure 1 ). That is, H / h < 0.8. Similarly, regarding a single-layered unit 10, as can be seen by observing Figure 4 and Figure 5 the thickness T 34 of the single-layered unit 10 of the multi-layer bipolar battery stack device 50 after multi-layer lamination (see Figure 5 ) is always at least 20% smaller than the thickness t 32 of the single-layered unit 10 of the multi-layer bipolar battery stack device 50 before completing the multi-layer lamination (see Figure 4 ), that is, T / t < 0.8. Due to the Poisson effect, after multi-layer lamination (see Figure 2 and Figure 5 [[ID=2)]]) the length L 24 of the current collector 12 in the contact electrode region (i.e., the positive electrode layer 14 and the negative electrode layer 18) is always greater than the length l 20 of the current collector 12 in the contact electrode region (i.e., the positive electrode layer 14 and the negative electrode layer 18) before multi-layer lamination (see Figure 1 and Figure 4 ), that is, l < L. As a result, the current collector 12 layer must be able to adapt to this size by plastically deforming together with the rest of the multi-layer bipolar battery stack device 50 without breaking, as can be seen in the deformation region 40 in Figure 5 . The amount of this plastic deformation needs to be at least 5%, preferably greater than 15%. This will prevent battery short circuit due to the fracture of the current collector 12 during the multi-layer lamination process. In addition, the yield strength of the current collector 12 cannot be lower than 50 MPa to prevent excessive expansion of the multi-layer bipolar battery stack device 50; on the contrary, the yield strength of the current collector 12 cannot be greater than 1000 MPa to prevent delamination due to the elastic deformation of the current collector 12.

[0048] Understandably, by utilizing the specific mechanical properties of the current collector 12, this disclosure enables the multilayer lamination of bipolar cells in the multilayer bipolar cell stack assembly 50 without damaging the current collector 12 during the multilayer lamination process. This contrasts with and offers advantages over conventional current collector materials, which cannot guarantee the absence of short circuits in multilayer stacks. For example, when comparing the elongation at break and yield strength of conventional current collectors with those of the current collector 12 of this disclosure, the following observations are made: For conventional current collectors, the elongation at break is typically 2% to 5%, while the yield strength is typically 150 MPa to 250 MPa. Conversely, for the current collector 12 of this disclosure, the elongation at break must be greater than 5%, while the yield strength can be from 50 MPa to 1000 MPa.

[0049] Therefore, this disclosure offers significant advantages for high-voltage electrochemical cells compared to conventional current collectors in multilayer bipolar cells. As described above, this disclosure achieves multilayer lamination of bipolar cell units, which significantly increases production throughput and yield as well as potential electrical performance, while minimizing the probability of cell short circuits due to bipolar current collector failure.

[0050] The foregoing description is an illustration of specific embodiments of the invention, but does not imply limitation on its practice. Although embodiments of this disclosure have been described with reference to various specific embodiments, those skilled in the art will recognize that embodiments of this disclosure can be practiced with modifications without departing from the spirit and scope of the invention.

Claims

1. A method of forming a stacked bipolar battery, comprising laminating together a plurality of layered cells of a stacked bipolar battery at one time.

2. The method of claim 1, comprising: forming a plurality of layered cells, wherein each of the plurality of layered cells comprises: a first current collector having a first side and a second side; a positive electrode layer having a first side and a second side, wherein the first side of the positive electrode layer is formed on the second side of the first current collector; a separator layer having a first side and a second side, wherein the first side of the separator layer is formed on the second side of the positive electrode layer; and a negative electrode layer having a first side and a second side, wherein the first side of the negative electrode layer is formed on the second side of the separator layer.

3. The method of claim 2, wherein each of the plurality of layered cells is circular, square, rectangular, hexagonal, or trapezoidal.

4. The method of claim 2, wherein the first side of the first current collector of the first layered cell is exposed.

5. The method of claim 2, wherein each of the plurality of layered cells comprises a second current collector having a first side and a second side, wherein the first side of the second current collector is connected to the second side of the negative electrode layer.

6. The method of claim 2, wherein each of the plurality of layered cells comprises a second current collector having a first side and a second side, wherein the first side of the second current collector is connected to the second side of the negative electrode layer, and the first current collector is under the second current collector.

7. The method of claim 2, wherein the first current collector has a thickness of 0.1 pm to 1 mm.

8. The method of claim 2, wherein the first current collector has a yield strength of 50 MPa to 1000 MPa, and an elongation at break of at least 5%.

9. The method of claim 2, wherein the first current collector is composed of a metal foil, a conductive film or a conductive paper, or a single layer or a sandwich composite material having a conductive agent.

10. The method of claim 9, wherein a carbon filler material is applied into the first current collector, wherein the carbon filler material comprises: acetylene black (AB), ketjen black (KB), VGCF, carbon nanotube, carbon nanohorn, graphite, needle-shaped graphite, or fullerene.

11. The method of claim 2, wherein the positive electrode layer has a thickness of 0.1 pm to 500 pm.

12. The method of claim 2, wherein the negative electrode layer has a thickness of 0.1 pm to 500 pm.

13. The method of claim 2, wherein the separator layer has a thickness of 0.1 pm to 50 pm.

14. The method of claim 2, wherein laminating the plurality of layered cells comprises compressing the plurality of layered cells, wherein a height H of the stacked bipolar battery after compression is reduced by at least 20% from a height h before compression.

15. The method of claim 2, wherein laminating the plurality of layered cells comprises compressing the plurality of layered cells, wherein a thickness T of each of the plurality of layered cells after compression is reduced by at least 20% from a thickness t before compression.

16. The method of claim 2, wherein laminating the plurality of layered units comprises compressing the plurality of layered units, wherein a length L of each of the first current collectors after compression is greater than a length / of each of the first current collectors before compression.

17. The method of claim 2, wherein laminating the plurality of layered units comprises compressing the plurality of layered units, wherein a length L of each of the first current collectors after compression is increased by 5% to 15% from a length / before compression.

18. The method of claim 2, wherein a yield strength of each of the first current collectors is greater than or equal to 50 MPa to prevent over-expansion and less than or equal to 1000 MPa to prevent delamination due to elastic deformation.

19. A method of forming a stacked bipolar battery, comprising: forming a plurality of layered units, wherein each of the plurality of layered units comprises: a first current collector having a first side and a second side, wherein a yield strength of the first current collector is greater than or equal to 50 MPa to prevent over-expansion and less than or equal to 1000 MPa to prevent delamination due to elastic deformation; a positive electrode layer having a first side and a second side, wherein the first side of the positive electrode layer is formed on the second side of the first current collector; a separator layer having a first side and a second side, wherein the first side of the separator layer is formed on the second side of the positive electrode layer; and a negative electrode layer having a first side and a second side, wherein the first side of the negative electrode layer is formed on the second side of the separator layer; and laminating the plurality of layered units of the stacked bipolar battery together at one time.

20. A method of forming a stacked bipolar battery, comprising: forming a plurality of layered units, wherein each of the plurality of layered units comprises: a first current collector having a first side and a second side, wherein a yield strength of the first current collector is greater than or equal to 50 MPa to prevent over-expansion and less than or equal to 1000 MPa to prevent delamination due to elastic deformation, wherein the first current collector allows 5% to 15% deformation; a positive electrode layer having a first side and a second side, wherein the first side of the positive electrode layer is formed on the second side of the first current collector; a separator layer having a first side and a second side, wherein the first side of the separator layer is formed on the second side of the positive electrode layer; and a negative electrode layer having a first side and a second side, wherein the first side of the negative electrode layer is formed on the second side of the separator layer; and laminating the plurality of layered units of the stacked bipolar battery together at one time.

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