Current collector for bipolar multilayer battery

Abstract

To provide a method for forming a bipolar battery that prevents short circuits between current collectors of different layers within the bipolar battery without requiring additional insulation within the bipolar battery.SOLUTION: A method for forming a bipolar battery includes forming a mixture of a conductive material and a non-conductive material, and compressing an area of the mixture such that the conductive material in the mixture comes into contact to form a conductive area of the bipolar battery's current collector, and the uncompressed mixture forms an insulating area of the bipolar battery's current collector.SELECTED DRAWING: None

Description

[Technical Field]

[0001] Related Applications This patent application is related to U.S. Provisional Application No. 63 / 632,086, entitled "Current Collector for Bipolar Stacked Battery," filed April 10, 2024, in the names of the same inventors, and 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.

[0002] Technical Field This disclosure relates generally to batteries, and more specifically to current collectors for bipolar stacked batteries. [Background technology]

[0003] 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 EV relies heavily on its battery system, which provides the electrical energy required to power the motor.

[0004] Traditionally, many batteries are connected in series to generate enough voltage to run the high-torque motors in vehicles. However, this design has several inherent drawbacks. One is that the series stacking of batteries requires a significant number of connecting parts.

[0005] Bonded components not only contribute to energy and power density losses due to volume loss, but also introduce additional resistance, leading to reduced power density. Furthermore, bonded components tend to concentrate current around the bonded area, resulting in uneven temperature and current distribution throughout the battery. This can ultimately contribute to premature battery system degradation.

[0006] 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 connecting components.

[0007] However, these bipolar batteries come with their own problems. Specifically, they present a risk of short circuits: 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 will also not be able to produce the required voltage.

[0008] U.S. Patent Publication US2015 / 0255797A1 discloses covering the ends of battery units with an insulating polymer to prevent electrical shorts. Similarly, Japanese Patent JP2011151016A discloses the use of resin to cover the ends of bipolar solid-state batteries to prevent shorts. Current collectors must be physically separated. The current collectors used in existing solutions conduct electrons throughout the current collector. Therefore, to prevent shorts caused by contact between current collectors, the ends of battery units must be covered with additional insulation.

[0009] Existing solutions involve two parts: an insulator and a current collector. The current collector in the existing solution conducts electrons throughout its structure. This creates a risk of short circuiting with other current collectors in the battery unit, so an insulator is inserted into the battery unit to physically maintain the spacing between the current collectors.

[0010] It is therefore desirable to provide a system and method that overcomes the above. Summary of the Invention

[0011] 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.

[0012] According to one embodiment of the present invention, a method for forming a bipolar battery is disclosed. The method may include forming a mixture of conductive and non-conductive materials. The method may include compressing regions of the mixture such that the conductive materials of the mixture contact to form conductive regions, and the uncompressed mixture forms insulating regions of a current collector of the bipolar battery.

[0013] According to one embodiment of the present invention, a method for forming a bipolar battery is disclosed. The method may include forming a current collector. The current collector may be formed from a mixture of conductive and non-conductive materials. The method may include compressing an interior region of the mixture to form a conductive region, and an outer periphery of the uncompressed mixture to form an insulating region around the periphery of the current collector.

[0014] According to one embodiment of the present invention, a method for forming a bipolar battery is disclosed. The method may form a current collector, the current collector being formed from a mixture of conductive and non-conductive materials. The method may compress an interior region of the mixture to form a conductive region, and an outer periphery of the uncompressed mixture may form an insulating region around the periphery of the current collector. The method may attach a cathode layer to a first surface of the conductive region. The method may attach an anode layer to a second surface of the conductive region, wherein the insulating region formed around the periphery of the current collector is insulating and not connected to the cathode layer and the anode layer, and wherein the mixture includes a porous material to reduce expansion during compression of the mixture.

[0015] 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. The same reference numbers will be used throughout the drawings to refer to the same or similar parts. [Brief explanation of the drawings]

[0016] [Figure 1]FIG. 1 illustrates a side view of an exemplary current collector used in a bipolar stacked battery according to an embodiment of the present disclosure;

[0017] [Figure 2] FIG. 2 illustrates a side view of an exemplary current collector used in a bipolar stack battery under compression, according to an embodiment of the present disclosure;

[0018] [Figure 3] FIG. 3 a shows a top view of an exemplary current collector used in a bipolar stacked battery having compressed and uncompressed regions according to an embodiment of the present disclosure;

[0019] FIG. 3 b shows an enlarged side view of an uncompressed region of the exemplary current collector of FIG. 3 a used in a bipolar stacked battery according to an embodiment of the present disclosure;

[0020] FIG. 3 c shows an enlarged side view of a compressed region of the exemplary current collector of FIG. 3 a used in a bipolar stacked battery according to an embodiment of the present disclosure;

[0021] [Figure 4a] FIG. 4 a shows a top view of an exemplary current collector used in a bipolar stack battery before being compressed, according to an embodiment of the present disclosure;

[0022] [Figure 4b] FIG. 4b shows a top view of an exemplary current collector used in a bipolar stack battery after being compressed, according to an embodiment of the present disclosure;

[0023] [Figure 5] FIG. 5 illustrates a side view of an exemplary bipolar stacked battery with fused current collectors in a post-compression state according to an embodiment of the present disclosure;

[0024] [Figure 6] FIG. 6 shows a side exploded view of a portion of the bipolar stacked battery of FIG. 5 according to an embodiment of the present disclosure;

[0025] [Figure 7] FIG. 7 illustrates a side view of an exemplary bipolar stacked battery showing spacing between current collectors according to an embodiment of the present disclosure; and

[0026] [Figure 8] FIG. 8 illustrates a side view of an exemplary current collector showing the thickness between compressed and uncompressed regions according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0027] Detailed Description of the Invention The following description is intended to describe presently preferred embodiments of the present disclosure and is not intended to represent the only mode in which the present disclosure may be constructed and / or utilized. The description sets forth functions and the sequence of steps for constructing and operating the present 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 present disclosure.

[0028] This disclosure provides a bipolar battery in which only one component is required to fulfill the functions of both insulation and current collector. The proposed current collector may be compressible by pressure, and only the compressed area may maintain electronic conductivity. When the bipolar battery is assembled, the proposed current collector may be compressed in the area that contacts the electrode and separator. Therefore, the ends of the bipolar battery, where the current collector cannot contact the electrode or the separator can remain uncompressed, may remain insulating.

[0029] The present disclosure allows users to limit the electronically conductive area within a current collector, allowing it to have both conductive and insulating areas. In other words, the current collector can function as both a current collector and an insulator. This can contribute to reducing the number of parts and improving yields. Furthermore, by eliminating the need for additional insulating material, the sides of the battery can be open-ended. This can also prevent air bubbles from being trapped during battery stacking, improving cell performance and yields.

[0030] As shown in FIG. 1, the current collector 10 can be a composite material 12 made from a mixture of electronically conducting and non-conducting materials, providing unique electrical properties and structural advantages. The conductive materials can include, but are not limited to, Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, stainless steel, or carbon. These conductive materials can be in various shapes, such as spherical, acicular, fibrous, or other shapes. Additionally, combinations of different conductive materials and shapes may be possible. Non-conductive materials may include, but are not limited to, plastic materials such as polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamideimide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). These materials may feature side chains modified with functional groups for improved performance. Additionally, the non-conductive parts may be made of inorganic materials such as SiO2, Al2O3, ZrO2, ZnO, TiO2, Fe2O3, Na2CO3, Na2SO4, MgCO3, MgSO4, CaCO3, CaSO4, S, P2S5, TiS2, and ZnS.

[0031] According to embodiments, the conductive material may include particles of a non-conductive material. The non-conductive material can be one of polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamideimide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), SiO2, Al2O3, ZrO2, ZnO, TiO2, Fe2O3, Na2CO3, Na2SO4, MgCO3, MgSO4, CaCO3, CaSO4, S, P2S5, TiS2, ZnS, and combinations thereof. The non-conductive material may be coated with a conductive material, which may be one of Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, stainless steel, carbon, or a combination thereof, thereby forming a conductive material.

[0032] The composition of composite material 12 made from conductive and non-conductive materials within the conductive regions can be varied. The volume occupied by the conductive and non-conductive materials can vary, and voids (air pockets) can be contained within the matrix. Additionally, the dispersion of voids, conductive materials, and non-conductive materials can be varied to optimize and customize current collector 10 for specific application requirements.

[0033] As shown in FIG. 2, current collector 10 can be compressible. When the thickness of current collector 10 is reduced due to compression, the embedded conductive materials come into contact with each other and form a network of conductive paths. The formed conductive network can impart anisotropic or isotropic conductivity to current collector 10, meaning that the conductivity of the current collector can be limited in various directions, can vary in various directions, or can be conductive in all directions. It may be important to note that current collector 10 conducts electrons but not ions.

[0034] The thickness of the current collector 10 before (T) and after (t) compression need not be specified, as the anisotropic properties and conductivity can be controlled by the degree of compression. This design flexibility can allow for customization according to specific application requirements.

[0035] The compression region is the conductive region 12 c While the area of ​​the current collector 10 that cannot be compressed is the insulating area 12 i (See FIGS. 2 and 3a, 3b, and 3c). c From isolation area 12 i According to an embodiment, the interior region may form a compressed region, allowing for a seamless transition to the conductive region 12. c The outer peripheral region of the current collector 10 cannot be compressed, and the insulating region 12 i It may remain as it is.

[0036] As shown in Figures 4a and 4b, the area of ​​the current collector 10 may or may not be different before and after compression. When the current collector 10 is subjected to pressure in the thickness direction of the current collector 10, the current collector 10 may expand in the planar direction. Generally, the greater the planar expansion of the current collector 10, the thinner the current collector 10 may be. This may help reduce the thickness of the battery stack. However, if the current collector 10 is made of voids (porous matrix), the planar expansion may be suppressed. This is because in Figures 4a and 4b, the area before compression (a i ) is the area after compression (A i), which means that

[0037] 5 may show a bipolar solid-state battery 16 using the above-described pressure-activated current collector 10 in a compressed state. From high voltage side to low voltage side, the bipolar battery 16 may consist of a current collector 10, a cathode layer 2, a separator 4, an anode layer 3, and another layer of current collector 10 (repeated in sequence (i.e., 10, 2, 4, 3, 10, 2, 4, 3, 10, ..., 10, 2, 4, 3, 10)).

[0038] 6, an exploded view of a portion of a bipolar solid-state battery 16 can be seen, where a current collector 10 is formed with an electronically conductive region 12 c and non-conductive insulating region 12 i The electron conducting region 12 c The outer edges of the current collector 10 may be in contact with or adjacent to the cathode layer 2 or anode layer 3, and may remain non-conductive, forming insulating regions 12. i This insulation at the ends of the current collectors 10 may eliminate the need for insulating frames that may be utilized in conventional bipolar cells. For example, existing bipolar battery designs suggest the use of resin to physically separate the current collectors from short circuits around the edges. However, by utilizing this pressure-activated current collector 10, short circuits may be prevented without the need for additional insulation within the bipolar battery 16. Furthermore, as shown in FIG. 7, the spacing (S) between current collectors 10 may be zero or greater, since contact between the insulated ends of the current collectors 10 will not result in a short circuit.

[0039] Referring to Figure 8, a side view of the current collector 10 can be seen. In Figure 8, the thickness between the compressed and uncompressed regions of the current collector 10 can be seen. The current collector 10 can have a total thickness T. The compressed electronically conductive region 12 c The electron conducting region 12 may have a thickness t. cThe conductive region 12 may be in contact with or adjacent to the cathode layer 2 or the anode layer 3. c First surface 12 c1 and isolation area 12 i First surface 12 i1 A first gap G1 can be formed between the conductive region 12. c Second surface 12 c2 and isolation area 12 i Second surface 12 i2 A second gap G2 can be formed between them.

[0040] 5 to 8, the cathode layer 2 may be a layer containing at least a cathode active material (CAM). Examples of CAM include layered lithium-containing oxide materials (LiCoO, LiMnO, LiNiO, LiNi x Mn y Co 1-x-y O2, LiNi x Co y Al 1-x-y O2, etc.), lithium-containing phosphates with an olivine structure (LiFePO4, LiFe x Mn 1-x PO4, LiMnPO4, LiFe x Co 1-x PO4, LiCoPO4, etc.), lithium-containing oxide materials with spinel structure (LiNi 0.5 Mn 1.5 O4, LiMn2O4, etc.), lithium-rich layered oxides (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, etc.), layered lithium-containing sulfide materials (TiS2, MoS2, NbS2, TaS2, sulfur, etc.), or lithium-containing sulfides with a Chevrel structure (LiCu x MoS 1-z These may include, but are not limited to:

[0041] The surface of the CAM may be coated with a thin layer (coating) of material. Example coatings may include, but are not limited to, crystalline phases (such as LiZrO, LiNbO, LiPO, LiPO, LiTi(PO), LiZr(PO), ZrO, AlO, EtOLi, MtOLi, LiOH, LiCO, etc.) and / or amorphous phases (such as metal alkoxides, or metal phosphates).

[0042] In addition to the CAM, the cathode layer 2 may further include a solid electrolyte, a binder, and an electronically conductive additive.

[0043] Examples of electrolytes may include, but are not limited to, organic liquids, organic polymers, and inorganic solids. Generally, the electrolyte may be an inorganic solid because it has a higher lithium transference number compared to liquids and has higher ionic conductivity than organic polymers. This is also because inorganic solids are usually hard and do not flow, which may be preferable for constructing stacked cells without ionic short circuits.

[0044] In general, examples of electrolytes 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 (wherein M is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-M'-SO (wherein M' is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-PSX (wherein X is F, Cl, Br, or a combination thereof), and Li-PSX (wherein X is F, Cl, Br, or a combination thereof). The materials may include, but are not limited to, materials that may have a composition of Li-PSO-X' (X' is F, Cl, Br, or a combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M is In, Zr, Sc, Ga, Nb, Ta, or a combination thereof; X" is F, Cl, Br, or a combination thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta, or a combination thereof; X" is F, Cl, Br, or a combination thereof).

[0045] Examples of binders that can be included in the cathode layer 2 include, but are not limited to, butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binder can be modified with functional groups.

[0046] In addition, the cathode layer 2 may contain an electronically conductive additive, for example, various types of carbon may include, but are not limited to, acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns, graphite, acicular / fibrous graphite, and fullerene.

[0047] The thickness of the cathode layer 2 is not particularly limited, but when higher capacity is required, a thicker layer may be preferable. For example, the thickness of the cathode layer 2 may be approximately 0.1 μm to 1 mm, and preferably approximately 60 μm to 500 μm.

[0048] The anode layer 3 may be a layer containing at least an anode active material (AAM). Examples of AAM include layered lithium-containing sulfide materials (TiS, MoS, NbS, TaS, etc.), titanium-containing oxides (LiTiO, etc.), and the like. 12 , Ti x Nb y O z , Li x Ti2(PO4)3, etc.), tungsten-containing oxides (Nb 16 W5O 55 , Nb 18 W 16 O 93 etc.), vanadium-containing oxides (LiVO2 etc.), artificial carbon (or hard carbon), graphite, Li metal alloys (Li x In, Li x Sn, Li x Si, Li x Ge, Li x Al), or metallic lithium.

[0049] In addition to the AAM, the anode layer 3 may further include a solid electrolyte, a binder, and an electronically conductive additive.

[0050] Examples of electrolytes may include, but are not limited to, organic liquids, organic polymers, and inorganic solids. Generally, the electrolyte may be an inorganic solid because it has a higher lithium transference number compared to liquids and has higher ionic conductivity than organic polymers. This is also because inorganic solids are usually hard and do not flow, which may be preferable for constructing stacked cells without ionic short circuits.

[0051] In general, examples of electrolytes 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 (wherein M is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-M'-SO (wherein M' is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-PSX (wherein X is F, Cl, Br, or a combination thereof), and Li-PSX (wherein X is F, Cl, Br, or a combination thereof). The materials may include, but are not limited to, materials that may have a composition of Li-PSO-X' (X' is F, Cl, Br, or a combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M" is In, Zr, Sc, Ga, Nb, Ta, or a combination thereof; X" is F, Cl, Br, or a combination thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta, or a combination thereof; X" is F, Cl, Br, or a combination thereof).

[0052] Examples of binders that may be included in the anode layer 3 include, but are not limited to, butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binder may be modified with functional groups.

[0053] In addition, the anode layer 3 may contain an electronically conductive additive, for example, various types of carbon may include acetylene black (AB), Ketjen black (KB), VGCF, carbon nanotubes, carbon nanohorns, graphite, acicular / fibrous graphite, and fullerene.

[0054] The thickness of the anode layer 3 is not particularly limited, but when higher capacity is required, a thicker layer may be preferable. For example, the thickness of the anode layer 3 may be approximately 0.1 μm to 1 mm, and preferably approximately 60 μm to 500 μm.

[0055] The separator 4 can be an electronic insulator and an ionic 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 made of a polymer such as polyethylene (PE), polypropylene (PP), and combinations thereof. The membrane can be immersed in the organic-based electrolyte.

[0056] Generally, separator 4 can be made of an inorganic solid because it has a higher lithium transport number than liquids and a higher ionic conductivity than organic polymers, and also because inorganic solids are typically hard and non-flowable, which can be preferable for constructing stacked cells without ionic short circuits.

[0057] Examples of electrolytes may include, but are not limited to, organic liquids, organic polymers, and inorganic solids. Generally, the electrolyte may be an inorganic solid because it has a higher lithium transport number compared to liquids and has higher ionic conductivity than organic polymers. This is also because inorganic solids are usually hard and do not flow, which may be preferable for constructing stacked cells without ionic short circuits.

[0058] Some examples of electrolytes are 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 (wherein M is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-M'-SO (wherein M' is B, Al, Si, P, Zn, Ge, Zr, Sn, or a combination thereof), Li-PSX (wherein X is F, Cl, Br, or a combination thereof), and Li-PSX (wherein X is F, Cl, Br, or a combination thereof). Li-PSO-X' (X' is F, Cl, Br, or a combination thereof), Li-BH, Li-BNH, Li-BHO, Li-BNHO, Li-M"-X" (M" is In, Zr, Sc, Ga, Nb, Ta, or a combination thereof; X" is F, Cl, Br, or a combination thereof), Li-M"-X"-O (M" is In, Zr, Sc, Ga, Nb, Ta, or a combination thereof; X" is F, Cl, Br, or a combination thereof).

[0059] The solid electrolyte layer may contain a binder in addition to the above-mentioned solid electrolyte material. Examples of binders that may be contained in the cathode layer 2 include, but are not limited to, butadiene rubber (BR), butyl rubber (IIR), acrylate butadiene rubber (ABR), polyvinylidene fluoride (PVDF), and polytetrafluoroethylene (PTFE). The side chains of the binder may be modified with functional groups.

[0060] The thickness of the separator 4 is not particularly limited, but thinner layers may be preferable when higher capacity is required. For example, the thickness of the separator 4 may be 0.1 μm to 1 mm, and preferably approximately 0.1 μm to 50 μm.

[0061] The present disclosure provides a system and method for forming a current collector 10. The current collector 10 can be formed from a conductive material and a non-conductive material. The current collector 10 can acquire electronic conductivity only in the compressed region. However, the current collector 10 can remain ion-insulating throughout its structure. The current collector 10 can have an electronic conduction region and an insulating region simultaneously. The insulating region can be both electron-insulating and ion-insulating. After compression of the current collector 10, the internal conductive particles can form a network of conductive paths and impart anisotropic or isotropic conductivity to the current collector. For example, the conductivity of the current collector can be limited in various directions, or can be different in various directions, or can be conductive in all directions. The thickness (t) after compression must be less than the thickness (T) before compression. That is, t < T. The spacing (S) between the ends of the compressed current collector can be 0 or more, that is, S ≥ 0. For example, the ends of the uncompressed current collector can remain insulated and can contact without causing a short circuit. However, the ends of the current collector 10 can also be physically separated. For example, an increased thickness of an electrode or separator sandwiched between current collectors 10 can cause a gap between the ends of the current collectors 10.

[0062] 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. Accordingly, 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 claim language, and references to elements in the singular are intended to mean "one and only one," unless otherwise specified, but rather "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 encompassed by the claims. Moreover, nothing disclosed herein is intended to be made available to the public.

Claims

1. 1. A method for forming a bipolar battery, comprising: forming a mixture of conductive and non-conductive materials; and compressing regions of the mixture such that the conductive material of the mixture contacts and forms a conductive region of the current collector of the bipolar battery, and the uncompressed mixture forms an insulating region of the current collector of the bipolar battery. The method comprising:

2. The method of claim 1 , comprising compressing the conductive material of the mixture so that the conductive region has one of anisotropic or isotropic conductivity.

3. 10. The method of claim 1, wherein the conductive material comprises at least one of Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, and stainless steel, carbon, or a combination thereof.

4. 10. The method of claim 1, comprising coating particles of a non-conductive material with a conductive material, wherein the conductive material is one of Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, stainless steel, carbon, or a combination thereof.

5. The non-conductive material may be polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamideimide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or SiO ２ , Al ２ O ３ , ZrO ２ , ZnO, TiO ２ , Fe ２ O ３ , Na ２ CO ３ , Na ２ SO ４ , MgCO ３ , MgSO ４ , CaCO ３ , CaSO ４ , S., P. ２ S ５ , TiS ２ 5. The method of claim 1, wherein the ZnS is one of ZnS, ZnS, and combinations thereof.

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

7. The non-conductive material is SiO ２ , Al ２ O ３ , ZrO ２ , ZnO, TiO ２ , Fe ２ O ３ , Na ２ CO ３ , Na ２ SO ４ , MgCO ３ , MgSO ４ , CaCO ３ , CaSO ４ , S., P. ２ S ５ , TiS ２ 5. The method of claim 1, wherein the SiO 2 is at least one of SiO 2 , ZnS, and combinations thereof.

8. The method of any one of claims 1 to 4, wherein the mixture comprises a porous material to reduce expansion during compression of the mixture.

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

10. 5. The method of claim 1, further comprising compressing an interior region of the mixture to form the conductive region, while leaving a periphery of the mixture uncompressed to form the insulating region around the periphery of the current collector, wherein a first gap is formed between a first surface of the conductive region and a first surface of the insulating region, and a second gap is formed between a second surface of the conductive region and a second surface of the insulating region.

11. attaching a cathode layer to the first surface of the conductive region; and attaching an anode layer to the second surface of said conductive region; The method according to any one of claims 1 to 4, comprising:

12. attaching a cathode layer to the first surface of the conductive region; and attaching an anode layer to the second surface of the conductive region; 10. The method of claim 9, wherein the insulating region formed around the periphery of the current collector is insulating and not connected to the cathode layer and the anode layer.

13. 1. A method for forming a bipolar battery, comprising: forming a current collector, wherein the current collector is formed from a mixture of conductive and non-conductive materials; and compressing an interior region of the mixture to form a conductive region of the current collector, wherein a peripheral portion of the mixture is not compressed to form the insulating region around the peripheral portion of the current collector; The method comprising:

14. 14. The method of claim 13, comprising compressing the interior region of the mixture to form the conductive region and forming a first gap between a first surface of the conductive region and a first surface of the insulating region, and a second gap between a second surface of the conductive region and a second surface of the insulating region.

15. attaching a cathode layer to the first surface of the conductive region; and attaching an anode layer to the second surface of said conductive region; 14. The method of claim 13, comprising:

16. The conductive material may be selected from the group consisting of polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamideimide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), SiO, and the like, coated with the conductive material comprising at least one of Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, stainless steel, carbon, and combinations thereof. ２ , Al ２ O ３ , ZrO ２ , ZnO, TiO ２ , Fe ２ O ３ , Na ２ CO ３ , Na ２ SO ４ , MgCO ３ , MgSO ４ , CaCO ３ , CaSO ４ , S., P. ２ S ５ , TiS ２ 16. The method of any one of claims 13 to 15, comprising particles of a non-conductive material comprising at least one of: ZnS, ZnS, and combinations thereof.

17. 16. The method of any one of claims 13 to 15, wherein the conductive material comprises at least one of Cu, Ni, Cr, Au, Pt, Ag, Au, Al, Fe, Ti, Zn, Co, and stainless steel, carbon, or a combination thereof.

18. The non-conductive material may be polyacrylic acid (PAA), poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyimide (PI), polyamideimide (PAI), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyethylene terephthalate (PET), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or SiO ２ , Al ２ O ３ , ZrO ２ , ZnO, TiO ２ , Fe ２ O ３ , Na ２ CO ３ , Na ２ SO ４ , MgCO ３ , MgSO ４ , CaCO ３ , CaSO ４ , S., P. ２ S ５ , TiS ２ , ZnS, and combinations thereof.

19. The method of any one of claims 13 to 15, wherein the mixture includes a porous material to reduce expansion during compression of the mixture.

20. 1. A method for forming a bipolar battery, comprising: forming a current collector, wherein said current collector is formed from a mixture of conductive and non-conductive materials; compressing an interior region of the mixture to form a conductive region, wherein a periphery of the mixture is not compressed to form the insulating region around the periphery of the current collector; attaching a cathode layer to the first surface of the conductive region; and attaching an anode layer to the second surface of the conductive region; Including, wherein the insulating region formed around the outer periphery of the current collector is insulating and is not connected to the cathode layer and the anode layer; wherein the mixture includes a porous material to reduce expansion during compression of the mixture. The method.

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