Bipolar battery

Abstract

To provide a bipolar battery that helps to prevent a short circuit in bipolar stacked cells.SOLUTION: A bipolar stacked battery has a plurality of bipolar electrodes. Each of the bipolar electrodes has a current collector. A cathode layer containing a cathode active material is formed on a first surface of the current collector. An anode layer containing 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, the separator layer extending beyond opposing side edges of the cathode layer and the anode layer. An insulator is formed on exposed side edges on at least one side of the current collector and extends beyond the current collector. A pair of terminal stacks is provided, one of the pair of terminal stacks being formed at a higher voltage side of the bipolar stacked battery and a second of the pair of terminal stacks being formed on a lower voltage side of the bipolar stacked battery.SELECTED DRAWING: None

Description

[Technical field]

[0001] Related Applications This patent application is related to U.S. Provisional Application No. 63 / 542,587, entitled "Bipolar Battery," filed on October 5, 2023 in the name of the present inventors, which is incorporated herein by reference in its entirety. This patent application claims the benefit under 35 U.S.C. § 119(e) of the aforementioned provisional application. [Background technology]

[0002] Technical Field This disclosure relates generally to batteries, and more specifically to bipolar batteries.

[0003] 2. Background of the Invention Electric vehicles (EVs) are becoming increasingly popular in the market as an alternative to traditional internal combustion engine vehicles, mainly due to their environmentally friendly nature and advanced technological features. The operation of an electric vehicle is highly dependent on its battery system, which provides the electrical energy required to power the motor.

[0004] Traditionally, a large number of batteries are connected in series to generate sufficient voltage to run a high torque motor in a vehicle. However, this design has some inherent drawbacks. One drawback, for example, is that a significant number of bonding parts are required for the series stacking of batteries. The bonding parts not only contribute to energy and power density losses due to volume loss, but also introduce additional resistance, leading to reduced power density. Furthermore, the bonding parts tend to concentrate current around the bonding area, resulting in uneven temperature and current distribution throughout the battery. This can ultimately contribute to premature degradation of the battery system.

[0005] To address these challenges, bipolar batteries have been developed in which the positive and negative electrodes are located on opposite sides of a current collector, greatly reducing the need for joining components.

[0006] However, these bipolar batteries come with their own problems: they present the risk of short circuits, and if the current collectors of different layers come into contact, the battery cell cannot produce the required voltage, resulting in a drop in the overall voltage; similarly, if the electrolytes of different battery layers come into contact, the cell also cannot produce the required voltage.

[0007] To avoid electrical shorts, separators made of inorganic solid electrolytes may be used. This particular method involves covering the current collectors with an insulating polymer to prevent electrical shorts. However, this approach still leaves the risk of ionic shorts. Specifically, if the electrolyte is disrupted by external impact, the separator may generate small particles that may cause the electrolytes of different layers to come into contact and result in ionic shorts. In that case, the separator is not covered, making it vulnerable to these problems. Therefore, there is a need to provide a bipolar battery that helps prevent shorts in bipolar stacked cells. Summary of the Invention

[0008] Summary of the Invention This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description of the Invention. 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.

[0009] According to one embodiment of the present invention, a bipolar stacked battery is disclosed. The bipolar stacked battery has a plurality of bipolar electrodes. Each bipolar electrode has a current collector. A cathode layer including a cathode active material is formed on a first surface of the current collector. An anode layer including 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, where the separator layer extends beyond the 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, where one of the pair of terminal stacks is formed on a high voltage side of the bipolar stacked battery and a second of the pair of terminal stacks is formed on a low voltage side of the bipolar stacked battery.

[0010] According to one embodiment of the present invention, a bipolar stacked battery is disclosed. The bipolar stacked battery has a plurality of bipolar electrodes. Each bipolar electrode has a current collector. A cathode layer including a cathode active material is formed on a first surface of the current collector. An anode layer including 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, where the separator layer extends beyond the 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 gap is formed between at least one of the anode layer and the insulator, the insulator is formed on an exposed area on a first surface of the current collector on which the anode layer is formed, where a separator is disposed in the gap between the anode layer and the insulator or between the cathode layer and the insulator, and the insulator is formed on an exposed area on a second surface of the current collector on which the cathode layer is formed, where the separator is disposed in the gap between the cathode layer and the insulator.

[0011] BRIEF DESCRIPTION OF THE DRAWINGS The present application will be described in further detail with reference to the following drawings, which are not intended to limit the scope of the present application, but rather to illustrate certain attributes thereof. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a top view of an exemplary stacked cell according to one embodiment of the present disclosure.

[0013] [Diagram 2] FIG. 2 is a cross-sectional view of the exemplary stacked cell of FIG. 1 taken along line AA', according to one embodiment of the disclosure.

[0014] [Diagram 3] FIG. 3 is a top view of the layers of the exemplary stacked cell of FIG. 1 according to one embodiment of the disclosure.

[0015] [Figure 4] FIG. 4 is a cross-sectional view of the exemplary layer of FIG. 3 taken along line AA' according to one embodiment of the present disclosure.

[0016] [Diagram 5] FIG. 5 is a top view of another exemplary layer of the stacked cell of FIG. 1 according to one embodiment of the disclosure.

[0017] [Figure 6] FIG. 6 is a cross-sectional view of the exemplary layer of FIG. 5 along line AA' according to one embodiment of the present disclosure.

[0018] [Figure 7] FIG. 7 is a top view of another exemplary layer of the stacked cell of FIG. 1 according to one embodiment of the disclosure.

[0019] [Figure 8] FIG. 8 is a cross-sectional view of the exemplary layer of FIG. 7 along line AA' according to one embodiment of the present disclosure.

[0020] [Figure 9] FIG. 9 is a cross-sectional view of an exemplary cathode termination stack according to one embodiment of the present disclosure.

[0021] [Figure 10] FIG. 10 is a cross-sectional view of another exemplary cathode termination stack according to one embodiment of the present disclosure.

[0022] [Figure 11] FIG. 11 is a cross-sectional view of an exemplary anode termination stack according to one embodiment of the present disclosure.

[0023] [Figure 12] FIG. 12 is a cross-sectional view of another exemplary anode termination stack according to one embodiment of the present disclosure.

[0024] [Figure 13] FIG. 13 is a front view of the exemplary stacked cell of FIG. 1 according to one embodiment of the disclosure.

[0025] [Figure 14] FIG. 14 is an exploded front view of the exemplary stacked cell of FIG. 13 according to one embodiment of the present disclosure.

[0026] [Figure 15] FIG. 15 is a top view of an exemplary airtight container according to one embodiment of the present disclosure.

[0027] [Figure 16] FIG. 16 is a cross-sectional view of the exemplary airtight container of FIG. 15 according to one embodiment of the present disclosure.

[0028] [Figure 17] FIG. 17 is a top view of an exemplary airtight container including stacked cells, according to one embodiment of the present disclosure.

[0029] [Figure 18] FIG. 18 is a cross-sectional view of the exemplary airtight container of FIG. 17 according to one embodiment of the present disclosure.

[0030] [Figure 19] FIG. 19 is a top view of an exemplary battery case containing stacked cells, according to one embodiment of the present disclosure.

[0031] [Figure 20] FIG. 20 is a cross-sectional view of the exemplary battery case of FIG. 19 according to one embodiment of the present disclosure.

[0032] [Figure 21] Figure 21 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure. Figure 22 is a close-up view of the exemplary stacked cell of Figure 21 according to one embodiment of the present disclosure.

[0033] [Figure 22] FIG. 23 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure.

[0034] [Diagram 23] FIG. 24 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure.

[0035] [Figure 24] Figure 25 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure. Figure 26 is a close-up view of the exemplary stacked cell of Figure 25 according to one embodiment of the present disclosure.

[0036] [Diagram 25] FIG. 27 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure.

[0037] [Figure 26] Figure 28 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure. Figure 29 is a close-up view of the exemplary stacked cell of Figure 28 according to one embodiment of the present disclosure.

[0038] [Figure 27] FIG. 30 is a cross-sectional view of an exemplary stacked cell according to one embodiment of the present disclosure.

[0039] [Figure 28]FIG. 31 is a graph showing the charge and discharge profile of an exemplary stacked cell according to one embodiment of the disclosure.

[0040] [Figure 29] FIG. 32 is a graph showing the charge and discharge profile of an exemplary stacked cell according to one embodiment of the disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] Detailed Description of the Invention The following description is intended to be a description of presently preferred embodiments of the disclosure and is not intended to represent the only manner in which the disclosure may be constructed and / or utilized. The description sets forth functions and sequences of steps for constructing and operating the disclosure. However, it should be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are intended to be within the spirit and scope of the disclosure.

[0042] 1-20 together illustrate an embodiment of a bipolar battery of the present invention. In its simplest form, the bipolar battery includes an insulator 5 that covers the entire surface of the stacked cells 13, electrodes, and separators 4, greatly reducing the risk of ionic short circuits. According to one embodiment, the components of the bipolar battery may be formed in an airtight container 23 and in a unique battery case with an electrical connector 36 in a recess 38.

[0043] Stacked Cells Figure 1 shows a schematic diagram of a laminated cell 13. Figures 3 to 12 show schematic diagrams of the layer structure of electrical elements 6 to 12 which are components of the laminated cell 13. Figures 13 to 14 show side views of the laminated cell 13.

[0044] For the terminal of the stack on the high voltage side, an electric cathode terminal laminate (either cathode terminal laminate 9 or cathode terminal laminate 10) is used depending on the position of the separator 4. For the terminal of the stack on the low voltage side, an anode terminal laminate (either anode terminal laminate 11 or anode terminal laminate 12) is used depending on the position of the separator 4. From the second layer counting from the terminal, electrical components 6, 7, 8 or combinations of these electrical components 6, 7, 8 are stacked. Each layer is stacked by a separator 4. As a result, the stacked cell 13 includes, from the high voltage side to the low voltage side, the following repeated layers: current collector 1, cathode layer 2, separator 4, anode layer 3, current collector 1, cathode layer 2, separator 4, anode layer 3, ...

[0045] As shown in FIG. 1, the ends of the stack are covered with a reinforcing material, including an insulator 5. The insulator 5 has no electrical or ionic conductivity. As shown in the top view of FIG. 1 and in the cross-sectional view of FIG. 2, the reinforcing material (insulator 5) covers the exposed ends of the current collector 1, the cathode layer 2, the anode layer 3, and the separator 4. That is, none of the layers contacts any of the other layers within / between the electrical stack. The sides of the stacked cells 13 are completely covered with the insulator 5, and none of the current collector 1, the cathode layer 2, the anode layer 3, and the separator 4 are exposed at the ends of the stacked cells 13.

[0046] The current collector 1 may be composed of a metal foil, a metal mesh, or other suitable material, with metal foil being preferred. Examples of metals that may 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 may be a metal pure element, doped, alloy, or clad. The surface of the metal may be covered with carbon or other materials. This ensures good adhesion with the cathode layer 2 and the anode layer 3. In addition to metals, carbon may also be used for the current collector 1. Resin composites with electronic conductors (metal or carbon) as fillers may 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 fullerenes. 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 needle-like or fibrous fillers are used, it can be effective to orient them, as this helps control the flow of electrons and makes it easier to interrupt the current in the event of an anomaly.

[0047] The thickness of the current collector 1 can be any suitable thickness. For example, the thickness of the current collector 1 is preferably between 0.1 μm and 1 mm, and more preferably between 1 μm and 50 μm.

[0048] The cathode layer 2 is a layer including at least a cathode active material (CAM). An example of a CAM is a layered lithium-containing oxide material (LiCoO 2 , LiMnO 2 , LiNiO 2 , LiNi x Mn y Co 1-x-y O 2 , LiNi x Co y Al 1-x-y O 2 ), lithium-containing phosphates with olivine structure (LiFePO4 , Life x Mn 1-x PO 4 , LiMnPO 4 , Life x Co 1-x PO 4 , LiCoPO 4 ), lithium-containing oxide materials with spinel structure (LiNi 0.5 Mn 1.5 O 4 , LiMn 2 O 4 etc.), lithium-rich layered oxide (Li 2 MnO 3 , Li 2 RuO 3 , Li 2 Ru x Ti 1-x O 3 , Li 2 Ru x Sn 1-x O 3 , Li 2 Mn x Ti 1-x O 3 , Li 2 Mn x Sn 1-x O 3 etc.), layered lithium-containing sulfide materials (TiS 2 , MoS 2 , NbS 2 , TaS 2 , sulfur, etc.), or lithium-containing sulfides with the Chevrel structure (LiCu x MoS 1-z etc.)

[0049] The surface of the CAM can be coated with a thin layer of material (coating). An example of a coating is a crystalline phase (Li 2 ZrO 3 , LiNbO 3 , Li 3 BO 3 , Li 3 B 11 O 18 , LiPO 3 , Li 3 PO 4 , LiTi 2(PO 4 ) 3 , LiZr(PO 4 ) 3 , ZrO 2 , B 2 O 3 , Al 2 O 3 , Nb 2 O 5 , EtOLi, MtOLi, LiOH, Li 2 CO 3 The cathode layer 2 may further include a solid electrolyte, a binder, and an electronically conductive additive in addition to the CAM. Examples of electrolytes include organic liquids, organic polymers, and inorganic solids. Preferably, the electrolyte includes inorganic solids because they have a higher lithium transport number compared to liquids and a higher ionic conductivity than organic polymers. Furthermore, inorganic solids are usually hard and do not exhibit flowability, making them preferable for constructing stacked cells 13 without ionic short circuits.

[0050] Preferred examples of the electrolyte include 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), and Li-P-X (X is F, Cl, Br, or any combination thereof). 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).

[0051] Examples of binders that may be included in the cathode layer 2 include butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binder may be modified with functional groups.

[0052] In addition, the cathode layer 2 may include an electronically conductive additive. For example, various types of carbon may include acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns, and fullerenes.

[0053] The thickness of the cathode layer 2 is not particularly limited, but a thicker layer may be preferred when higher capacity is required. For example, the thickness of the cathode layer 2 is preferably between 0.1 μm and 1 mm, and ideally between 60 μm and 500 μm.

[0054] The anode layer 3 is a layer that includes at least an anode active material (AAM). An example of an AAM is a layered lithium-containing sulfide material (TiS 2 , MoS 2 , NbS 2 , TaS 2 etc.), titanium-containing oxides (Li 4 Ti 5 O 12 , Ti x Nb y O z , Li x Ti 2 (PO 4 ) 3 etc.), tungsten-containing oxides (Nb 16 W 5 O 55 , Nb 18 W 16 O 93 ), vanadium-containing oxides (LiVO 2 etc.), artificial carbon (or hard carbon), graphite, Li metal alloy (Li x In, Lix Sn, Li x Si, Li x Ge, Li x Al), or metallic lithium.

[0055] In addition to the AAM, the anode layer 3 may further include a solid electrolyte, a binder, and an electronically conductive additive. Examples of the electrolyte include an organic liquid, an organic polymer, and an inorganic solid. Preferably, the electrolyte includes an inorganic solid because it has a higher lithium transport number than a liquid and has a higher ionic conductivity than an organic polymer. Furthermore, an inorganic solid is usually hard and does not show fluidity, which is preferable for constructing a laminated cell 13 without ionic short circuit.

[0056] Preferred examples of the electrolyte include 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), and Li-P-SOX (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).

[0057] Examples of binders that may be included in the anode layer 3 include butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE). The side chains of the binder may be modified with functional groups.

[0058] In addition, the anode layer 3 may include an electronically conductive additive. For example, various types of carbon may include acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns, and fullerenes.

[0059] The thickness of the anode layer 3 is not particularly limited, but a thicker layer may be preferred when higher capacity is required. For example, the thickness of the anode layer 3 is preferably between 0.1 μm and 1 mm, more preferably between 60 μm and 500 μm.

[0060] The separator 4 is an electronic insulator but an ion conductor. The electrolyte can be either 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 such as polyethylene (PE), polypropylene (PP), and any combination thereof, and the membrane is soaked in the organic-based electrolyte.

[0061] Preferably, the separator 4 is made of an inorganic solid because it has a higher lithium transport number than a liquid and has higher ionic conductivity than an organic polymer. This is also because an inorganic solid is usually hard and does not exhibit fluidity, making it preferable for constructing a laminated cell 13 without ionic short circuit.

[0062] Examples of the electrolyte include organic liquids, organic polymers, and inorganic solids. Preferably, the electrolyte is an inorganic solid because it has a higher lithium transport number than a liquid and has a higher ionic conductivity than an organic polymer. This is also because inorganic solids are usually hard and do not exhibit flowability, making them preferable for constructing a laminated cell 13 without ionic short circuits. Preferred examples of the electrolyte include 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), and Li-PSX (X is F, Cl, Br, or a combination thereof). Li-PSO-X' (X' is F, Cl, Br or combinations thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M" is In, Zr, Sc, Ga, Nb, Ta or combinations thereof; X" is F, Cl, Br or combinations thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta or combinations thereof; X" is F, Cl, Br or combinations thereof).

[0063] The solid electrolyte layer may include a binder in addition to the above solid electrolyte material. Examples of the binder 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 with a functional group.

[0064] The thickness of the separator 4 is not particularly limited, but a thinner layer may be preferred when a higher capacity is required. For example, the thickness of the separator 4 is preferably between 0.1 μm and 1 mm, more preferably between 0.1 μm and 50 μm.

[0065] The electronic and ionic insulator 5 is fabricated to provide increased insulation between layers and enable the stacked cell 13 to deliver high voltages. The electronic and ionic insulator 5 is expertly formed on the current collector 1, carefully wrapping around both the long and short sides. Its very presence ensures that any surface area of ​​the current collector 1 not occupied by the cathode layer 2 or the anode layer 3 is completely shielded.

[0066] The electronic and ionic insulator 5 is constructed to be a good insulator in terms of its electrical properties. Its electrical conductivity is 10 -8 S / cm, and a more stringent and desirable threshold is 10 -10 S / cm. This ensures that the insulation functions optimally and provides maximum protection against any unwanted currents.

[0067] The location of the electronic and ionic insulator 5 is not bound by any strict restrictions. The guiding principle is that the current collector 1 needs to be comprehensively shielded. In practical terms, this may mean that the insulator 5 can cover both sides of the current collector, i.e. both the side facing the cathode layer 2 and the side facing the anode layer 3.

[0068] The exact area of ​​the insulator 5 on the surface of the current collector 1 is not strictly defined, but it is essential to adequately cover any area left exposed from the edge of the electrode active material layer. The key is to electronically insulate the surface of the current collector 1. However, it is important to avoid the formation of the insulator 5 on either the cathode layer 2 or the anode layer 3. Such an arrangement can be problematic during the bonding process when making the stacked cell 13. The overlap between the electrode layer and the insulator layer can create an area of ​​uneven pressure. Such pressure imbalance can damage the current collector 1 or even the separator layer. Furthermore, the overlap area is naturally bulkier than just the edge of the electrode, compromising the sealing function of the insulator. A loose seal could possibly allow the ionic conductor to leak or slip out of the separator, resulting in an ionic short circuit. In the worst case, direct contact between the separator layers can cause an ionic short circuit, severely compromising the function of the battery.

[0069] The gap or distance between the cathode layer 2 and the insulator 5 is denoted as the width (r) of the exposed surface of the current collector 1 and needs to be carefully adjusted to ensure insulation between the layers. It is not limited by strict parameters, but ideally the width r should range from 0.0001% to 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, providing optimum insulation while maintaining the structural integrity and performance of the cell. The criteria for the gap or distance between the cathode layer 2 and the insulator 5 are also applicable to the criteria between the anode layer 3 and the insulator 5.

[0070] The material used for the electronic and ionic insulator 5 is not limited to a specific material as long as the material has the required performance for insulation. A heat-softening plastic may be preferred because the softened plastic can fill gaps or voids that occur during the lamination process and can cover the ends of the current collector 1 and the separator 4 by flow or plastic deformation after the lamination process. Examples of materials for the electronic and ionic insulator 5 include acrylic (polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), etc.); 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).

[0071] The insulator 5 can be made of a number of different materials. For example, as shown in FIG. 1, the vertical ends 5a need not be of the same material as the horizontal ends 5b.

[0072] The bipolar battery of the present invention is an improvement over existing bipolar batteries because in the stacked cell 13, only the top and bottom current collectors 1 are exposed to the outside environment. In the stacked cell 13, the ends of the stack are completely covered with a reinforcement made of insulator 5, and none of the current collectors 1, cathode layer 2, anode layer 3, or separator 4 are exposed. Furthermore, in the stacked cell 13, the area of ​​the separator 4 is larger than both the cathode layer 2 and the anode layer 3, but smaller than the current collector 1. This configuration avoids internal short circuits (cathode and anode) while avoiding short circuits due to ionic contact with another layer. Finally, in the stacked cell 13, none of the current collectors 1 and separators 4 are contacted with different layers.

[0073] Airtight container 15-18 plays a multifaceted role in the overall configuration of the proposed battery system. The airtight container 23 contains the current collector 21 and the insulator 20, and the container 23 serves several functions.

[0074] One of the primary roles of the airtight container 23 is its robust protection against moisture ingress. By being airtight, the airtight container 23 forms an impenetrable barrier, ensuring that moisture does not ingress into the stacked cells 13 housed therein. The importance of this feature cannot be overemphasized, as moisture ingress can be detrimental to the overall health, efficiency, and lifespan of the battery cells.

[0075] Apart from protection from moisture, the container 23 has the remarkable feature of being able to create a vacuum environment for the laminated cells 13. This ensures that the environment within the container 23 remains inert, which is crucial for maintaining the chemical and physical integrity of the laminated cells 13. The inert environment ensures that there are no unwanted chemical reactions that may compromise the performance or safety of the cells. The airtight container 23 also provides atmospheric pressure to the laminated cells 13. This feature is expertly engineered without adding any mechanical parts. Subjecting the battery to a slight pressure can have many advantages. It can help in reducing the internal resistance within the battery, thereby improving its cycleability and overall efficiency.

[0076] After the vacuum lamination process, the airtight container 23 is compatible with further densification of the laminated cells 13 using an isostatic press. This ensures that the cell components are uniformly compressed, ensuring optimal performance and lifespan.

[0077] The airtight container 23 serves to facilitate vacuum operation of the system. The current collectors 21 in the airtight container 23 establish electrical connection with the stacked cells 13, ensuring seamless operation of the cells under vacuum conditions.

[0078] The insulator 20 may be the same material as the electronic and ionic insulator 5 used in the laminated cell 13, or it may be a different material. Any suitable material may be used, as long as it is not electronically and ionically conductive. It may be ceramic or plastic, especially if it has low permeability to moisture and oxygen. Plastic is particularly desirable when the process calls for pressurizing the laminated cell 13 using an airtight container 23. This is because plastics are generally more flexible than ceramics, and some plastic deformation during pressing is expected, with a lower risk of cracking than brittle ceramics.

[0079] Plastic materials for the insulator 20 include acrylics (polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), etc.); 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).

[0080] There may be a different thermoplastic material 22 inside the insulator 20. This is expected to improve the thermal weldability of the insulator 20, reduce the moisture permeability, and maintain a high vacuum. When the thermoplastic material 22 is used, the welding temperature must be lower than the temperature of the insulator 20. This improves the airtightness of the airtight container 23 while maintaining the mechanical strength of the insulator 20.

[0081] The thermoplastic layer 22 may be made of a single material or may be a multi-layer made of multiple materials. For example, if it is a single material, acrylic (polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), etc.); 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) are possible materials. If it is a multi-layer, it is a combination of the above materials. For example, it can be a PP / PE two-layer structure, a PP / PE / PP three-layer structure, a PE / PP / PE three-layer structure, etc., but is not limited thereto.

[0082] The location of the thermoplastic layer 22 is not specified as long as sufficient hermeticity can be guaranteed at the junction of an insulator 20 with another insulator 20, as well as at the junction between an insulator 20 and a current collector 21. For example, it may cover the entire surface of an insulator 20, or it may cover only the junction between two insulators 20, or it may cover only the junction between a current collector 21 and an insulator 20.

[0083] The thickness of the insulator 20 is not particularly limited, but thinner layers may be preferred when higher capacitance is required. For example, the thickness of the insulator 20 is preferably between 1 μm and 2 mm, and more preferably between 10 μm and 1,000 μm.

[0084] The current collector 21 in the airtight container 23 may be made of a metal foil, a metal mesh, etc., and is particularly preferably a metal foil. 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 may be a metal pure element, doped, alloy, or clad. The surface of the metal may be covered with carbon or other materials. This ensures good adhesion with the cathode layer 2 and the anode layer 3. In addition to metals, carbon may also be used for the current collector 21. Resin composites filled with electronic conductors (metal or carbon) may 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 fullerenes.

[0085] 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 needle-like or fibrous fillers are used, it can be effective to orient them, as the orientation controls the flow of electrons, making it easier to interrupt the current during anomalies.

[0086] The thickness of the current collector 21 is not particularly limited, and is, for example, preferably between 0.1 μm and 2 mm, and more preferably between 10 μm and 1000 μm.

[0087] The bipolar battery of the present invention is an improvement over existing bipolar batteries because the airtight container 23 is provided with current collectors 21 and insulating surfaces 20. Additionally, the airtight container 23 allows for a densification process of stacking, and the airtight container 23 is placed in a vacuum.

[0088] Battery case The bipolar battery is preferably housed in a battery case as a whole stacked cell 13 to prevent external shock and environmental degradation during use, as shown in Figures 19-20. The case also allows for handling of the high voltage battery system during operation, installation in an apparatus, disassembly, or maintenance.

[0089] The battery case includes a housing 37 that protects the stacked cells 13 (which may or may not be in an airtight container 23) from external air and impact during actual use. In addition to the mechanical strength required of a normal battery cell, the stacked cells 13 have a higher voltage than normal electrochemical cells, so the housing 37 needs to have a more insulating structure. The material needs to be made of only electrically insulating materials. For example, a metal housing such as that normally used for lithium-ion or nickel-metal hydride batteries is not desirable because it may impair the battery performance due to dielectric breakdown.

[0090] Ceramic, rubber, or plastic are materials for the housing 37. In the case of ceramic, alumina, silica, or zirconia can be considered. In the case of plastic, examples include acrylic (polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), etc.); 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); and polytetrafluoroethylene (PTFE).

[0091] In order to ensure the performance of the stacked cell 13, the housing 37 is preferably a sealed structure. For example, the sealed structure may be created using an O-ring, welding, adhesive, etc. When sealing the housing 37, the internal atmosphere needs to be considered from two perspectives. First, from the viewpoint of the chemical stability of the battery itself, the concentration of moisture and oxygen should preferably be low. In addition, considering the possibility of high voltage in the stacked cell 13, noble gases such as He, Ar, and Xe should be avoided because they tend to cause dielectric breakdown under high voltage conditions. In consideration of the above, the atmosphere in the stacked cell 13 may be a vacuum, N 2 ,SCIENCE FICTION 6 It is necessary to do something like this.

[0092] The housing 37 is provided with an electrical connector 36 for electrical connection to the stacked cells 13, and the electrical connector 36 is characterized in that it is disposed at a position lower than the upper surface of the housing 37 by a height h. For this purpose, the housing 37 has a recess 38 in which the electrical connector 36 is disposed. This structure reduces the risk of the stacked cells 13 accidentally being short-circuited externally during installation, transportation, and maintenance of the battery. In addition, the distance of the electrical connectors 36a and 36b along the housing 37 also reduces the risk of an external short circuit due to creeping discharge.

[0093] The recess 38 has a depth h and has the electrical connector 36 therein. The shape of the recess can be cylindrical, square, polygonal, hemispherical, or any other shape. The low area of ​​the recess needs to be as small as possible to reduce the risk of accidental external short circuit. In other words, the recess 38 should be larger than the electrical connector 36, the connector to the external circuit, and the wiring, and large enough for maintenance, etc., but not unnecessarily larger than that. The depth h of the recess 38 is not specified, but from the viewpoint of energy density, it needs to be as small as possible, and from the viewpoint of insulation resistance and risk of external short circuit, it is preferable to be large. It can be designed appropriately according to the battery voltage. For example, h can be between 2 mm and 100 mm, but is not limited to this value. The depth h1 of the positive electrode side and the depth h2 of the negative electrode side do not need to be the same. For example, one of them can be set to zero.

[0094] The shape of the electrical connector 36 can be, for example, a screw (male or female), a pin, a foil, a plate, a needle, etc. Preferred materials are metals such as Cu, Al, and stainless steel.

[0095] The bipolar battery of the present invention is an improvement over existing bipolar batteries because the battery case is made of electronic / ionic insulators. The battery case has an electrical connector 36 located in a recess 38 to avoid short circuits during handling / installation / disassembly / connection. Furthermore, the battery case is sealed and the interior is protected from vacuum, N 2 ,SCIENCE FICTION 6 It is filled with an inert gas such as argon, but not with a noble gas.

[0096] The method for manufacturing a high voltage electrochemical cell includes the following steps, which are described below.

[0097] The method for producing a high voltage electrochemical cell includes a process of protecting the end of the current collector 1 by placing an insulator 5 on the end of the current collector 1, a process of producing an electrode layer by preparing a free-standing film of a cathode layer 2 and an anode layer 3, a process of placing the free-standing film prepared by the above process at an r position inside the current collector 1 of the insulator 5 formed on the end of the current collector 1, and a process of producing the cathode layer 2 and the anode layer 3. The process includes an electrode bonding process of placing the free-standing film prepared by the above process at an r position inside the current collector 1 of the insulator 5 formed on the end of the current collector 1, bonding the cathode layer 2 and the anode layer 3 to the current collector 1, and bonding the anode layer 3 / current collector 1 / cathode layer 2 / anode layer 3 prepared by the above process 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.

[0098] A cathode termination stack 9 or 10 in which only the cathode layer 2 is formed on the current collector 1, and an anode termination stack 11 or 12 in which only the anode layer 3 is formed on the current collector 1 are prepared. A stack 11 or 12 in which only the anode layer 3 is formed on the current collector 1 are prepared. Each process is the same as the bipolar stack process, so a description thereof will be omitted in this specification.

[0099] The laminates and terminal laminates produced by the above processes are laminated and compressed under high pressure to obtain the laminated cell 13. At this time, the airtight container 23 may or may not be provided.

[0100] The laminated cell 13 produced by the above process is inserted into a case 30 and sealed. By this process, a high voltage electrochemical cell is manufactured.

[0101] 21-24, another embodiment of stacked cell 13' can be shown. Similar to stacked cell 13, in the direction from high voltage side to low voltage side, stacked cell 13' can consist 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 stacked cell 13'. Each layer is formed such that it does not contact any of the other layers within / between the electrical stacks.

[0102] The stacked cell 13' may have an insulator 5. The insulator 5 may be fabricated to increase the insulation between layers and thus enable the stacked cell 13' to develop high voltages. The insulator 5 may be intricately formed on the current collector 1. The insulator 5 may be configured to ensure that the surface area of ​​the current collector 1 that is not occupied by the cathode layer 2 or the anode layer 3 is completely shielded.

[0103] In terms of its electrical properties, the insulator 5 can be constructed to be a good insulator. The insulator 5 can be formed of a material that has neither electronic nor ionic conductivity. -8 Although it may have an electrical conductivity of less than 10 S / cm, a stricter and more desirable threshold is 10 -10 S / cm. This ensures that the insulator 5 will function optimally and provide maximum protection against any unwanted currents.

[0104] The location of the insulator 5 is not bound by any strict restrictions. The guiding principle is that at least one of the exposed sides of the current collector 1 must be comprehensively shielded. For example, the insulator 5 may cover a portion of the exposed end of one side of the current collector 1. In the embodiment shown in FIG. 21 and FIG. 22, the insulator 5 may be formed on the surface 1A of each current collector 1 disposed adjacent to the anode layer 3. As can be seen in FIG. 22, the height of the insulator 5 may be lower than the height of the anode layer 3. Alternatively, the insulator 5 may be formed on the surface 1B of each current collector 1 disposed adjacent to the cathode layer 2, as can be seen in FIG. 23. As can be seen in FIG. 23, the height of the insulator 5 may be lower than the height of the cathode layer 2. Alternatively, the insulator 5 may be formed on both the surfaces 1A and 1B of each current collector 1 attached to both the cathode layer 2 and the anode layer 3, as can be seen in FIG. 24. As can be seen in FIG. 24, the height of the insulator 5 may be less than the height of the anode layer 3 and the height of the cathode layer 2 .

[0105] The insulator 5 may be laminated to the current collector 1, but this is not strictly necessary. By laminating the insulator 5 to the current collector 1, the manufacturing process may be simplified.

[0106] The insulator 5 may not completely seal the ends of the current collector 1. This configuration allows gas to escape. Complete sealing of the ends of the current collector 1 may trap gas and form bubbles during the densification process. These bubbles may increase the impedance of the stacked cells 13' and accelerate degradation. Additionally, complete sealing may trap gas during extended cycling, leading to increased impedance and further degradation of the stacked cells 13'.

[0107] Furthermore, leaving the edges unsealed helps relieve stress during the pressing step in the fabrication process of the stacked cells 13', thereby avoiding damage to the current collectors 1 or insulators 5.

[0108] While the exact area of ​​the insulator 5 on the exposed surface of the current collector 1 cannot be precisely defined, it may be essential that the insulator 5 adequately covers any areas left exposed from the edge of the electrode active material layer. The importance of the insulator 5 may be to electronically insulate the surface of the current collector 1. However, it may be important to avoid the formation of the insulator 5 on the exposed areas of either the cathode layer 2 or the anode layer 3. Such an arrangement may be problematic during the bonding process when making the laminated cell 13'. The overlap between the electrode and the insulator 5 may create areas of uneven pressure. Such pressure imbalance may damage the current collector 1 or even the separator 4. Furthermore, the overlapping areas are naturally bulkier than just the edge of the electrode, compromising the insulating ability.

[0109] When applying the insulator 5, a gap T may be formed on the current collector 1. The distance of the gap T on the current collector 1 needs to be carefully adjusted to ensure the insulation between the layers. It is not limited by strict parameters, but the distance should range from 0.0001% to 10% of the square root of S6, where S6 is in cm 2 The area of ​​the anode layer 3 measured in mm may represent the area of ​​the anode layer 3 measured in mm. This may ensure a balanced design to provide optimal insulation while maintaining the structural integrity and performance of the stacked cell 13'. The criteria for the gap or distance between the anode layer 3 and the insulator 5 may also be applicable to that between the cathode layer 2 and the insulator 5.

[0110] The material used for the insulator 5 is not limited to a specific material as long as it has the required insulation ability. The material used may be one already listed above. A heat-softening plastic may be preferred because the softened plastic may fill gaps or voids that may be generated during the lamination process and may also cover the ends of the current collector 1 and separator 4 after the lamination process by flow or plastic deformation. Examples of insulator 5 may include, but are not limited to, acrylic (polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), etc.); 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). Insulator 5 may be made of multiple different materials, such as combinations of the above.

[0111] 25-30, another embodiment of stacked cell 13" can be shown. Similar to stacked cells 13 and 13', in the direction from high voltage side to low voltage side, stacked cell 13' can consist 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 sequence to form stacked cell 13". Each layer is formed such that it does not contact any of the other layers within / between the electrical stacks.

[0112] The exposed end of the current collector 1 may be covered with an insulator 5. The insulator 5 has neither electronic nor ionic conductivity. The insulator 5 may cover a portion of the exposed end of one side of the current collector 1. In the embodiment shown in Figures 25-26 and Figures 28-29, the insulator 5 may be formed on the surface 1A of each current collector 1 adjacent to the anode layer 3. Alternatively, as can be shown in Figure 27, the insulator 5 may be formed on the surface 1B of each current collector 1 adjacent to the cathode layer 2. Alternatively, as can be shown in Figure 30, the insulator 5 may be formed on both the surfaces 1A and 1B of each current collector 1 attached to both the cathode layer 2 and the anode layer 3.

[0113] As shown in FIGS. 25-26 , when attaching the insulator 5 to the exposed surface of the current collector 1 adjacent to the anode layer 3, the current collector 1 may be designed to bend upward at the end of the anode layer 3, creating an angled end 1A of the stacked cell 13″. This angled end 1A can increase the structural integrity and ionic insulation of the cell by covering the separator 4 from the exterior of the cell. The insulator 5 may be laminated onto the current collector 1 and bent upward along with the current collector 1 to ensure proper insulation and alignment within the stacked cell 13″ configuration.

[0114] The separator 4 may also be bent upwards along with the current collector 1. In particular, the separator 4 may be smaller than the current collector 1 and the insulator 5, ensuring that the separator 4 may not be exposed to the outside surface. This design minimizes the risk of damage to the separator 4 and maintains the insulation integrity.

[0115] The angle X of the angled end 1A relative to the base of the current collector 1, which may be laminated to the anode layer 3, may range from 3 degrees to 90 degrees. More specifically, the angle X may range from 5 degrees to 80 degrees. The angled end 1A may be beneficial in improving the insulation between layers and preventing electrical shorts.

[0116] As can be seen in Figure 27, if the insulator 5 is attached to the cathode side of the surface of the current collector 1, the same criteria used between the anode layer 3 and the insulator 5 are applicable between the cathode layer 2 and the insulator 5. Also, as can be seen in Figure 30, if the insulator 5 is laminated on both sides of the current collector 1, the angle X can range from 3 degrees to 90 degrees. More specifically, the angle X can range from 5 degrees to 80 degrees.

[0117] In the stacked cell 13'', similar to the stacked cell 13', a gap T may be formed on the current collector 1. The separator 4 may be applied and pressed into the gap T between the cathode layer 2 or the anode layer 3 when forming an angled end 1A, as may be shown in FIG. 30. The pressed separator 4 may cover the anode layer 3 (or the cathode layer 2, or both) with the separator 4, thereby improving the electrical insulation of the stacked cell 13''.

[0118] The laminated cell 13″ was fabricated and tested as described below. The formed laminated cell 13″ may satisfy the following area relationships: S1>S3>S4>S2>S5≧S6 or S1>S3>S4>S2>S6≧S5, where: S1 = area generated by the outer edge of insulator 5 S2 = area generated by the inner edge of insulator 5 S3 = Area of ​​collector 1 S4 = Area of ​​separator 4 S5 = Area of ​​cathode layer 2 S6 = area of ​​anode layer 3

[0119] A 40 μm thick carbon coated aluminum foil (area S3) is prepared as current collector 1, and a 25 μm thick polyetherimide (PEI) film (which may be provided with adhesive polyisobutene (PIB)) can be attached to one of the carbon coated aluminum foils as insulator 5. The area generated by the outer edge of insulator 5 and the area of ​​its inner edge are S1 and S2, respectively.

[0120] The cathode layer 2 is made of a cathode active material (LiNi 1 / 3 Co 1 / 3 Mn 1 / 3 O 2 The cathode layer 2 was fabricated by mixing powders of ZnO (MTI), solid electrolyte (SSE-10, NEI), and PTFE (Daikin America) in a ratio of 87:12:1 (wt%). The mixture was then spread into a sheet with a thickness of 120 μm to form the cathode layer 2. The area of ​​the cathode layer 2 is S5.

[0121] The anode layer 3 is made of an anode active material (Li 4 Ti 5 O 12 The anode layer 3 was fabricated by mixing powders of ethylenediaminetetraacetate (E.S., MSE supplies LLC), solid electrolyte (SSE-10, NEI), carbon black (Imerys), and PTFE (Daikin America) in a ratio of 80:15:1:4 (wt%). The mixture was then spread into a sheet with a thickness of 300 μm to form the anode layer 3. The area of ​​the anode layer 3 is S6.

[0122] Separator 4 can be fabricated by mixing powders of solid electrolyte (SSE-10, NEI) and PTFE (Daikin America) in a ratio of 97:3 (wt%). The mixture was then spread into a sheet with a thickness of 120 μm to form separator 4. The area of ​​separator 4 is S4.

[0123] The cell of the stacked cell 13" can be fabricated by stacking unit cells consisting of a current collector 1, an anode layer 3, a separator 4, and a cathode layer 2. The layers can be stacked in the following order: 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 repeating order. A total of 10 electrochemical cells can be stacked to form the bipolar stacked cell 13". The last current collector 1, which only contacts the cathode layer 2, can be one without an insulator on its surface. The areas of S1, S2, S3, S4, S5 and S6 are listed in Table 1 below. The areas satisfy S1>S3>S4>S2>S6≧S5.

[0124] The end of the angled end 1A of the laminated cell 13'' may be bent to have an angle (X) of 80 degrees. [Table 1]

[0125] Bipolar stacked cell 13" has a current of 1.0mA / cm2 over a voltage range of 15V to 27V. 2 The bipolar stacked cell 13″ could be charged and discharged without ionic or electronic short circuit. The charge and discharge profiles can be shown in FIG.

[0126] As a comparison with the above example, the laminated cell 13″ was fabricated and tested again as described below. In this embodiment, the laminated cell 13″ satisfied the same area relationship as above. The current collector 1 was formed in the same manner as the previous test embodiment, except for the thickness of the polyetherimide (PEI) film. In this test embodiment, a 250 μm thick PEI film with adhesive polyisobutene (PIB) was attached to a piece of carbon-coated aluminum foil as an insulating frame. The remaining structure of the laminated cell 13″ remained the same. Thus, the fabrication of the cathode layer 2, anode layer 3, separator 4, and the fabrication of the laminated cell 13″ were the same as the previous test embodiment.

[0127] In this test embodiment, the ends of the laminated cell 13'' were not bent; therefore, the angle X was 0°. [Table 2] [Table 3]

[0128] Bipolar stacked cell 13" has a current of 1.0mA / cm2 over a voltage range of 15V to 27V. 2The cell was charged and discharged at a current density of 1000 mA / s. However, the second cycle shows a low coulombic efficiency (64.9%). Also, the voltage profile is lower than the previous test embodiment, despite the same number of stacks. The low coulombic efficiency and overall low voltage profile indicate that a short circuit is occurring in the cell. The charge and discharge profiles can be seen in FIG.

[0129] The foregoing description is provided to enable any person skilled in the relevant art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the relevant art, and the general principles defined herein may 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, and references to elements in the singular are intended to mean "one and only one" unless otherwise specified, but are intended to mean "one or more." All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or that later become known to those skilled in the relevant art are expressly incorporated herein by reference and are intended to be included in the claims. Moreover, nothing disclosed herein is intended to be made available to the public.

Claims

1. A bipolar stacked battery including a plurality of bipolar electrodes, Each of the plurality of bipolar electrodes includes: Current collector; a cathode layer comprising a cathode active material formed on the 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, where the separator layer extends beyond opposing side edges of the cathode layer and the anode layer; and an insulator formed on an exposed edge of at least one side of said current collector and extending beyond said current collector; Including, a pair of terminal stacks, where one of the pair of terminal stacks is formed on a high voltage side of the bipolar laminate battery, and a second of the pair of terminal stacks is formed on a low voltage side of the bipolar laminate battery; A bipolar stacked battery comprising:

2. 2. The bipolar stack 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 pair of terminal stacks includes a cathode terminal stack formed on a high voltage side of the bipolar laminate battery and an anode terminal stack formed on a low voltage side of the bipolar laminate battery, The cathode termination stack comprises: a cathode terminal current collector; and a cathode termination layer including a cathode termination active material formed on a first surface of the cathode termination current collector; The anode terminal stack comprises: an anode terminal current collector; and 10. The bipolar stacked battery of claim 1, further comprising an anode termination layer comprising an anode termination active material formed on a first surface of the anode termination current collector.

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

5. The bipolar stacked battery according to any one of claims 1 to 4, further comprising an airtight container surrounding the plurality of bipolar electrodes.

6. 6. The bipolar stacked battery according to claim 5, further comprising a battery case surrounding the plurality of bipolar electrodes and the airtight container, wherein an electrical connector is disposed within a recess of the battery case.

7. 2. The bipolar stacked battery according to claim 1, wherein opposite side ends of the current collectors of the plurality of bipolar electrodes are bent upward or downward with respect to a plane of the current collectors.

8. 8. The bipolar stacked battery according to claim 7, wherein the opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward at an angle ranging from 5° to 85°.

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

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

11. 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 on which the anode layer is formed; and a second gap formed between the cathode layer and the insulator, the insulator being formed on an exposed area on a second surface of a current collector on which the cathode layer is formed, wherein the separator is disposed within the second gap.

2. The bipolar stacked battery of claim 1, comprising:

12. The gap distance is cm ２ 10. The bipolar stacked battery of claim 9, wherein the anode layer area is in the range of 0.0001% to 10% of the square root of the area of ​​the anode layer measured at 1000 nm.

13. 10. The bipolar stacked battery of claim 9, wherein opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward or downward with respect to a plane of the current collectors.

14. 11. The bipolar stacked battery of claim 10, wherein opposite side edges of the current collectors of the plurality of bipolar electrodes are bent upward or downward with respect to a plane of the current collectors.

15. 12. The bipolar stacked battery of claim 11, wherein opposing 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.

16. 14. The bipolar stacked battery of claim 13, wherein opposing side edges of the current collectors of the plurality of bipolar electrodes are bent upward at an angle ranging from 5° to 85°.

17. A bipolar stacked battery including a plurality of bipolar electrodes, Each of the plurality of bipolar electrodes includes: Current collector; a cathode layer comprising a cathode active material formed on the 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 opposing side edges of the cathode layer and the anode layer; an insulator formed on an exposed edge of at least one side of said current collector and extending beyond said current collector; Including, a gap formed between at least one of the anode layer and the insulator; an insulator formed on an exposed area on a first surface of a current collector on which the anode layer is formed, the separator being disposed in the gap between the anode layer and the insulator or the cathode layer and the insulator; an insulator formed on an exposed area on a second surface of a current collector on which the cathode layer is formed, the separator being disposed in the gap between the cathode layer and the insulator; A bipolar stacked battery comprising:

18. The gap distance is cm ２ 20. The bipolar stacked battery of claim 17, wherein the anode layer area is in the range of 0.0001% to 10% of the square root of the area of ​​the anode layer measured at 1000 nm.

19. 20. The bipolar stacked battery of claim 17, wherein opposing 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. 20. The bipolar stacked battery of claim 19, wherein opposing side edges of the current collectors of the plurality of bipolar electrodes are bent upward at an angle ranging from 5° to 85°.

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