Battery Plate and Battery Assembly

Abstract

To provide battery plates useful in bipolar battery assemblies and methods for assembling such battery plates.SOLUTION: A battery plate 10 has a substrate 11, the substrate has opposing surfaces and one or more nonplanar structures, and one or more active materials are disposed on at least one of the opposing surfaces. The battery plate includes one or more of: i) one or more projections disposed within but do not extend beyond the active material; ii) one or more projections which project beyond the active material and substantially free of the active material or dust formed from the active material; and / or iii) a frame 20 about the periphery of the substrate, which projects beyond the active material and is substantially free of the active material or dust formed from the active material. The battery plate is adapted to form part of one or more electrochemical cells in a battery assembly.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to battery plates useful in bipolar battery assemblies and methods of preparing such assemblies. The disclosure may find particular utility in the preparation of battery plates having non-planar structures. [Background technology]

[0002] Bipolar batteries are well known in the art, see US 2009 / 0042099 to Tatematsu, which is incorporated herein by reference in its entirety. Bipolar batteries offer advantages over other battery designs, such as scalability, relatively high energy density, high power density, and design flexibility. A bipolar battery comprises multiple bipolar plates and two monopolar end plates. Bipolar and monopolar plates are formed by applying active materials to one or both opposing surfaces of a substrate. Bipolar plates are formed by applying a cathode material, often referred to as a positive electrode active material (PAM), to one surface of a substrate and an anode material, often referred to as a negative electrode active material (NAM), to the opposing surface of the substrate. Monopolar plates are formed by applying active materials, either a positive or negative electrode active material, to one surface of a substrate to create a cathode or anode electrode, respectively. A conductive sheet may be disposed between the substrate and the anode or cathode material. The bipolar plates are stacked so that the anode material of one plate faces the cathode material of the next plate. Most assemblies include a battery separator between adjacent plates that allows electrolyte to flow from the cathode material to the anode material. An electrolyte, a material that allows electrons and ions to flow between the anode and cathode materials, is disposed in the space between the plates. The adjacent surfaces of the bipolar plates with the separator and the electrolyte disposed between the plates form an electrochemical cell, where electrons and ions are exchanged between the anode and cathode materials. The battery structure is arranged to seal each cell formed by the bipolar plates to prevent electrolyte from flowing out of the cell. The structure used to seal each electrochemical cell contacts the portions of the plates that do not have anode or cathode material on the substrate. In addition, to help seal the cell, the battery separator may extend beyond the portions of the substrate on which the anode and cathode materials are disposed. Each cell has a current conductor connected to it that transmits electrons from the cell to one or more terminals that transmit the electrons to a load, which is essentially another system that utilizes the electrons in the form of electricity.In a conventional design, a stack of battery plates is placed into a housing that is sealed around the stack of plates, and one or more pairs of positive and negative terminals are located on the outside of the battery, each pair connected to a current conductor that is further connected to one or more cells as described herein.

[0003] Important in the performance of bipolar batteries is the control of the paste weight and paste thickness on the bipolar or monopolar plate substrate. Traditionally, active paste is applied to lead alloy grids using a pasting machine that delivers paste through an orifice as a suitable metal grid passes under the machine supported by a belt. The process is designed to apply the paste to the thickness of the grid to control the paste thickness and weight. A belt pasting machine may be used to apply active paste on bipolar plates. Typically, bipolar plates are designed as flat plates. Flat bipolar plates can pass under a paste box with a shoe installed to control the paste height. Typically, bipolar plates are first coated with positive active material and then flipped over and passed under a second paste line to deposit negative active material. Bipolar plates with a paste frame may be pasted using a belt pasting machine. Monopolar plates with a paste frame may be pasted using a belt pasting machine. Paste is deposited in pockets formed by the frames of the bipolar and / or monopolar plates as they pass under the paste box. Due to the high pressure of the paste delivered to the bipolar plates, it may be necessary to add shims to the bottom of the pockets to minimize deflection of the bipolar plates as they pass under the paste box. The bipolar plates can be flipped over and paste can be applied to the pockets on the negative side of the plates. As the battery plates pass under the box, the leading and trailing edges of the bipolar plate frames are coated with a thin layer of paste that must be removed to minimize the possibility of the formed battery shorting out during operation. In some groups, the pasting is done on grids, sometimes made of plastic, sized to fit into or over the bipolar plates. This eliminates the need for clean leading and trailing edges of the frames, but at the expense of increased cost and reduced energy density.As a result, bipolar plate designs useful in these processes have flat surfaces with no protrusions, and any planar features are usually consistent with the thickness of the paste. Thus, a secondary cleaning operation is required to ensure that there is no paste dust or film that could interfere with the sealing of the bipolar plate or the operation of the battery made from the bipolar plate. Similar problems occur with these processes with respect to the manufacture of monopolar plates located at the ends of the battery plate stack.

[0004] There is a need for a process that allows for the preparation of bipolar and monopolar plates where the battery plates may be non-planar, i.e., include curved or partially curved surfaces, have protrusions that protrude beyond the paste to be substantially free of paste and paste dust, and have protrusions incorporated into the plates to enhance adhesion of the paste to the substrate, etc. There is a need for a process that facilitates the preparation of such battery plates. Summary of the Invention

[0005] The present disclosure relates to a battery plate comprising: a) a substrate having a first surface, an opposing second surface, and one or more non-planar structures; and b) one or more active materials disposed on the first surface, the second surface, or both the first and second surfaces, the battery plate having one or more of the following features: i) one or more protrusions extending from the first surface, the second surface, or both surfaces of the substrate, the one or more protrusions being disposed within the active material and not extending beyond the active material; ii) one or more protrusions extending from the substrate and protruding beyond the active material, the one or more protrusions having a surface that is substantially free of active material or active material dust; and / or iii) a frame about a periphery of the substrate, the frame or a portion thereof protruding beyond the active material in a direction transverse to the one or more surfaces on which the active material is deposited, the frame being substantially free of active material or active material dust; and the battery plate is adapted to form a portion of one or more electrochemical cells in a battery assembly.

[0006] The present disclosure further relates to a battery assembly including one or more stacks of a plurality of battery plates, the one or more stacks including: a) one or more bipolar plates including a substrate having i) a first active material disposed on a first surface to function as an anode, the first active material having a first transfer sheet bonded to an opposite side of the first surface, and ii) a second active material disposed on a second surface to function as a cathode, the second active material having a second transfer sheet bonded to an opposite side of the second surface; b) a first monopolar plate including a substrate having a first active material disposed on a first surface to function as an anode, the first active material having a first transfer sheet bonded to an opposite side of the first surface, the opposing second surface being devoid of active material; and c) a first monopolar plate including a substrate having a first active material disposed on a first surface to function as an anode, the first active material having a first transfer sheet bonded to an opposite side of the first surface, the opposing second surface being devoid of active material. a second monopolar plate comprising a substrate having a first surface and a second active material disposed on a second surface to function as a cathode, the second active material having a second transfer sheet bonded to an opposite side of the second surface; and d) a liquid electrolyte disposed between each pair of adjacent battery plates, the liquid electrolyte functioning with an anode and a cathode disposed in the space between the pair of battery plates to form an electrochemical cell, the plurality of battery plates being arranged such that the surface of the substrate on which the cathode is disposed faces a surface of another battery plate on which the anode is deposited, the first and second monopolar plates being disposed at opposite ends of each battery plate stack, and each transfer sheet comprising a porous material adapted to allow the liquid electrolyte to pass through the transfer sheet while preventing the active material from passing through the pores of the transfer sheet.

[0007] The disclosure further relates to a method of assembling a battery plate, the method including: a) placing a transfer sheet on a movable plate in an electrode mold, the movable plate being positioned opposite an opening in the electrode mold and movable through the opening toward the opening in the electrode mold; b) injecting active material in the form of a paste onto the transfer sheet on the movable plate such that the active material forms a layer in at least a shape defined by the movable plate; c) placing a substrate over the mold opening such that an area of ​​one of the surfaces of the substrate on which it is desired to place the active material is aligned with the active material in the mold; d) extending the movable plate through the mold opening until the active material contacts and bonds to the substrate; and e) pulling the movable plate away from the substrate and back into the mold such that the active material remains bonded to one of the surfaces of the substrate plate and the transfer sheet remains bonded to an active material surface opposite the active material surface bonded to one of the surfaces of the substrate.

[0008] The battery plates disclosed in the present invention are useful in battery assemblies for electrical storage and are useful for generating electricity for use in a variety of environments. The disclosed battery assemblies provide high power input while requiring less volume and weight, thus providing high power density. The battery assemblies are designed to handle the pressure and heat generated during operation and contain liquid electrolyte within the product without undue damage to the outer surface of the product. The disclosed battery plates and battery assemblies can be assembled using conventional materials, processes, and can fit into different shaped spaces based on available packaging space, allowing them to be scaled in size to provide various levels of energy. The device does not require a specific top and bottom orientation where some parts must be placed facing downwards in the direction of gravity. The disclosed battery plates and methods allow the battery plates to be prepared without active material (e.g., paste) or dust from the active material contacting one or more non-planar structures of the substrate. The disclosed battery plates and methods are advantageous in that they allow a non-planar structure without active material to form a seal with one or more other non-planar structures without active material in between. The absence of active material between the non-planar structures prevents potential leakage paths for liquid electrolyte and / or gas, thus avoiding potential shorting of the battery assembly. The method requires less operating capital and allows for higher throughput. Specifically, the cycle time for applying the paste to the surface can be about 2 seconds or more, about 15 seconds or less, about 10 seconds or less, or even about 6 seconds or less. [Brief description of the drawings]

[0009] [Figure 1] FIG. [Diagram 2] FIG. [Diagram 3] 1 shows a cross section of a bipolar plate. [Figure 4] 1 shows a cross section of a bipolar plate. [Diagram 5] 1 shows a top view of a mold for transferring paste to a transfer sheet. [Figure 6]1 shows a cross section of a transfer sheet that has been pasted and placed onto the movable tray of a mold. [Figure 7] 1 illustrates a process for preparing battery plates in a mold. [Figure 8] Figure 8A shows a mold with a moving plate, Figure 8B shows the application of paste to a transfer sheet placed in the mold, and Figure 8C shows the application of the transfer sheet and paste to a substrate to form a battery plate. [Figure 9] FIG. 2 is a partially exploded view of a stack of battery plates. [Figure 10] FIG. 2 is a perspective view of a stack of battery plates. [Figure 11] 1 shows a cross section of a battery assembly. [Figure 12] 1 shows an end of a battery assembly having an end plate. [Figure 13] The installation of the membrane is shown. [Figure 14] FIG. 2 is a perspective view of a battery assembly. [Figure 15] FIG. [Figure 16] FIG. 2 is a perspective view of a battery assembly. [Figure 17] FIG. 2 is a plan view of the battery assembly. [Figure 18] 18 is a cross-section of the battery assembly taken along section AA in FIG. 17. [Figure 19] 18 is a cross-section of the battery assembly taken along section BB of FIG. 17. [Figure 20] 18 is a cross-section of the battery assembly taken along section CC of FIG. 17. [Figure 21] FIG. 2 is a plan view of the battery assembly. [Figure 22] 22 is a cross-section of the battery assembly taken along the E-E section of FIG. 21. [Diagram 23] 22 is a cross-section of the battery assembly taken along the cross-section FF of FIG. 21. [Figure 24] Fig. 24A is a plan view of the separator, and Fig. 24B is an enlarged view of the insert portion of the separator in Fig. 24A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The explanations and examples provided herein are intended to acquaint those skilled in the art with the present teachings, their principles, and their practical applications. The specific embodiments of the present teachings set forth are not intended to be exhaustive or limiting of the present teachings. The scope of the present teachings should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and published literature, are incorporated herein by reference for all purposes. Other combinations are possible, as can be gleaned from the claims below, and are also incorporated herein by reference.

[0011] Battery plate(s)

[0012] The present disclosure relates to battery plates useful for use as bipolar plates, monopolar plates, dual polar plates, etc., or any combination thereof. A battery plate can include one or more electroactive materials that can function as one or more electrodes, can be part of an electrochemical cell, can form part of one or more sealing structures, or can perform any combination thereof. A plurality of battery plates can function to conduct current (i.e., a flow of ions and electrons) within a battery assembly. A plurality of battery plates can form one or more electrochemical cells. For example, a pair of battery plates that can sandwich a separator and / or electrolyte therebetween can form an electrochemical cell. The number of battery plates present can be selected to provide a battery of a desired voltage. Depending on the design of the battery assembly, it is possible to flexibly generate a voltage. A plurality of battery plates can have any desired cross-sectional shape, and the cross-sectional view can be designed to fit the available mounting space in the use environment. The cross-sectional shape can refer to the shape of the plate as viewed from the plane of the sheet. The flexible cross-sectional shape and size enable the preparation of the disclosed assembly to accommodate the required voltage and size of the system in which the battery is utilized. Opposing end plates can sandwich a plurality of battery plates therebetween. One or more battery plates can include one or more non-planar structures.

[0013] A non-planar structure may mean that the shape of the surface of the battery plate may be any shape in which the plate can function. A non-planar structure may be any feature that protrudes from and / or recesses into a planar portion of the battery plate. A non-planar structure may mean that the battery plate may be a non-planar battery plate. A non-planar structure may include one or more recessed and / or protruding surfaces with respect to any plane across the plate. The one or more non-planar structures may be regular or irregular shapes. The shapes may include one or more concave or convex surfaces. Non-planar structures include rectangles, cylinders, hemispheres, pyramids, sawtooth, and the like. The one or more non-planar structures may include one or more inserts, ridges, frames, protrusions, openings, lattice edges, corrugated structures, or any combination thereof. The one or more non-planar structures may function to form one or more seals, channels, or both. The one or more non-planar structures may be part of a substrate. The one or more non-planar structures may function to increase the overall surface area of ​​the substrate, the battery plate, or both. For example, a substrate having a corrugated surface may have a larger surface area than a substrate having a relatively flat surface. The larger surface area may allow for higher voltages, currents, or both. One or more non-planar structures may be present within any portion of a battery plate. In a stack of battery plates, the planar and / or non-planar structures of the battery plates may be identical to provide efficient functioning of the electrochemical cells that the battery plates help form. The multiple battery plates may include one or more monopolar plates, one or more bipolar plates, or any combination thereof.

[0014] The one or more battery plates may include one or more bipolar plates. The one or more bipolar plates may include a single or multiple bipolar plates. Multiple, as used herein, means there are two or more plates. The bipolar plate comprises a substrate. The substrate may be in the form of a sheet having two opposing faces. The cathode and anode are disposed on the opposing faces. The cathode and anode may be in the form of a paste applied onto the substrate. The cathode, anode, or both may comprise a transfer sheet. The bipolar plates may be arranged in one or more stacks within the battery assembly such that the cathode of one bipolar plate faces the anode of another bipolar or monopolar plate, and the anode of each bipolar plate faces the cathode of the bipolar or monopolar plate.

[0015] The one or more battery plates may be one or more monopolar plates. The one or more monopolar plates may include a single or multiple monopolar plates. The one or more monopolar plates may include a monopolar plate located at each opposing end of the multiple battery plates. The opposing monopolar plates may include one or more bipolar plates located therebetween. The one or more monopolar plates may be located adjacent to one or more end plates, may be part of one or more end plates, or may be one or more end plates. For example, each of the monopolar plates may be located between an adjacent end plate and an adjacent bipolar plate. The one or more monopolar plates may be attached to one or more end plates. The one or more monopolar end plates may be attached to an end plate as taught in any of U.S. Patent Nos. 8,357,469, 9,553,329, and U.S. Patent Application Publication No. 2017 / 0077545, the entirety of which are incorporated herein by reference for all purposes. One or more of the monopolar end plates may include one or more reinforcing structures as disclosed in US Patent Application Publication No. 2017 / 0077545. One or more of the monopolar plates may be prepared with the same substrate, anode, and cathode used in one or more of the bipolar plates. One monopolar plate of the cell assembly may have a substrate with a cathode disposed thereon. One monopolar plate of the cell assembly may have a substrate with an anode disposed thereon. The cathode, anode, or both may be in the form of a paste applied onto the substrate. The cathode, anode, or both may include a transfer sheet. The surface or side of the monopolar plate opposite the anode or cathode and / or facing the end plate may be an exposed surface of the substrate.

[0016] The one or more battery plates may include one or more dual polar plates. The dual polar battery plates may function to facilitate electrical connection of one or more battery plate stacks with one or more other battery plate stacks, simplify the manufacture and assembly of two or more stacks, or both. The dual polar plate stacks may be used to electrically connect two or more battery plate stacks, allowing individual battery plate stacks to be formed in standard sizes (e.g., number of plates and / or electrochemical cells) and then assembled to form a bipolar battery assembly, and / or allowing the number of individual battery plate stacks to be easily changed to increase or decrease the power generated by the bipolar battery assembly. The dual polar plate may include one or more substrates. The one or more substrates may include a single substrate or multiple substrates. The one or more substrates may include one or more conductive substrates, one or more non-conductive substrates, or a combination of both. The multiple conductive substrates may include a first conductive substrate and a second conductive substrate. For example, the dual polar plate may include a first conductive substrate and a second conductive substrate with a non-conductive substrate disposed therebetween. In another example, the dual polar plate may include a non-conductive substrate. In another example, the dual polar plate may include a single conductive substrate. One or more substrates of the dual polar plate include opposing surfaces. The opposing surfaces may have an anode, a cathode, a current conductor, a current collector, or any combination thereof, deposited on a portion of the surface. The conductive substrate of the dual polar plate may have an anode or a cathode deposited on one surface or on both opposing surfaces. By having the same anode or cathode on the opposing surfaces, only one electrical connection (e.g., via another positive or negative current conductor) is required to the current conductor of one or more stacks (e.g., a positive or negative current conductor or terminal of a monopolar plate), simplifying manufacturing. The substrate of the dual polar plate may have a current collector disposed on one surface or on both opposing surfaces. The current collector may be disposed between the cathode or anode and the surface of the substrate.Exemplary dual polar plates and their integration into battery assemblies are disclosed in U.S. Pat. Nos. 9,685,677, 9,825,336, and U.S. Patent Application Publication No. 2018 / 0053926, which are incorporated by reference in their entireties for all purposes.

[0017] The one or more battery plates include one or more substrates. The one or more substrates function to provide structural support for the cathode and / or anode, function as cell barriers to prevent electrolyte flow between adjacent electrochemical cells, and cooperate with other battery components to form an electrolyte-tight seal around the edges of the battery plates, which may be formed on the outer surface of the battery, and in some embodiments, may function to transfer electrons from one surface to the other. The substrates may be formed of a variety of materials, depending on the function or battery chemistry. The substrates may be formed of materials that are structurally robust enough to provide the support of the desired battery plates, that can withstand temperatures above the melting point of any conductive material used in the battery construction, and that have high chemical stability during contact with the electrolyte (e.g., sulfuric acid solution) so that the substrate does not degrade when in contact with the electrolyte. The substrates may be formed of any suitable material and / or configured to allow electrical transfer from one surface of the substrate to the opposing substrate surface. The substrates may be formed of conductive materials, such as metallic materials, or non-conductive materials. Exemplary non-conductive materials may include polymers such as thermosetting polymers, elastomeric polymers, thermoplastic polymers, or any combination thereof. The substrate may include a generally non-conductive substrate (e.g., a dielectric substrate). The non-conductive substrate may have conductive features constructed therein or thereon. Examples of polymeric materials that may be employed include polyamide, polyester, polystyrene, polyethylene (including polyethylene terephthalate, high density polyethylene, and low density polyethylene), polycarbonate (PC), polypropylene, polyvinyl chloride, bio-based plastics / biopolymers (e.g., polylactic acid), silicone, acrylonitrile butadiene styrene (ABS), or any combination thereof, such as PC / ABS (a mixture of polycarbonate and acrylonitrile butadiene styrene). Composite substrates may be utilized. Composite materials may include a reinforcing material such as fibers or fillers as commonly known in the art, or two different polymeric materials such as a thermosetting core and a thermoplastic shell or thermoplastic rim around the thermosetting polymer, or a conductive material disposed in the non-conductive polymer.The substrate may include or have a bondable, preferably melt-bondable, thermoplastic material at the edge of the plate. One or more of the substrates may have one or more non-planar structures. The one or more non-planar structures may be integrated into the substrate or attached to the substrate. The one or more non-planar structures may be molded as part of the substrate. The one or more non-planar structures may include one or more raised edges, frames, inserts, protrusions, projections, openings, etc., or any combination thereof.

[0018] To facilitate stacking of the battery plates and formation of the electrochemical cell, one or more of the substrates may have a raised edge on the periphery. A raised edge as used herein means a raised edge on at least one of the two opposing surfaces of the plate. The raised edge may include a thermoplastic edge formed around another substrate material. The raised edge may function as a separator plate as described herein. The substrate or the periphery of the substrate may be a non-conductive material, which may be a thermoplastic material. One or more of the substrates may include a frame. The frame may or may not include a raised edge. The frame around the substrate or integrated with the substrate may be composed of a non-conductive material, such as a thermoplastic material. The use of a non-conductive material improves the sealing of the outside of the battery stack. The frame may include one or more assembly aids formed therein. The assembly aids may function to help hold one or more substrates, separators, or both in place during stacking to form the battery assembly. The assembly aids may include one or more protrusions, recesses, or both. For example, one or more male protrusions from one surface of a frame may align and fit within one or more female wells of the frame of an adjacent substrate and / or separator, and the one or more female wells of the frame may be located on the opposite surface of the frame from the one or more male protrusions.

[0019] One or more of the battery plates may include a cathode. The cathode may be any material capable of functioning as a battery cathode and may be in any form commonly used in batteries. A bipolar plate may include a cathode on a surface opposite the surface on which the anode is deposited and opposite the anode of another bipolar plate or a monopolar plate. A monopolar plate may have a cathode deposited on a surface opposite the exposed surface of the cathode or anode, or opposite the surface adjacent to an end plate, or both. The cathode is also referred to as the positive electrode active material (PAM). Positive electrode active materials may include composite oxides, sulfates, or phosphates of lithium, lead, carbon, or transition metals commonly used in lithium-ion, nickel-metal hydride, or lead-acid secondary batteries. Examples of composite oxides include LiCoO 2 Li / Co-based composite oxides such as LiNiO 2 Li / Ni composite oxides such as spinel LiMn 2 O 4 Li / Mn-based composite oxides such as LiFeO 2 Exemplary phosphate and sulfate compounds of transition metals and lithium include LiFePO 4 , V 2 O 5 , MnO 2 , TiS 2 , MoS 2 , MoO 3 , PbO 2 , AgO, and NiOOH. The cathode material can be in any form that enables it to function as a cathode in an electrochemical cell. Exemplary forms include preformed pieces in paste form, prefabricated sheets or films. Lead acid in batteries contains lead dioxide (PbO 2 ) is preferred as the cathode material.

[0020] One or more of the battery plates may include an anode. The anode may be any material capable of functioning as the anode of the battery and may be in any form commonly used in batteries. A bipolar plate may include an anode on a surface opposite the surface on which the cathode is deposited and opposite the cathode of another bipolar plate or a monopolar plate. A monopolar plate may have an anode deposited on a surface opposite the exposed surface of the cathode or anode, or opposite the surface adjacent to an end plate, or both. The anode is also referred to as the negative electrode active material (NAM). Anode materials include any material used in secondary batteries, including lead acid, nickel metal hydride, and lithium ion batteries. Exemplary materials useful for the construction of the anode include lead, and composite oxides of carbon or lithium and transition metals, such as titanium oxide or composite oxides of titanium and lithium. The anode material for a lead acid battery may be sponge lead. The cathode material may be in any form that allows the cathode material to function as a cathode in an electrochemical cell. Exemplary forms include pastes, prefabricated sheets or film forming parts. The paste compositions may contain numerous beneficial additives, including flock or glass fibers for reinforcement, various ligano-organic compounds for paste stability, and conductive additives such as carbon, particularly for the negative active material. For phosphoric acid batteries, sponge lead is the preferred form of anode material. Once a circuit containing the electrochemical cell is formed, an anode and cathode are selected that cooperate to function as the electrochemical cell.

[0021] The anode and / or cathode can be of any desired shape or thickness. The anode and / or cathode can have a shape that matches, does not match, is contrary to, and / or is not contrary to the substrate, transfer sheet, or both on which the anode and / or cathode are disposed. The anode and / or cathode can have a non-planar structure formed similarly to the substrate, transfer sheet, or both. The anode and / or cathode may have a shape different from that of the substrate. One or more recesses, protrusions, openings, lattice edges, waveform structures, or combinations thereof of the substrate, transfer sheet, or both on which the anode and / or cathode are disposed can be formed on the anode and / or cathode to match and align. One surface of the anode and / or cathode can be contrary to the substrate, transfer sheet, or both, while the opposing surface is not contrary. One surface of the anode and / or cathode can be contrary to the substrate, transfer sheet, or both, while the opposing surface of the anode and / or cathode is contrary to another transfer sheet, substrate, or both. For example, the surface of the anode and / or cathode disposed on the substrate can be contrary to the substrate surface, while the surface of the same anode and / or cathode disposed on the transfer sheet can be contrary to the surface of the transfer sheet.

[0022] The anode and / or cathode may each have a uniform thickness or may vary in thickness. The thickness of the anode and / or cathode may be about 0.3 mm or more, about 0.5 mm or more, or even about 1 mm or more. The thickness of the anode and / or cathode may be about 3 mm or less, about 2 mm or less, or even about 1.5 mm or less. The thickness of the layer of the anode active material or the cathode active material disposed between one surface of the substrate and a surface of the transfer sheet may be uniform or may vary according to the needs of a particular battery assembly. The total thickness of the layer of the anode active material, the cathode active material, or both may vary by about 0% or more, about 25% or more, or even about 50% or more. The total thickness of the layer of the anode active material, the cathode active material, or both may vary by about 90% or less, about 80% or less, or even about 75% or less.

[0023] One or more battery plates may include one or more transfer sheets. The transfer sheet, such as when formed in a mold, may function to define one surface of the negative active material (e.g., anode) or positive active material (e.g., cathode), to facilitate the transfer of the negative active material or positive active material from the mold to a surface of the substrate, or both. The transfer sheet may be disposed on a surface of the negative active material or positive active material. The transfer sheet may be disposed on a surface of the negative active material or positive active material opposite the surface that contacts the substrate. The transfer sheet may substantially cover a surface of the negative active material or positive active material. The surface of the negative active material or positive active material opposite the transfer sheet may contact the substrate. The transfer sheet may have any suitable shape to cooperate with the mold, substrate, positive active material, negative active material, or combinations thereof. The transfer sheet may be planar, non-planar, or both. The transfer sheet may include one or more non-planar structures. The non-planar structure may be a protrusion, a projection, a recess, an opening, a ridge, a corrugated structure, or a combination thereof. The one or more non-planar structures may be formed reciprocally or non-reciprocally with the structure of the substrate. The transfer sheet may include one or more openings. The one or more openings may be aligned with one or more openings in the substrate. The openings may share one or more of the same characteristics as those described with respect to the substrate. The one or more non-planar structures may be non-reciprocally with the structure of the substrate. For example, the transfer sheet may have a corrugated structure, while the substrate is generally planar. The corrugated structure allows the surface of the positive or negative active material applied on the transfer sheet to have a reciprocal corrugated structure, while its opposing surface is substantially planar and conforms to the substrate. When the negative or positive active material is transferred to the substrate in a shape formed by the mold, the negative or positive active material is bonded on one surface to the substrate and on the opposing surface to the transfer sheet. The layer of anode active material or cathode active material may be a relatively thin layer between one surface of the substrate and one surface of the transfer sheet. Thus, the edges of such layers may be relatively thin and protected by the formed structure. For example, the edges of the anode active material, cathode active material, transfer sheet, or any combination thereof may be protected by the frame of the battery plate, the substrate, or both.

[0024] The transfer sheet may be prepared from one or more materials. The one or more materials may function to resist corrosion, to allow the transfer of ions from the anode to the cathode and / or vice versa, or any combination thereof. The transfer sheet may be prepared from any material that will not degrade in the presence of an electrolyte. Electrolytes such as sulfuric acid may be highly corrosive. The transfer sheet may be porous. Porous materials may be advantageous in that they allow the electrolyte, including ions, to pass through the transfer sheet. By allowing the electrolyte to pass through, the transfer sheet allows the anode and cathode to collectively function to generate electrons as part of an electrochemical cell. The pores may be of a suitable size such that the transferred paste does not pass through the transfer sheet. The transfer sheet may comprise any material that can withstand exposure to the electrolyte, can bond to the anode and cathode active materials away from the mold base, can prevent the cathode and cathode active materials from passing through the transfer sheet, and can form the desired pores. The pores in the transfer sheet may be formed by any means that provide the desired pore size. The desired pore size may be in the micron range. The pore size of the transfer sheet pores can be about 35 microns or more, about 150 microns or more, about 250 microns or more, or even about 500 microns or more. The pore size of the transfer sheet pores can be about 2000 microns or less, about 1500 microns or less, about 1000 microns or less, or even about 800 microns or less. The transfer sheet can be formed from woven and non-woven structures. The transfer sheet can be formed from a sheet of suitable material that is treated to introduce pores. The process of introducing pores can include chemical pore formers, perforation, drilling, and the like. Examples of such structures include absorbent glass mats, pasting paper, cellulose, and the like. The transfer sheet can be prepared from glass or polymeric materials. Useful polymeric materials can be polyester, polyolefin, natural or synthetic rubber, natural cellulose, synthetic cellulose, and the like. The transfer sheet can be prepared. Exemplary materials include polyethylene separators, porous rubber separators, or both.Suitable polyethylene separators may include Entek's RhinoHide and various Daramic materials. Suitable porous rubber separators may be those from Amerace, AGM, Hollingworth & Vose, and the like. The transfer sheet may have any thickness that functions to hold the active material in place, allows transfer from the mold to the substrate, allows electrolyte and ions to transfer through the transfer sheet, or any combination thereof. The thickness of the transfer sheet may be about 10 μm or more, about 250 μm or more, or even about 500 μm or more. The thickness of the transfer sheet may be about 4 mm or less, about 2 mm or less, or even about 1 mm or less.

[0025] A bipolar or monopolar plate having negative or positive active material on its surface may have a transfer sheet bonded to the active material. Active material may refer to an electroactive material, a cathode, an anode, a transfer sheet bonded to a cathode or anode, or any combination thereof. Prior to assembly of the battery plate and battery assembly, the transfer sheet may function to protect the active material, to assist in transferring the active material from a mold to a substrate, to allow the formation of one or more non-planar structures in the active material, or any combination thereof. Once the battery plate is assembled as part of a battery assembly, the one or more transfer sheets may be present in one or more electrochemical cells. The one or more transfer sheets may act in conjunction with or in place of a separator to perform the function of the separator.

[0026] Battery Assembly

[0027] A battery assembly may include one or more electrochemical cells. An electrochemical cell may be formed of a pair of opposing battery plates with opposing anode and cathode pairs therebetween. The one or more electrochemical cells may be sealed. The electrochemical cell space (i.e., between the opposing anode and cathode pairs) may include one or more separators, transfer sheets, electrolytes, or combinations thereof. For example, the electrochemical cell space may include two transfer sheets, a separator therebetween, and an electrolyte. For example, the electrochemical cell space may include two transfer sheets and an electrolyte, but no separate separator. The electrochemical cell may be sealed via one or more seals formed around one or more channels, via one or more frames and / or edges of the battery plates, separators, or both, or via any combination thereof that may form a closed electrochemical cell. The closed electrochemical cell may be sealed from the environment to prevent leakage and shorting of the cell.

[0028] The battery assembly may include an electrolyte. The electrolyte may allow electrons and ions to flow between the anode and the cathode. The electrolyte may be disposed within the electrochemical cell. Since one or more of the electrochemical cells may be sealed, the electrolyte may be a liquid electrolyte. The electrolyte may be any liquid electrolyte that facilitates the electrochemical reaction with the anode and cathode utilized. The electrolyte may be aqueous or organic. Organic-based electrolytes useful herein include electrolyte salts dissolved in organic solvents. In lithium-ion secondary batteries, lithium must be included in the electrolyte salt. Lithium-containing electrolyte salts include, for example, LiPF 6 , LiClO 4 , LiBF 4 , LiAsF 6 , LiSO 3 CF 3 , and LiN(CF 3 SO 2 ) 2can be used. These electrolyte salts can be used alone or in combination of two or more. The organic solvent must be compatible with the separator, the transfer sheet, the cathode and the anode, and the electrolyte salt. It is preferable to use an organic solvent that does not decompose even when a high voltage is applied. For example, it is preferable to use carbonates such as ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate, dimethyl carbonate (DMC), diethyl carbonate, and ethyl methyl carbonate, cyclic ethers such as tetrahydrofuran (THF) and 2-methyltetrahydrofuran, cyclic esters such as 1,3-dioxolane and 4-methyldioxolane, lactones such as γ-butyrolactone, sulfolane, 3-methylsulfolane, dimethoxyethane, diethoxyethane, ethoxymethoxymethane, and ethyl diglyme. These solvents can be used alone or in combination of two or more. The concentration of the electrolyte in the liquid electrolyte is preferably 0.3 to 5 mol / l. Usually, the electrolyte shows the highest conductivity at around 1 mol / l. The liquid electrolyte preferably comprises 30 to 70 weight percent, particularly 40 to 60 weight percent, of the electrolyte. The aqueous electrolyte comprises a solution of an acid or salt that enhances the function of the cell. Preferred salts and acids include sulfuric acid, sodium sulfate, or potassium sulfate. The salt and acid are present in an amount sufficient to facilitate operation of the cell. The concentration may be about 0.5 weight percent or more, about 1.0 weight percent or more, or about 1.5 weight percent or more, based on the weight of the electrolyte. The preferred electrolyte for lead-acid batteries is a sulfuric acid solution. The electrolyte may be capable of passing through one or more separators, transfer sheets, or both of the electrochemical cell.

[0029] The battery assembly may or may not include one or more separators. The one or more separators may function to separate the electrochemical cell (i.e., separate the cathode of the electrochemical cell from the anode of the electrochemical cell), to prevent shorting of the cell due to dendrite formation, to allow liquid electrolyte, ions, electrons, or any combination of these elements to pass through, or to do any combination of these. Any known battery separator that performs one or more of the listed functions may be utilized in the battery assembly of the present teachings. The one or more separators may be placed between the anode and cathode of the electrochemical cell. The one or more separators may be placed between an adjacent pair of battery plates, which may include between bipolar plates or between a bipolar plate and a monopolar plate. The separators may be prepared from non-conductive materials such as porous polymer films, glass mats, porous rubber, ion-conducting gels, or natural materials such as wood. The separator may include holes or tortuous paths through the separator that allow electrolyte, ions, electrons, or combinations thereof to pass through the separator. The holes may be sized as described herein with respect to the pore size of the transfer sheet. Exemplary materials useful as separators include absorbent glass mats and porous ultra-high molecular weight polyolefin membranes. The separator may be attached at its periphery and / or within itself to one or more end plates, battery plates, other separators, or any combination thereof. The separator may receive one or more posts therethrough. For example, one or more posts extending through one or more end plates, one or more battery plates, and / or a stack of one or more separators may hold multiple battery plates and one or more separators together. The separator may have a cross-sectional or surface area that is larger than the area of ​​the adjacent cathode and anode. The larger area may allow the anode to be isolated from the cathode of the same electrochemical cell. The separator may completely separate the cathode portion of the cell from the anode portion of the cell, and the edges of the separator may contact the peripheral edges of the adjacent battery plates.To completely separate the anode portion of the cell from the cathode portion of the cell, the edges of the separator, the battery plates, or both may be free of anodes or cathodes. Applying the active material to a transfer sheet and then attaching the transfer sheet to the substrate may be particularly advantageous in ensuring that the edges of the separators and battery plates are free of active material. The use of one or more transfer sheets in an electrochemical cell may eliminate the need for a separator in the electrochemical cell, if desired.

[0030] One or more separators may include a frame. The frame may function to match the edge or frame of an adjacent battery plate to form a seal between the electrochemical cell and the outside of the battery. The frame may be attached to the separator or may be integral to the separator. The frame may be attached to the separator at the periphery of the sheet forming the separator by any means capable of joining the separator to the frame and withstanding exposure to the electrolyte. For example, the frame may be attached by adhesive bonding, fusion bonding, or by molding the frame to the periphery of the separator. The frame may be molded in place by any known molding technique, such as, for example, thermoforming, injection molding, rotational molding, blow molding, and compression molding. The frame may be formed around the separator sheet by injection molding. The frame may include a raised edge adapted to match a raised edge located at the periphery of the substrate of the battery plate. The raised edges of one or both of the battery plate substrates and separator frames may be aligned to form a common edge of the battery stack and to enhance the seal between the electrochemical cells and the outside of the battery. To seal around the edges of the battery plates and one or more separators to prevent leakage of electrolyte and evolved gases from the electrochemical cells and to isolate the electrochemical cells to prevent short circuits, the product may be sealed using an endoskeleton or exoskeleton sealing system, as disclosed in commonly owned U.S. Patent Publication Nos. 2010 / 0183920, 2014 / 0349147, 2015 / 0140376, and 2016 / 0197373, which are incorporated by reference herein in their entireties.

[0031] The battery assembly may include one or more inserts. The one or more inserts may include multiple inserts. The one or more inserts may function to mate with one or more other inserts, to define a portion of one or more channels through the stack, to form a leak-proof seal along one or more channels, to cooperate with one or more valves, or any combination thereof. The one or more inserts may be part of one or more end plates, battery plates, separators, or any combination thereof. The one or more inserts may be free of active material, transfer sheets, or both. The one or more inserts may have any size and / or shape to mate with one or more inserts of a battery plate, end plate, separator, or combination thereof, to form a portion of a channel, to form a leak-proof seal along one or more channels, to cooperate with one or more valves, or any combination thereof. The one or more inserts may be formed in or attached to an end plate, a battery plate substrate, a separator, or combination thereof. The one or more inserts may be located within the periphery of the battery plate, separator, end plate, or combination thereof. The one or more inserts may protrude from a surface of the substrate, separator, end plate, or combination thereof, thereby forming one or more raised inserts. The one or more inserts may protrude from a center of the substrate of the battery plate, separator, or both. The one or more inserts may protrude substantially perpendicularly or obliquely from a surface of the substrate, separator, end plate, or combination thereof. The one or more inserts may be attached to or integrated into a portion of the battery plate, separator, end plate, or combination thereof. An insert that is integrated into and protrudes from a surface may be defined as a ridge. The surface opposite the surface from which the insert protrudes may have a reciprocal recess to allow for the formation of a ridge. The reciprocal recess may receive another insert therein, thereby allowing for the formation of a channel. The one or more inserts may have one or more openings therethrough. The one or more inserts may be concentric with and formed around the one or more openings.The one or more inserts may extend into the openings for a length. A sealing surface may be formed between the outer diameter of the one or more openings and the inside of the one or more inserts. For example, a surface of the substrate, end plate, and / or separator may be substantially perpendicular to the longitudinal axis of the battery assembly located between the inserts and the openings and may be the sealing surface. The one or more inserts may be capable of interlocking with one or more inserts of an adjacent battery plate, separator, and / or end plate to form a leak-proof seal around the channel. For example, the one or more battery plates may be machined or formed to have recesses on a surface opposite the inserts that match the ridges, inserts, sleeves, or bushings of the separators, battery plates, and / or end plates. The one or more inserts may pass through one or more non-planar features of the one or more active materials, transfer sheets, or both. For example, the one or more inserts may pass through openings (e.g., voids) in the active materials and transfer sheets to allow them to interlock with adjacent inserts. One or more suitable inserts may be those disclosed in U.S. Patent Nos. 8,357,469, 9,553,329, and U.S. Patent Publication No. 2017 / 0077545, which are incorporated by reference in their entirety for all purposes. One or more inserts may include one or more vent holes. One or more inserts of one or more separators may include one or more vent holes. The one or more vent holes may allow communication of selected fluids from one or more electrochemical cells to one or more channels. Each of the electrochemical cells may be electrochemically formed individually.

[0032] The battery assembly may include one or more openings. The one or more openings may include a plurality of openings. The openings may function to form one or more channels, to accommodate one or more seals, to secure one or more end plates, battery plates, separators, or combinations thereof to one another, or any combination thereof. The one or more openings may be formed in one or more of the end plates, battery plates, separators, active materials, transfer sheets, or any combination thereof. One or more openings in an end plate, battery plate, separator, active material, transfer sheet, or combination thereof may be aligned (i.e., substantially concentric) with one or more openings in one or more other end plates, battery plates, separators, active materials, transfer sheets, or any combination thereof. The one or more openings may be aligned laterally across the length of the battery assembly. The lateral direction may be substantially parallel to a longitudinal axis of the product. The lateral direction may be substantially perpendicular to the facing surfaces of the substrate on which the cathode and / or anode may be deposited. The openings may be machined (e.g., milled), formed during the manufacture of the substrate (e.g., by molding or shaping operations), or otherwise manufactured. The openings in the paste may be formed during a previous application process. The openings may have straight and / or smooth interior walls or surfaces. The size and frequency of the openings formed in the substrate may affect the resistivity of the battery. One or more openings may have a diameter capable of receiving a post therethrough. One or more openings in the active material and / or transfer sheet may have a diameter capable of receiving a post, an insert, or both therethrough. The diameter of the openings may be about 0.2 mm or more, about 1 mm or more, about 2 mm or more, or even about 5 mm or more. The diameter of the openings may be about 30 mm or less, about 25 mm or less, or even about 20 mm or less. The diameter of one or more openings in the transfer sheet and / or active material (e.g., paste) may be larger than the diameter of the openings and / or inserts in the separator, substrate, battery plates, end plates, or combinations thereof.One or more openings in a battery plate and / or substrate may have a larger diameter than one or more other openings in the same battery plate and / or substrate. The size of an opening may be at least about 1.5 times, at least about 2 times, or even at least about 2.5 times the size of another opening. The size of an opening may be no more than about 4 times, no more than about 3.5 times, or even no more than about 3 times the size of another opening. 1 cm. 2 The apertures may be formed to have an aperture density of at least about 0.02 per cm. 2 The apertures may be formed to have an aperture density of less than about 4 per cm. 2 Approximately 2.0 to 1 cm per 2 The openings can be formed to have a density of about 2.8 openings per square inch.

[0033] The one or more openings may be filled with a conductive material, such as a metal-containing material. The conductive material may be a material that undergoes a phase transformation at a temperature below the thermal degradation temperature of the substrate, such that at the operating temperature of the battery assembly below the phase transformation temperature, the dielectric substrate has a conductive path through the material mixture between the first surface and the second surface of the substrate. Furthermore, at temperatures above the phase transformation temperature, the conductive material mixture undergoes a phase transformation, which disables electrical conductivity through the conductive path. For example, the conductive material may be or include a solder material, including at least one or any two or more mixtures of lead, tin, nickel, zinc, lithium, antimony, copper, bismuth, indium, or silver. The conductive material may be substantially free of any lead (i.e., contains at most trace amounts of lead) or may contain a functionally operable amount of lead. The material may include a mixture of lead and tin. For example, it may comprise a majority of tin and a minority of lead (e.g., about 55 to about 65 parts by weight tin and about 35 to about 45 parts by weight lead). The material may have a melting temperature below about 240°C, below about 230°C, below about 220°C, below about 210°C, or even below about 200°C (e.g., within the range of about 180 to about 190°C). The material may comprise a eutectic mixture. A feature of using solder as the conductive material to fill the opening is that the solder has a defined melting temperature that can be adjusted, depending on the type of solder used, such that it melts at a temperature that may be dangerous to continued battery operation. Once the solder melts, the board opening containing the molten solder loses electrical conductivity, creating an open circuit within the battery plate. The open circuit may act to dramatically increase the resistance within the bipolar battery, thereby stopping further electrical flow and terminating the dangerous reaction within the battery. Thus, the type of conductive material selected to fill the openings may vary depending on whether it is desirable to include such an internal termination mechanism in the battery, and if so, what is the desired temperature at which such an internal termination occurs. The substrate is configured such that it functions to disable battery operation by disrupting electrical conductivity through the substrate under operating conditions that exceed predetermined conditions.For example, a conductive material filling a hole in a dielectric substrate may undergo a phase transformation (e.g., melt) such that electrical conductivity throughout the substrate is disrupted, which may be to the extent that it partially or even completely disables the ability to conduct electricity through the substrate.

[0034] The battery assembly may include one or more channels. The one or more channels may function to present one or more vent, fill, and / or cooling channels, to accommodate one or more posts, to position one or more posts throughout the interior of the battery assembly, to prevent liquid electrolyte from contacting one or more posts or other components, or any combination thereof. The one or more channels may be formed by aligned one or more openings in one or more end plates, battery plates, and / or separators. The one or more channels may extend through one or more openings in the active material, transfer sheet, or both. The one or more channels may be referred to as one or more integrated channels. The one or more channels may run through one or more electrochemical cells. The one or more channels may run through the liquid electrolyte. The channels may be sealed to prevent electrolyte and gases evolved during operation from entering the channels. Any sealing method that achieves this purpose may be employed. One or more seals, such as inserts in one or more end plates, battery plates, and separators, may connect and surround the one or more channels to prevent liquid electrolyte from leaking into the one or more channels. The one or more channels may run laterally through the battery assembly to form one or more transverse channels. The size and shape of the channel may be any size or shape that can accommodate one or more posts therein. The shape of the channel may be circular, elliptical, or polygonal, such as square, rectangular, hexagonal, etc. The size of the channel that accommodates the one or more posts is selected to correspond to the posts used. The diameter of the channel may be equal to the diameter of the opening aligned to form the one or more channels. The one or more channels comprise a series of openings in the component arranged to allow the posts to be placed in the formed channel and to allow fluid to be routed through the channel for cooling and / or for venting and filling. The number of end plates and channels that support the edges of the end plates, battery plates, and separators are selected to prevent leakage of electrolyte and gases generated during operation and to prevent compressive forces occurring during operation from damaging the components and seals of the individual electrochemical cells.There may be multiple channels to distribute the compressive forces generated during operation. The number and design of channels are sufficient to minimize edge stresses that exceed the fatigue strength of the seal. The location of the multiple channels is chosen to distribute the compressive forces generated during operation. The channels may be distributed evenly throughout the stack to better handle the stresses. The cross-sectional size of the multiple channels may be about 2 mm or more, about 4 mm or more, or about 6 mm or more. The upper limit of the cross-sectional size of the channels is based on practicality. If the size is too large, the efficiency of the assembly decreases. The cross-sectional size of the channels may be about 30 mm or less, about 25 mm or less, or even about 20 mm or less. Even if the cross-sectional size of the channels is large, a non-planar surface of the active material may be able to compensate or improve the efficiency. For example, a corrugated form of the active material may be able to increase the surface area and therefore improve the efficiency of the battery assembly.

[0035] The battery assembly may include a seal between one or more channels and one or more posts. The one or more seals may be located within the channel, around the outside of the channel, and / or around the post. The seal may include any material or form that prevents electrolyte and gases evolved during operation from leaking out of the electrochemical cell. The seal may be a membrane, a sleeve, or a series of aligned inserts in the end plates, battery plates, and / or separators, or may be inserted into the channel. The membrane may be elastic. The channel may be formed by a series of sleeves, bushings, inserts, and / or ridges inserted or integrated into the plates and / or separators. The inserts and / or ridges may be compressible or capable of interlocking with each other to form a leak-proof seal along the channel. The inserts and / or ridges may be formed in place in the battery plates and / or separators, such as by molding the inserts and / or ridges in place. The inserts and / or ridges may be molded in place by injection molding. The seals may be prepared from any material that can withstand exposure to the electrolyte, the operating conditions of the electrochemical cell, and the forces exerted by the post insertion or the post within the channel. The polymeric materials described as useful are preferred for the posts and substrate. The seals may be formed by sleeves, inserts, or bushings disposed between the bipolar and monopolar plates. The sleeves or inserts may be relatively rigid, while the bushings are generally resilient. The inserts, ridges, sleeves, and / or bushings may be adapted to fit within recesses in the bipolar and monopolar plates and / or separators, or to have ends that insert into openings in the plates to create one or more channels. The dual polar, bipolar, and monopolar plates may be formed or machined to include recesses that match the ridges, inserts, sleeves, and / or bushings. A stack of plates may be assembled with ridges, inserts, sleeves, or bushings to create an interference fit that effectively seals the channel.Alternatively, the ridges, inserts, sleeves, and / or bushings may be melt or adhesively bonded to the plates to form a seal at the junction. Alternatively, the ridges, inserts, sleeves, and / or bushings may be coated on the inside with a coating that serves to seal the channel. As mentioned above, the posts may serve to seal the channel. It is contemplated that a combination of these sealing methods may be utilized in a single channel or in different channels. The components of a stack of plates, including dual polar, monopolar, and bipolar plates, preferably have the same shape and common edges. This facilitates sealing the edges. If a separator is present, it will typically have a similar structure to the battery plates to accommodate the formation or creation of the transverse channels. The seal may be a thermosetting polymer, such as an epoxy, polyurethane, or acrylic polymer, injected between the bolt and the transverse channel. One or more channels may be formed with inserts, ridges, sleeves, and / or bushings that are bonded to, bonded within, or integrated with the openings of one or more battery plates and / or one or more separators. One or more posts in one or more channels may apply sufficient pressure to hold the inserts, holes, ridges, sleeves, and / or bushings in place to form a sealed passage. One or more channels may be formed from inserts and / or ridges bonded and / or integrated into one or more battery plates and one or more separators. One or more posts may be bonded to one or more inserts, ridges, and / or substrates of the battery by adhesive bonding, by fusing of a thermoplastic polymer, or both. The inserts and / or ridges may be inserted into one or more battery plates and / or separators by an interference fit or may be bonded in place by an adhesive. The inserts and / or ridges of one or more separators may include one or more vent holes that may allow communication between one or more electrochemical cells and one or more channels.One or more vent holes may allow delivery of gas from one or more electrochemical cells to one or more channels and may prevent delivery of one or more liquids (i.e., electrolytes) from the one or more electrochemical cells to the one or more channels.

[0036] The battery assembly may include a membrane. The membrane may function to seal around the edges of one or more end plates, battery plates, one or more separators, one or more transfer sheets, one or more channels, or any combination thereof. The membrane may be bonded to the edges of one or more end plates, battery plates, and / or one or more separators by any means that seals the edges of the end plates, battery plates, and separators to isolate one or more electrochemical cells. Exemplary bonding methods include adhesive bonding, fusion bonding, vibration welding, RF welding, and microwave welding, among others. The membrane may be a sheet of polymeric material that can seal the edges of the end plates, monopolar plates, and bipolar plates and can withstand exposure to the electrolyte and conditions to which the battery is exposed internally and externally. The same materials useful for the battery plate substrates may be utilized for the membrane. The membrane may be a thermoplastic polymer that can be fusion bonded, vibration welded, or molded around the substrates of the monopolar and bipolar plates. The same thermoplastic polymer may be utilized for the monopolar substrate, bipolar substrate, and membrane. Exemplary materials include polyethylene, polypropylene, ABS, and polyester, with ABS being most preferred. The membrane may have the size of the side of the stack to which it is bonded, with a membrane bonded to each side of the stack. The edges of adjacent membranes may be sealed. The edges may be sealed using adhesives, fusion bonding, or a molding process. The membrane may comprise one unitary sheet wrapped around the entire periphery of the stack. The membrane may have a leading edge and a trailing edge. The leading edge may be the first edge that contacts the stack. The trailing edge may be the end or last portion of the membrane attached to the stack. The leading edge and trailing edge may be bonded to the stack, to each other, or both to complete the seal of the membrane around the stack. This may be done by use of adhesives, fusion bonding, or a molding process. In fusion bonding, the surfaces of the membrane and / or stack edges are exposed to conditions where one or both of the surfaces melt, bringing the membrane and stack edges into contact while the surfaces are molten. When the surfaces solidify, the membrane and stack edges join, forming a bond that can seal the components together.The membrane may be cut to the desired length from a continuous sheet of membrane material. The width of the membrane may match the height of the stack of monopolar and bipolar plates. The membrane is thick enough to seal the edges of the stack of monopolar and bipolar sheets to isolate the cell. The membrane may also act as a protective enclosure surrounding the edges of the stack. The thickness of the membrane may be about 1 mm or more, about 1.6 mm or more, or about 2 mm or more. The thickness of the membrane may be about 5 mm or less, 4 mm or less, or about 2.5 mm or less. When bonding the membrane to the edges of the stack, any adhesive may be used that can withstand exposure to the electrolyte and the operating conditions of the cell. Exemplary adhesives include plastic cement, epoxy, cyanoacrylate adhesives, or acrylate resins. Alternatively, the membrane may be formed by molding a thermoplastic or thermoset material around some or all of the stack of battery plates. Any known molding method may be used, including thermoforming, reaction injection molding, injection molding, rotational molding, blow molding, compression molding, and the like. The membrane may be formed by injection molding the membrane around some or all of the stack of battery plates. If the membrane is formed around some of the stack of plates, it may be formed around the edges of the battery plates or the battery plates and separators.

[0037] To protect the formed battery, the sealed battery assembly may be placed in a housing. Alternatively, a membrane may be used as the battery housing, together with a protective cover covering the monopolar plate at the end of the stack. The monopolar plate may be fitted or bonded with a suitable protective cover on the surface opposite the anode or cathode. The cover may be of the same material as the membrane, or may be of a material that can be adhesively or fusion bonded to the membrane and have a thickness within the ranges recited for the membrane. If the cover is attached to the end of the plate, it may be attached by any mechanical connection, including posts with overlapping portions. The housing may be formed by molding the membrane around both sides of the stack of battery plates and / or the monopolar plate.

[0038] The battery assembly may include one or more posts. The one or more posts may function to hold the stack of components together in a manner that prevents damage to the components or breakage of the seal between the edges of the components of the stack, to ensure uniform compression across the separator material, and to ensure uniform thickness of the separator material. The one or more posts may have overlapping portions at each end that engage the outer surface of the opposing end plate, such as the sealing surface of each end plate. The overlapping portions may function to apply pressure on the outer surface of the opposing end plate in a manner that prevents damage to the components or breakage of the seal between the edges of the components of the stack and prevents overhang or other displacement of the stack during battery operation. The overlapping portions may contact the sealing surfaces of the end plates. The stack may have a separate structure or protective end piece on the monopolar plate, and the overlapping portion contacts the outer surface of the structure or protective end piece. The overlapping portion may have any structure that, together with the post, prevents damage to the components or breakage of the seal between the edges of the components of the stack. Exemplary overlapping portions include bolt heads, nuts, molded heads, brads, cotter pins, shaft collars, and the like. The posts have a length that runs through the entire stack, with such length varying depending on the desired capacity of the battery. The posts may have a cross-sectional shape and size that fills the channel. The posts may have a cross-sectional size that is larger than the cross-sectional size of one or more of the channels, such that the posts form an interference fit with one or more of the channels. The number of posts that support the edges of the end plates and substrates is selected to prevent leakage of electrolyte and gases evolved during operation, prevent compressive forces generated during operation from damaging the components and seals of the individual electrochemical cells, and minimize edge stresses that exceed the fatigue strength of the seals. There may be multiple posts to distribute the compressive forces generated during operation. There may be fewer posts than channels, with one or more of the channels being utilized as a cooling channel or a vent / fill channel. For example, there may be four channels, three of which have posts installed inside and one channel that can be used as a cooling, vent, and / or fill channel. The posts may comprise any material that performs the required function.If posts are utilized to seal the channels, the material used is chosen to withstand the operating conditions of the cell, not corrode when exposed to the electrolyte, and can withstand the temperatures and pressures encountered during operation of the cell. If the posts perform a sealing function, they may include polymeric or ceramic materials capable of withstanding the listed conditions. In this embodiment, the material must be non-conductive to prevent shorting of the cell. The posts may include polymeric materials such as thermosetting polymers or thermoplastic materials. The posts may include thermoplastic materials. Exemplary thermoplastic materials include ABS (acrylonitrile-butadiene-styrene copolymer), polypropylene, polyester, thermoplastic polyurethane, polyolefin, composite thermoplastics, polycarbonate, and the like. ABS is most preferred. If the channels are sealed separately, the posts may include any material that has the structural integrity to perform the desired function. Of the above polymeric materials, ceramics, and metals may be utilized. Suitable metals may be steel, brass aluminum, copper, and the like. The posts may include molded posts, threaded posts, or posts with one or more end attachments. The post may be bonded to a portion of the stack, such as a substrate, an insert, or a ridge in a channel. The bond may be formed from bonding or fusing a polymeric material, such as a thermoplastic material. One or more of the openings may have a threaded surface. If threaded, one or more of the posts may also be threaded to engage with the threaded opening. The post may include a head or nut on one end opposite a nut, a brad hole, a cotter pin, or the like, or a combination thereof. This is typically the case for non-molded posts. The post may be constructed to be a one-way ratcheting device that can be shortened but not lengthened. Such a post is placed in place and when the stack is compressed, the post shortens to maintain pressure on the stack. The post in this embodiment may have ridges to facilitate ratcheting so that the post can act as part of a structure like a cable tie. Matching nuts and / or washers may be used with the post, which may compress adjacent plates when in place.The nut and / or washer pass over the post in one direction and ridges may be present to prevent the nut and / or washer from moving along the post in the other direction. In use, the holes in the post have brads, cotter pins, etc. suitable to perform the recited functions. If the post is molded, it may be molded individually or in place. If molded in place, in situ, the presence of a seal may be required in the channel to hold the molten plastic in place. The seal may be formed by a mating insert, a separate seal in the channel, or both. A threaded non-conductive post may be used, which may provide the necessary seal. Alternatively, a pre-molded non-conductive polymer post may be designed to form an interference fit in the channel in a manner that seals the channel. The post may be formed in place by molding, such as injection molding.

[0039] The battery assembly may include one or more valves. The one or more valves may function to draw a vacuum inside the battery assembly, to fill the battery assembly with electrolyte, and / or to vent the battery assembly during operation. The one or more valves may include a pressure relief valve, a check valve, a fill valve, a safety valve, or the like, or any combination thereof. The one or more valves may connect and / or communicate with one or more channels formed by one or more openings in the end plates, the battery plates, the separators, or any combination thereof. The one or more valves may communicate with a channel, such as a channel with a post passing therethrough, or a channel without a post. The product may include one or more valves as described in U.S. Patent Application Publication No. 2014 / 0349147, which is incorporated herein by reference in its entirety for all purposes. The assembly may include a pressure relief valve for one or more of the cells to relieve pressure if the cell reaches a dangerous internal pressure. The pressure relief valve is designed to prevent catastrophic failure that could damage the system in which the battery is used. Once the pressure relief valve is released, the battery will not function. The disclosed assembly may include one check valve that releases pressure from the entire assembly when or before a dangerous pressure is reached. Some exemplary suitable valves are disclosed in U.S. Patent Nos. 8,357,469, 9,553,329, 9,685,677, 9,825,336, and U.S. Patent Application Publication No. 2018 / 0053926, which are incorporated by reference in their entirety for all purposes.

[0040] The product may include one or more terminals. The assembly may include one or more pairs of conductive terminals, each pair connected to a positive terminal and a negative terminal. The one or more terminals may function to send electrons generated in the electrochemical cells to a system that utilizes the generated electrons in the form of electricity. The terminals are adapted to connect each battery stack to a load, essentially a system that utilizes the electricity generated in the cells. The one or more terminals may pass through one or more end plates, one or more battery plates, the membrane, and / or the housing. The one or more terminals may pass through the battery plates from the end plates to the outside, or through the sides of the housing or membrane around the assembly essentially parallel to the plane of the end plates. The terminals match the polarity of the anode or cathode of the monopolar plate, dual polar plate, bipolar plate, or combinations thereof. The terminals contact conductive conduits within the assembly. The cathode of the monopolar plate and the cathode of one or more of the bipolar plates with cathode current collectors may be connected to independent positive terminals. The anode of the monopolar plate and the anode of one or more of the bipolar plates having an anode current collector may be connected to a separate negative terminal. The cathode current collectors may be connected and the anode current collectors may be connected in parallel. The individual terminals may be covered by a membrane, leaving only a single connected positive terminal and a single connected negative terminal exposed. Some exemplary suitable terminal assemblies are disclosed in U.S. Patent Nos. 8,357,469, 9,553,329, 9,685,677, 9,825,336, and U.S. Patent Publication No. 2018 / 0053926, which are incorporated by reference in their entirety for all purposes.

[0041] The battery assembly may include one or more conductive conduits. The conductive conduits may function to route electrons from a current collector in contact with the cathode to one or more positive terminals. A typical bipolar battery passes electrons from cell to cell through a substrate. The substrate includes at least a portion of a conductive material or includes a conductive pathway through the substrate. When a circuit including the cells is closed, electrons flow from cell to cell through the substrate to the positive terminal. It is believed that in an assembly, electrons may flow through the substrate and cell, through the current collector to a current conductor, or both. In batteries disclosed herein having two or more stacks, each stack has a current conductor and / or conductive conduit connecting the current collector in contact with the anode to the negative terminal and a current conductor and / or conductive conduit connecting the current collector in contact with the cathode to the positive terminal. The conductive conduits from two or more stacks may be arranged in parallel or in series. A parallel circuit includes two or more circuits that are not connected to each other. A series circuit includes two or more circuits arranged such that electrons flow through the circuit in sequence. When the conductive conduits are arranged in a series configuration, the battery may have only one negative terminal and one positive terminal. When the conductive conduits are arranged in parallel, the battery may have a single positive and negative terminal, with each circuit connecting to the negative or positive terminal, respectively. Alternatively, each circuit may have a separate negative and positive terminal. The terminals may be connected to a load that typically utilizes the electricity stored in the battery. Each of the parallel current conductors and / or conductive conduits in contact with the current collector in contact with the cathode may contact a separate positive terminal. Each of the parallel current conductors and / or conductive conduits in contact with the current collector in contact with the anode may contact a separate negative terminal.

[0042] To protect the formed battery, the sealed stack may be placed in a housing. Alternatively, the membrane may be used as the housing for the battery, together with a protective cover covering the monopolar plate at the end of the stack. The monopolar plate may be fitted or bonded with a suitable protective cover on the surface opposite the anode or cathode. The cover may be of the same material as the membrane, or may be of a material that can be adhesively or fusion bonded to the membrane and have a thickness within the ranges recited for the membrane. If the cover is attached to the end of the plate, it may be attached by any mechanical connection, including posts with overlapping portions. The housing may be formed by molding the membrane around both sides of the stack of battery plates and / or the monopolar plate.

[0043] Using the Battery Assembly

[0044] The battery assemblies disclosed herein are particularly useful for attaching to a load and forming a circuit that includes the electrochemical cells. Electrons can flow from the terminals to the load and back from the load to the terminals. The load can be a system that uses electricity. This flow is maintained as long as the cells can generate electricity. If the stack of cells is fully discharged, the battery may need to undergo a charging step before further use. If the substrate of the bipolar plate includes a conductive material mixture at the operating temperature of the battery assembly below its phase transformation temperature, the substrate has a conductive path through the material mixture between the first surface of the substrate and the opposing second surface, and at temperatures above the phase transformation temperature of the conductive material mixture, a phase transformation occurs in the conductive material mixture that disables the conductivity through the conductive path. This allows the battery to be disabled before adverse consequences occur. Once the battery is discharged, it can be recharged by forming a circuit with an electron source. During charging, the function of the electrodes changes, the anode becomes the cathode during discharging, and the cathode becomes the anode during discharging. Essentially, an electrochemical cell allows electrons and ions to flow in the opposite direction when discharging.

[0045] The edges of the battery plates and separator plates may be sealed to prevent electrolyte and evolved gases from leaking from the cells and to isolate the individual cells to prevent shorting of the cells. The edges may be sealed using any known battery sealing method. The edges of the assembly may be sealed using an endoskeleton or exoskeleton sealing system as disclosed in commonly owned U.S. Patent Application Publication No. 2010 / 0183920A1, entitled "Bipolar Battery Assembly," by Shaffer, II et al., which is incorporated herein by reference in its entirety. The sealing system disclosed by Shaffer, II et al. contemplates a unique structure for bipolar battery stack structures, such as those described above. Whether based on the above method or not, the structure generally comprises a first separator frame, a negative paste frame member having one or more edges and a support grid structure, the support grid structure extending between one or more of the negative paste frame edges, a negative current collector foil, a substrate having a plurality of openings formed therein, a positive current collector foil, a positive paste frame member having one or more edges, and a support grid structure extending between one or more of the positive paste frame edges and a second separator frame. The first separator frame may include one or more edges. The negative paste frame member may have one or more edges such that at least one edge of the negative paste frame member is in planar contact with at least one edge of the separator frame. The substrate may also have one or more edges such that at least one edge of the substrate is in planar contact with at least one edge of the negative paste frame member. The positive paste frame member may have one or more edges such that at least one edge of the positive paste frame member is in planar contact with at least one edge of the substrate. The second separator frame may have one or more edges such that at least one edge of the separator frame is in planar contact with at least one edge of the positive paste frame member. The planar contact of the edges of the separator frame, negative paste frame member, positive paste frame member, and substrate forms an exterior seal on the cell such that electrolyte introduced therein does not leak from within the cell.The edges of the paste frame member may further include openings to receive alignment pins or support members mounted on the edges of the separator frame. By locating the alignment pins within the openings of the paste frame member, the formation of an external seal may be further facilitated. It is also envisioned that frame structures may be used in which one or more separator frames and one or more paste frames are combined with a substrate and each positioned in planar contact with an adjacent frame and / or substrate such that the internal structure of the battery cell creates an external seal that does not allow any liquid or gas (air) to leak out of the battery. The edges of the paste frame member may further include openings to receive alignment pins or support members mounted on the edges of the separator frame. By locating the alignment pins within the openings of the paste frame member, the formation of an external seal may be further facilitated. Thus, electrolyte introduced into the battery is safely retained without risk of battery leakage and subsequent battery failure. Furthermore, no heavy end plates or external support structures are required to effectively seal the battery. As described above, the paste frame member may further include support members (e.g., pins) mounted between the edges of the paste frame member. The use of support members is just one approach to address the problem of compression stresses in the battery and the resulting unwanted edge / peel stresses. Additionally, pins can be added to the outer periphery or edges of the frame members to align the separating frame members, if desired, allowing the frame members to slide up and down or back and forth during compression. If desired, a bipolar battery can be constructed using a combination of endoskeleton and exoskeleton construction techniques. For example, a bipolar battery can be constructed using internal support pins as described above. Additionally, a frame structure can also be placed on the terminal side of the monopole. This external battery construction can be reinforced with end covers as part of the aesthetic box. The substrate for the battery plates can have a raised edge (e.g., frame) on the periphery of the substrate, which acts as a paste frame that seals together. The raised edge can also seal to the outer membrane, if utilized.

[0046] The battery assembly may be capable of withstanding internal pressures of 10 psi or more, about 20 psi or more, about 50 psi or more, and about 100 psi or less without leakage or distortion due to internal pressure. The battery assembly may withstand internal pressures of about 6 psi to about 10 psi. The battery assembly may provide an energy density of about 34 watt-hours / kilogram, about 40 watt-hours / kilogram, or about 50 watt-hours / kilogram. The battery assembly of the present teachings may generate any desired voltage, such as 6, 12, 24, 48, or 96 volts. Higher voltages are possible, but about 200 volts is a practical upper limit.

[0047] Method(s) of Preparing Battery Plate(s)

[0048] One or more battery plates, battery assemblies, or both disclosed herein can be prepared by the following steps.

[0049] Substrates useful for bipolar plates, dual polar plates, monopolar plates, or combinations thereof may be formed or cut into shapes. If the substrate comprises a non-conductive material, the substrate may be converted into a composite substrate. Composite substrates may be particularly useful for conventional bipolar battery assemblies. To convert a substrate into a composite substrate, one or more holes (e.g., openings) may be formed in the substrate. The holes may be formed by molding holes in the substrate, machining the substrate to form holes, any other suitable process, or combinations thereof. The openings may be filled with a conductive material. The conductive material may be one that melts at a prescribed temperature, as previously described herein. When utilized, one or more conductors may be adhered to one or both sides (e.g., surfaces) of the substrate. The one or more conductors may include one or more metal sheets, screens, wires, foils, or the like, or any combination. U.S. Pat. No. 9,553,329 discloses the use of such conductors to distribute electrons in an electrochemical cell, and this patent is incorporated herein in its entirety for all purposes. The metal sheet, foil, or both may be bonded to the substrate using an adhesive, for example, the adhesive may be a nitrile-based rubber cement.

[0050] One or more active materials may be attached to the substrate. The active materials on the substrate function to allow the battery plate, the substrate, or both to function as electrode plates. The active materials may be disposed on one or both sides (e.g., surfaces) of the substrate. The active materials may be directly attached to the substrate or may be attached to a conductor (e.g., metal sheet, screen, wire, and / or foil) disposed on the substrate. The active materials may include positive active materials (e.g., cathode), negative active materials (e.g., anode), or both. Active materials of only one polarity (e.g., positive or negative) may be disposed on only one surface of a monopolar plate. Active materials of different polarity may be disposed on opposing surfaces of a bipolar plate. Active materials of the same polarity may be disposed on opposing surfaces of a dual polar plate. One or more active materials may be applied as a paste to the substrate, the battery plate, or both. To place the active materials on the substrate, the active materials (e.g., anode, cathode) in paste form may be applied to a transfer sheet. When the paste is applied to the transfer sheet, the transfer sheet may be placed in a mold. After applying the active material to the mold, the transfer sheet with the paste thereon may be moved from the mold so as to contact the substrate, the conductor on the substrate, or both. Upon contacting the substrate, the conductor, or both, the active material may bond to the substrate, the conductor, or both. The mold may apply additional pressure to the transfer sheet, the active material, or both to assist in bonding the active material to the substrate, the conductor, or both. After applying the active material as part of the battery plate, the transfer sheet may remain bonded to the active material or may be removed. The transfer sheet may be placed on the active material on a surface opposite the surface of the active material (e.g., paste) that is bonded to the battery plate (e.g., substrate, conductor, or both). For example, in the case of one or more bipolar plates, the cathode paste with the transfer sheet bonded thereto may be applied to one surface of the substrate and the anode paste with the transfer sheet bonded thereto may be applied to the other opposing surface of the substrate. As another example, in the case of one or more monopolar plates, the cathode paste or anode paste with attached transfer sheet may be applied to one surface of a substrate, while the opposing surface of the substrate is kept free of active material.In another example, for one or more dual polar plates, a cathode paste with a bonded transfer sheet or an anode paste with a bonded transfer sheet is bonded to a surface of the substrate, and a paste of the same polarity (e.g., positive or negative) with a bonded transfer sheet is applied to the opposite surface of the substrate. During attachment of the active material to the substrate, one or more non-planar structures in the active material may receive, align with, or interlock with one or more non-planar structures of the substrate, or any combination thereof. One or more openings formed in the active material may be aligned (e.g., concentric) with one or more openings, inserts, or both of the substrate. One or more openings formed in the active material may receive and pass one or more inserts. One or more recesses, wells, or both formed in the active material may receive one or more protrusions or projections of the substrate. One or more protrusions or projections of the substrate may help the active material to remain bonded to the substrate during curing. During attachment of the active material to the substrate, the active material may conform to one or more non-planar features of the substrate. For example, one or more protrusions extending from the substrate may compress, displace, or both, a portion of the active material. Some of the protrusions and / or recesses may not allow the active material to pass through and may function to enhance the bonding of the active material to the substrate, the battery plate, or both. During and / or after attachment of the active material, the active material may remain out of contact with one or more portions of the substrate, the battery plate, or both. The active material may remain out of contact with one or more non-planar features of the active material. By remaining out of contact with one or more non-planar features, the active material may not interfere with the sealing or bonding of one or more components of the battery assembly. The active material may remain out of contact with one or more frames, raised edges, protrusions, inserts, openings, or any combination thereof, of the substrate. The use of a transfer sheet allows for controlled placement of the active material on the substrate and may allow the active material to remain free of contact with one or more portions of the substrate, the battery plate, or both.

[0051] A paste of active material is applied to a transfer sheet. The paste may be applied to a transfer sheet disposed within a mold. This may allow the transfer sheet with the paste applied to be easily bonded later to a substrate with the non-planar features formed thereon, or both. The mold may include one or more movable plates. The movable plates may function to move the transfer sheet, the active material, or both. The movable plates may move the transfer sheet under a pasting location (e.g., nozzle, extruder) so that the paste is applied. The movable plates may move the transfer sheet, the active material, or both to the substrate, away from a cavity (e.g., nest) of the mold, or both. The movable plates may be movable within the mold by one or more transport elements. The one or more transport elements may be located below, adjacent to, or above the movable plate. The one or more transport elements may be located in any suitable location such that the transfer sheet, the active material, or both may be placed on the moving plate, the moving plate may move toward the substrate, the moving plate may apply pressure to the transfer sheet, the active material, or both to bond to the substrate, the battery plate, the electrical conductor, or any combination thereof. The one or more transport elements may include one or more rolling elements such as one or more separate ball transfer units (i.e., drop-in, flange-mounted, flush-mounted, and / or stud-mounted, etc.), ball transfer tables, ball transfer rails, one or more gravity rollers, one or more automated rollers, roller conveyors, flat-top conveyors, etc., or any combination thereof. The moving plate may be located on a transport system of the mold. The transport system may enable the moving plate to move toward, away from, or both of the extrusion portion (e.g., nozzle) of the mold. The moving plate may be movable within the mold by one or more extension elements.The one or more extension elements may function to lift the movable plate out of the cavity, to retract the movable plate into the cavity, to lift the movable plate out of the cavity, to lift the movable plate towards the substrate, the battery plate, or both, to apply pressure to the movable plate to apply pressure to the transfer sheet and / or the active material, or any combination thereof. The one or more extension elements may be located anywhere suitable to lift the movable plate out of the cavity to allow the movable plate to transfer the transfer sheet and active material onto the battery plate. The one or more extension elements may be located below the movable plate, opposite the cavity, the transfer sheet, the active material, or any combination thereof, or any combination thereof. The one or more extension elements may include hydraulic, mechanical, and / or pneumatic lifting mechanisms. The movable plate may be located within the base of the mold. The movable plate may move far enough to completely move the formed electrode paste out of the mold and into contact with the substrate. The substrate may be located opposite the opening of the mold. The opening may be an opening in a nest of a mold.

[0052] The movable plate may have a shape that matches the shape of the substrate to which the active material is applied. Matching may mean having a shape that is substantially opposite to the shape of the substrate. The movable plate may be formed with one or more non-planar structures that substantially match the structure of the substrate. The movable plate may include one or more protrusions, recesses, inserts, frames, raised edges, openings, etc., or any combination thereof, that match one or more similar features of the substrate. The movable plate may have a cross-sectional area and / or surface area that is equal to or less than the cross-sectional area of ​​the substrate. The cross-sectional area and / or surface area may be the area of ​​the surface facing the substrate, transfer sheet, or both. The movable plate may have a cross-sectional area that is smaller than the cross-sectional area defined by the interior of one or more frames, raised edges, or both of the substrate, battery plate, or both. The movable plate may be able to fit within the area defined by one or more frames, raised edges, or both when placing active material on the substrate, conductor, battery plate, or combination thereof. By having a cross-sectional area or surface area smaller than that defined by the frame, the raised edge, or both, the movable plate can prevent contact between the active material and the frame, the raised edge, or both. A portion of the movable plate can be substantially flat. The movable plate can be adapted to receive one or more different inserts. The one or more inserts can extend into the cavity of the mold.

[0053] The mold may further include a cavity in which the movable plate resides. The cavity functions to hold the movable plate, the insert, the transfer sheet, the active material, or any combination thereof. The cavity is defined by one or more walls. The one or more walls may surround the periphery of the movable plate and define the cavity. The one or more walls may be substantially perpendicular or oblique to the movable plate. The angle of the wall may be measured relative to the surface of the movable plate facing the transfer sheet, the substrate, the battery plate, in the cavity, or any combination thereof. The walls of the mold may form electrodes of any desired shape to match the shape of the battery plate described herein. When the mold moves during the filling step, the walls of the mold may have a thickness sufficient to prevent the dispensing of the electrode paste when the walls are under the dispensing nozzle, and when the nozzle is not in contact with the walls, the paste is dispensed into the mold. The cavity may be defined as a nest. The nest may be particularly useful for holding the movable plate, the transfer sheet, the active material, or any combination thereof. A nest can be an area where active material is placed so that it rests on a transfer sheet.

[0054] The mold may have one or more covers. The covers may function to partially close the mold, the cavities, or both, to protect the cavities, the movable plate, the transfer sheet, the active material, or combinations thereof from debris and contaminants, to cooperate with the extrusion portion of the mold, to receive the active material therethrough, to guide the dispersion of the active material, or any combination thereof. Each cavity may have its own cover, or may share a cover. The covers may be located on opposite sides of the movable plate. The covers may at least partially close the cavities. The covers may impart a shape to the active material in the cavities. The active material may fill the cavities such that the active material contacts the covers. The covers may have a shape that substantially matches the shape of the substrate, battery plate, or both to which the active material is applied. Matching may mean having a shape that is substantially opposite the shape of the substrate, battery plate, or both. The covers may be formed with one or more non-planar structures that substantially match the structure of the substrate. The one or more inserts of the mold may contact or be adjacent to the cover. The cover may cooperate with the one or more inserts to form one or more non-planar structures in the active material. The cover may include one or more orifices. The one or more orifices may be adapted to receive the active material, cooperate with an extrusion portion of the mold, be capable of ejecting the active material into the cavity, or any combination thereof. The shape and size of the one or more orifices may be tailored to the process of applying the paste to the mold. If the mold is stationary during filling, the number of orifices and the size of the orifices may be tailored to this process. The cover may include a single orifice or multiple orifices. The multiple orifices may be evenly distributed throughout the cover, allowing for an even distribution of the active material in the cavity. If the mold moves during filling, the one or more orifices may be stretched. The stretched orifices may extend over the length of the mold in the direction of movement. The mold can be designed to form the active material to a uniform or varying thickness according to the design criteria of the electrode.

[0055] The process of applying active material (e.g., active) to one surface of a battery plate generally includes: a) placing a transfer sheet on a movable plate in a mold; b) closing a cover over the mold; injecting a material capable of forming an electrode through one or more orifices in the cover and onto the transfer sheet on the movable plate such that the electroactive material forms a layer in the shape created by the mold walls, the movable plate, and the cover; removing the cover from over the mold; placing an electrode substrate over the mold opening such that an area of ​​one of the surfaces of the substrate where it is desired to place electrode material is aligned with the active material in the mold; moving the movable plate through the mold opening until the active material contacts the substrate and forms a bond with the substrate; and moving the movable plate away from the substrate and to the bottom of the mold such that the active material remains bonded to one of the surfaces of the substrate plate and the transfer sheet is bonded to an active material surface opposite the active material surface bonded to one of the surfaces of the substrate. In preparing a bipolar plate, the process further includes placing a second transfer sheet on a second movable plate of a second mold; placing a second mold cover over the second mold; injecting a second active material capable of forming an electrode through one or more orifices in the second mold cover onto the second transfer sheet on the second movable plate such that the second active material forms a layer in a shape defined by the second mold walls, the second movable plate, and the second mold cover; removing the cover from over the second mold; and depositing a second active material on a surface opposite to the surface to which the first active material was bonded. placing an electrode substrate over the opening in the second mold such that an area of ​​the second surface of the substrate where it is desired to deposit a second active material is aligned with the second active material in the second mold; moving a second movable plate through the opening in the second mold until the second electrode material contacts and forms a bond with the opposing surface of the substrate; and moving the movable plate away from the substrate to the bottom of the mold such that the second electrode material remains bonded to one of the opposing surfaces of the substrate plate and a second transfer sheet is bonded to the second electrode material opposite the surface of the electrode material bonded to the opposing surface of the substrate.The cycle time for applying the paste to the surface can be about 2 seconds or more, about 15 seconds or less, about 10 seconds or less, or even about 6 seconds or less.

[0056] The transfer sheet may cover the entire moving plate to prevent the paste from contacting the surface of the moving plate and allow the paste to be completely transferred to the substrate. After insertion of the transfer sheet, the cover may be closed on the mold. The paste may then be injected into the mold through one or more orifices in the cover using one or more injection nozzles that inject the paste. The one or more nozzles are sealed around the one or more orifices to control the flow of the paste into the mold. If the mold moves, such as on a conveyor belt, it may move under the injection nozzles and the orifices may be stretched in the direction of movement. The mold may shape the injected paste into the desired shape of the active material for use with the battery plate. Extrusion into the mold may be initiated by pumping the active material through one or more orifices. Extrusion into the mold may be terminated by stopping the pumping action. The active material may be injected into the mold (e.g., cavity) at a relatively low pressure. The pressure at which the active material is injected into the mold (e.g., via a mold line, etc.) can be about 50 psi or less, about 40 psi or less, or even about 30 psi or less. The pressure at which the active material is injected into the mold transfer plate can be about 10 psi or more, about 15 psi or more, or even about 20 psi or more. After the active material is injected and formed into the desired shape, the cover can be removed from the mold. A substrate is placed on the opposite side of the mold, and the movable plate is moved toward the substrate until the paste contacts the substrate and / or electrodes disposed thereon. The substrate and / or electrodes thereon can be treated to roughen the surfaces of the substrate and / or electrodes thereon to enhance adhesion of the paste to the surfaces. Any known method of roughening these surfaces can be utilized. The substrate can be aligned with the movable plate such that the active material is placed in the desired location on the substrate. The movable plate is held in contact with the substrate and / or battery plate for a time sufficient to form a bond between the active material and the substrate and / or battery plate. The movable plate can then be pulled back into the mold (eg, cavity) leaving the active material bonded to the substrate and / or battery plates on the substrate.The transfer sheet may remain attached to the active material after the movable plate is retracted from the battery plate. If the active material is applied to one surface of the battery plate, the substrate, or both, it may be a monopolar plate.

[0057] To prepare a bipolar plate, a dual polar plate, or both, an active material may be formed in a subsequent mold (e.g., a cavity). The active material prepared in the subsequent mold may be the active material disposed on the opposing surface of the substrate, the battery plate, or both. An active material of different polarity or the same polarity may be injected into a second, or subsequent mold (e.g., a cavity). To form a bipolar plate, the active material may be of opposite polarity different from the active material already applied on the plate. To form a dual polar plate, the active material may be of the same polarity as the active material already applied on the plate. A first electrode is prepared from the first mold using active material of any polarity useful for forming a cathode or anode, and a second mold is used to form the opposite electrode of the anode or cathode. Either electrode may be applied first, but conventionally the cathode may be applied first. A second electrode may be formed similarly to the first electrode. The electrodes may have the same thickness or shape on both sides. The electrodes may have different shapes or thicknesses on either side. After formation of the second electrode, the substrate is moved to a position where the surface of the substrate and / or electrode not having active material disposed thereon is opposite the second mold. The second electrode is then contacted with the second surface and / or electrode of the battery plate. The battery plate may be rotated 180 degrees between applying the first electrode to the substrate and the second electrode.

[0058] Protrusions, depressions, or openings on the surface of a battery plate or frame can be molded into the structure when they are formed by a molding process or when they are added by a subsequent common molding process. Using one or more inserts of a mold, the surface of a transfer sheet, active material, or both can be formed to receive one or more portions of a substrate, to pass through one or more portions of a substrate, or both, such that they are substantially opposite to the surface of the substrate. One or more inserts can correspond to one or more protrusions, projections, depressions, openings, lattice edges, corrugated structures, or any combination thereof of the substrate. One or more inserts can be a part of a movable plate, one or more walls of a mold, a part of a cover, any other protrusion into the cavity of a mold, any other depression away from the cavity of a mold, or any combination thereof. One or more inserts of a movable plate can protrude into the cavity or nest of a mold in a direction away from the movable plate, can be recessed into the movable plate in a direction away from the cavity or nest of a mold, or both. One or more inserts can function to form one or more non-planar structures within the active material (e.g., paste). One or more inserts can function to create one or more voids, depressions, projections, lattice edges, corrugated structures, or any combination thereof within the active material. One or more inserts of a mold can create one or more depressions or wells within the active material. One or more depressions or wells within the active material can receive one or more protrusions from the substrate, battery plate, or both. One or more inserts of a mold can extend through one or more voids (e.g., openings) of a transfer sheet, can create one or more voids in a transfer sheet, or both. One or more inserts prevent or guide the placement of the active material (e.g., paste) relative to the transfer sheet. For example, one or more inserts of a mold that extend through one or more openings (e.g., voids) of a transfer sheet prevent the paste from entering the one or more openings, thus forming an opening (e.g., void) in the active material. The opening in the active material is then aligned with the transfer sheet.The one or more voids may function to provide space therein for and / or receive one or more inserts of the substrate, battery plate, or both, to prevent contact between the one or more inserts of the substrate, battery plate, or both and the active material, to have one or more channels extending therethrough, or any combination thereof. In other words, the first mold or the first and second molds include inserts that function to form voids in the first and / or second active material injected into the mold. The size of the diameter of the one or more inserts may be smaller, approximately equal, or larger than the size of the diameter of the one or more openings, inserts, or both of the one or more substrates, battery plates, or both. The one or more inserts of the mold may have a diameter larger than the diameter of the inserts of the substrate. By having a larger diameter, the voids created in the electroactive layer may allow the inserts and / or channels to pass with minimal or no contact. The inserts may have a height that is approximately less than, equal to, or greater than the thickness of the transfer sheet, the active material layer (e.g., the cathode paste layer, the anode paste layer), or any combination thereof. Some of the protrusions may penetrate the paste. Forming voids in the active material that match the protrusions allows the battery plates to be assembled into the battery without the protrusions contacting the active material, and avoids the protrusions from being contaminated with active material. By avoiding contact, costly cleaning operations are prevented. In addition, by avoiding contact, the risk that the presence of active material on such protrusions may adversely affect the operation of the battery assembly is prevented. The adverse effects on operation may include poor sealing and shorting of the battery assembly. Such protrusions may be substantially free of active material. By substantially free, it may be meant that about 5% or less, about 1% or less, or even about 0.1% or less of the surface area of ​​the protrusions that extend beyond the active material may include active material or active material dust on its surface.Substantially free can mean that about 0% or more, about 0.01% or more, or even about 0.05% or more of the surface area of ​​the protrusions that extends beyond the active material can include active material or active material dust disposed on its surface.

[0059] Method(s) of Preparing a Battery Assembly

[0060] The present disclosure further relates to a method of preparing a battery assembly using a plurality of battery plates disclosed herein. The method may include forming a stack of a plurality of substrates having active material on one of the surfaces and active material on an opposing surface. The method may include disposing (e.g., stacking) one or more separators between a pair of substrates. One or more inserts, openings, or other non-planar structures of one or more separators may be aligned with one or more inserts, openings, or other non-planar structures of one or more battery plates, substrates, separators, active materials, transfer sheets, or any combination thereof. The method may not require disposing one or more separators between a pair of substrates. Separators may not be disposed between the substrates and / or battery plates, since if the transfer sheets remain attached to the active materials, the one or more transfer sheets may be disposed between the active materials of adjacent pairs to prevent contact between the active materials of one battery plate and the active materials of the adjacent battery plate. The method may include exposing the battery assembly or stack of battery plates to conditions that cure one or more active materials. The active material may be hardened by exposing it to a temperature of about 15°C or higher, about 20°C or higher, about 30°C or higher, or even about 40°C or higher. The active material may be hardened by exposing it to a temperature of about 95°C or lower, about 90°C or lower, about 80°C or lower, or even about 70°C. For example, an active material in paste form may be hardened by exposing it to a first temperature of about 40°C to about 70°C for about 12 to about 48 hours. The active material may be hardened by exposing it to a second temperature and drying it. The active material may be dried by exposing it to a temperature of about 25°C or higher, about 30°C or higher, about 40°C or higher, or even about 50°C or higher. The active material may be dried by exposing it to a temperature of about 105°C or lower, about 100°C or lower, about 90°C or lower, or even about 80°C. For example, the active material in the form of a paste can be dried by exposing it to a temperature equal to or higher than the second temperature, that is, about 50° C. to about 80° C., for about 24 to about 72 hours.

[0061] The transverse channel holes can be preformed or machined into the substrate, metal sheet or foil, separator, anode, cathode, transfer sheet, and any other present components. Holes can be formed in the active material by forming voids in the active material while the active material is being applied to the transfer sheet. The voids in the active material can align with one or more openings in the transfer sheet. If the channels are formed using sleeves, inserts, ridges, and the like, they can be inserted into the battery plates and / or separators. If the inserts are molded in place, they are molded into the battery plates and / or separators using known molding processes.

[0062] The following steps may be used to mold the frame and / or insert into or on the separator or battery plate substrate: The separator sheet may be cut to size (die punched, slit, stamped, etc.). One or more sheets may be stacked to the required thickness of the separator. The sheets may be placed into a mold that places the sheets in a fixed position. The mold may form a peripheral frame around the separator, any internal features of the transverse channels as needed (e.g. bushings, inserts, ridges), or both. Additionally, the mold is designed to avoid overcompressing the separator material and to prevent the plastic from damaging the separator material. The plastic is injected into the mold and once the plastic has cooled, the part is removed.

[0063] The components are then stacked such that the anode of each plate faces the cathode of the other plate. It is preferred that the sheets are stacked such that the edges of the substrates are aligned along the edges of any other frame components. Plates with two or more guide pins or bolts may be used to support the stack. One or more assembly aids of one battery plate may be aligned with one or more assembly aids of an adjacent battery plate to support the stack during assembly. For example, one or more posts protruding from the frame may engage and reside in one or more wells of an adjacent frame. The components are stacked on the plates with guide pins in a suitable order consistent with the disclosure herein. Two or more of the transverse channels may be used for alignment pins or bolts. Once the stack is complete, an elastic membrane or sleeve may be inserted into the transverse channel. If the channel is sealed with a bushing, insert, or plastic sleeve placed between the holes of the plate, a coating may be applied to the inside of the channel, the inside of the hole, the sleeve, insert, and / or the bushing. If the holes in the plates need to be internally threaded, they may be internally threaded prior to or after assembly using known techniques. Inserts in adjacent battery plates and / or substrates interlock to seal and form the channels, eliminating the need for additional seals to be placed within the channels.

[0064] One or more posts may be inserted into the stack. One or more posts may be secured to the opposing sealing surfaces of the monopolar plates by overlapping portions. If the overlapping portions are mechanical interlocking structures, such interlocking structures are secured to the posts. If the posts are injection molded in place, a thermoplastic molten material is inserted into the channel and overlapping portions of the molten material are formed on the sealing surfaces at both ends. The surface of the channel is heated to melt the inner surface of the channel, in this embodiment, the injected thermoplastic material bonds well to the inside of the channel. The thermoplastic material may be cooled. The channel may have a form inserted into the channel and an overlapping portion formed at each end. A two-part thermosetting material may then be added to the channel and hardened to form the posts. If the posts are designed to fit into the channel by an interference fit, the posts are inserted with a suitable force. Once the posts are secured and stable, the stack may be removed from the guide pins and the posts may be inserted into the channels that were used for the guide pins.

[0065] The method of assembling the battery assembly may further include attaching the membrane. If the membrane is attached to the edge surface of the stack, an adhesive is applied to either the membrane or the edge of the stack, or both, and the membrane and the edge of the stack are brought into contact to bond together. The membrane may be held in place using known mechanical means while the adhesive sets or hardens. The edge of the membrane may be sealed to the unsealed edge of another membrane sheet or membrane or end plate on the opposite surface of the monopolar plate. Sealing may be done by adhesive or by fusion bonding. Alternatively, the membrane may be attached by fusion bonding. In fusion bonding, both the edge of the stack and the surface of the membrane that will bond to the edge are exposed to conditions that melt the surfaces without adversely affecting the structural integrity of the membrane or stack. This may be accomplished by exposing each to a hot surface, platen, hot fluid, air, heat radiation, vibration, etc., and then contacting the membrane and edge of the stack along the molten surface and allowing the molten surfaces to cool and bond together. The membrane may be cut to fit a particular edge or may be a continuous sheet wrapped around the edge of the stack. The leading and trailing edges of the membrane are joined together where they meet, preferably by fusion bonding. The membrane may be sealed to the membrane on the outer surface of the monopolar plate or to the end plate in the case of a monopolar plate. If a case is used, the assembly may be inserted into the case. Preferably, the membrane serves as the case. In a fusion bonding embodiment, the membrane and the edge of the stack are exposed to a temperature or condition at which the respective surfaces melt and are in a molten state for a time sufficient to melt the respective surfaces. The temperature chosen is preferably higher than the melting temperature of the material used for the membrane and / or substrate, as well as any other structural elements. The temperature used is preferably about 200° C. or higher, more preferably about 220° C. or higher, and most preferably about 230° C. or higher. The temperature used is preferably about 300° C. or lower, more preferably about 270° C. or lower, and most preferably about 240° C. or lower.

[0066] The assembly may further comprise one or more air holes that communicate with one or more of the electrochemical cells. The air holes may enable the discharge of gas from the electrochemical cells and the introduction of a liquid electrolyte into the electrochemical cells. Pressure may be applied to move liquid within the cells, or a vacuum may be applied to the electrochemical cells to draw electrolyte into the cells through the air holes. When a vacuum is used to introduce the electrolyte, each electrochemical cell may have two vent holes. A vacuum may be applied to one vent hole and electrolyte may be drawn into the cell through the other vent hole. Alternatively, the electrochemical cell may have a single vent hole and may be present within a vacuum chamber. A vacuum may be applied and then electrolyte may be drawn in through the same vent hole. The vent holes may contact any combination of manifolds and channels. The vent holes may contact each electrochemical cell. The vent holes may contact the cell separator of each cell. The assembly may comprise a manifold. One or more vent holes may contact the manifold, and the manifold may form a common headspace for all the vent holes. One or more ports are formed in the manifold, and one or more valves, such as check valves, may be disposed in the manifold ports. The battery may further comprise a fill valve. The fill valve may be installed within the manifold or may be connected to a cross-channel. The product may further comprise one or more integrated fill and / or vent channels. Such channels are formed near the center of the battery stack and communicate with the region between the cathode and anode where the separator is installed, and when electrolyte is added to the region, this region becomes the region forming the electrochemical cells. Before assembly, the channels may be formed by creating holes or slots in the separator and the battery plates and then aligning the holes or slots. Inserts, sleeves, or ridges may be used as discussed herein with respect to cross-channels as long as the regions adapted for use as electrochemical cells communicate with the channels. The channels preferably communicate with the outside of the battery stack in two places. This facilitates filling the battery with electrolyte. After filling the electrochemical cells with electrolyte, one of the openings may be filled or closed.The other opening is used to vent the battery and electrochemical cell. During filling, a vacuum is pulled on one of the exterior holes and electrolyte is pulled through the other hole. Alternatively, a single hole is used and the electrochemical cell is filled as described later in this specification. In this embodiment, once the sealed battery is formed, a vacuum is pulled on the single hole or port to create a low pressure environment in the cell. The pressure in the electrochemical cell can be 50 Torr or less, or can be 10 Torr or less. The vacuum is then disconnected and an electrolyte source is connected to the hole or port, and the low pressure in the cell causes the electrolyte to quickly fill the battery. The vacuum and electrolyte source can be connected through a switchable valve so that the switch from vacuum to electrolyte source is efficient. This system can be used when one transverse channel is formed from the sleeve, insert, and / or ridge where the vent hole, such as a ridge, insert, or notch in the sleeve, contacts the electrochemical cell. This system even allows the electrochemical cell to be filled with fresh electrolyte. Filling under these conditions can occur in about 600 seconds or less, or about 300 seconds or less. Valves, such as check valves, safety valves, and pressure relief valves, can be inserted into the remaining holes after filling. After assembly of the stack, the channels can be pre-threaded or tapped.

[0067] After assembly, vent holes can be drilled through the sealed membrane, if necessary, in each cell located in the center of the thickness of the absorbent glass mat separator. A manifold can then be attached to the top of the battery assembly to form a common head space above the vent holes. A single port can be made in the manifold. The single manifold port can be used as a vacuum purge port and electrolyte fill port. A vacuum is applied to the manifold port to a low pressure, such as about 29 inches Hg, via a vacuum pump, and then the vacuum source valve is turned off and the fill valve is connected to an electrolyte source and opened, allowing electrolyte to fill all cells of the battery simultaneously. When the frame is assembled or molded, vent holes can be formed in the frame around the separator. An integral vent channel can be formed by pre-drilling or forming holes in the frame of the separator and the substrate used in the battery plate. These holes can be aligned to form a channel. This channel can communicate with the vent hole that communicates with the electrochemical cell. The integral vent channel may be one of the transverse channels, the transverse channel having a vent hole communicating with each of the electrochemical cells. There may be two integral channels with a vent hole communicating with each electrochemical cell. Formation of the integral channel may be accomplished by providing a membrane or insert in the transverse channel with a vent hole for each electrochemical cell. The channel may be formed from an insert, sleeve, or ridge having or forming a vent hole communicating with the electrochemical cell. The integral channel may be pressurized to prevent backflow of electrolyte. The integral channel may be terminated with a valve that controls the internal pressure of the assembly. The electrochemical cell may be filled with electrolyte using the channel prior to use. A valve may be located in one of the end plates. The channel may be threaded after assembly or may be pre-threaded prior to assembly to insert the valve. The valve may be inserted and retained using any known means for insertion and retention. Some of the components used in the products disclosed herein are adapted to be placed adjacent to other disclosed components.Components designed to be placed next to other components may have or utilize components or techniques known in the art to hold the parts in a suitable relationship to one another. The particular components or techniques used to hold the components in a suitable relationship to one another are selected based on the components, relationships, and design preferences of the person skilled in the art who designs or assembles the assemblies of the present disclosure.

[0068] Exemplary embodiments

[0069] The following description of the figures is provided to illustrate the teachings herein, but is not intended to limit the scope thereof. One or more features shown in one figure may be combined with one or more features of another figure.

[0070] Both Figures 1 and 2 show a battery plate 10. Battery plate 10 includes substrate 11. Substrate 11 includes frame 20 around its periphery. Frame 20 protrudes from substrate 11. Substrate 11 includes insert 41 protruding from substrate 11. Insert 41 includes opening 40. Insert 41 protrudes through voids 128a,b. Voids 128a,b are formed in both paste 105 and transfer sheet 103. Insert 41 protrudes beyond paste 105 and transfer sheet 103. In Figure 1, transfer sheet 103 is shown as generally planar. In Figure 2, transfer sheet 103 includes a corrugated surface.

[0071] Both Figures 3 and 4 show a battery plate 10 configured as a bipolar plate. The battery plate 10 includes a substrate 11. The substrate 11 includes a frame 20 disposed on its edge. For example, the frame 20 may be at the periphery of the substrate 11. The frame 20 includes a non-planar feature such as a raised edge. The raised edges 20a,b extend in a direction away from the substrate 11 and the active materials 12, 13. The raised edges 20a,b may be useful to allow the battery plate 10 to be stacked with an adjacent battery plate (not shown). The active materials include a cathode 13 and an anode 12. The cathode 13 and the anode 12 each include a paste 105. In Figure 4, a protrusion 114 extends from the substrate 11. The protrusion 114 is disposed below the surface of the paste 105.

[0072] FIG. 5 shows a mold 101 for applying paste 105 (not shown) onto a transfer sheet 103 (not shown). The transfer sheet 103 can be placed into a nest 130 of a movable plate 102 of the mold 101 so that the paste 105 can be applied onto the transfer sheet 103. The nest 130 is formed as a recess or cavity in the movable plate 102. The mold 101 includes an insert 124. The insert 124 is placed into the nest 130 such that the insert 124 projects away from the movable plate 102. The insert 124 can resemble a post that projects into the nest 130. The mold 101 includes an extrusion nozzle 106. The extrusion nozzle 106 includes a ram 120. The ram 120 exerts a constant low pressure onto the paste 105 (not shown) present in a paste box 122. The paste 105 is extruded through an extrusion nozzle 106 into a mold area 104 such that the paste 105 is applied onto a surface of a transfer sheet 103. Once the paste 105 has been applied, a moving plate 102 moves the transfer sheet 103, with the paste 105 applied thereon, in a movement direction 107 away from the extrusion nozzle 106. A plurality of conveying elements 132 effect the movement of the moving plate 102 in the movement direction 107.

[0073] FIG. 6 shows the movable plate 102 of the mold 101 (as shown in FIG. 5). The movable plate 102 includes a nest 130. Within the nest 130 is a transfer sheet 103. A paste 105 is disposed on the transfer sheet 103, for example after the paste 105 has been applied to the transfer sheet 103 via an extrusion nozzle 106 (as shown in FIG. 5). The mold 101 includes an insert 124. The insert 124 projects into the nest 130 in a direction away from the movable plate 102. The insert 124 projects through an opening 128a in the transfer sheet 103. The opening 128a is formed in the transfer sheet 103 before the transfer sheet 103 is placed in the nest 130. The insert 124 projects beyond a top surface 134 of the transfer sheet 103. When paste 105 is applied to top surface 134 of transfer sheet 103, insert 124 prevents paste 105 from filling opening 128a, resulting in the formation of opening 128b in paste 105. Opening 128b in paste 105 thus aligns with opening 128a in transfer sheet 103. When transfer sheet 103 and paste 105 are assembled into battery plate 10 (as shown in FIG. 1 or FIG. 2), openings 128a,b may align with other openings to form one or more channels.

[0074] FIG. 7 illustrates a process 200 for preparing battery plates 10 in a mold 101 and then assembling a stack of battery plates 10 to form a battery assembly. The battery plates 10 can be bipolar plates, but the process is similar for monopolar plates. A first step 202 involves placing a transfer sheet 103 in the mold 101. The transfer sheet 103 can be a positive electrode transfer sheet. A second step 204 involves applying a paste 105 to the transfer sheet 103. The paste 105 is a positive electrode active material (PAM). The combination of the transfer sheet 103 and the positive electrode active material (PAM) paste 105 forms the cathode 13. A third step 206 involves removing the transfer sheet 103 and paste 105, i.e., the cathode 13, from the mold 101 and transferring them to a substrate 11. A fourth step 208 involves placing the transfer sheet 103 in the mold 101. The transfer sheet 103 can be a negative electrode transfer sheet. A fifth step 210 involves applying a paste 105 to the transfer sheet 103. The paste 105 is a negative electrode active material (NAM). The combination of the transfer sheet 103 and the negative electrode active material (NAM) paste 105 forms the anode 12. A sixth step 212 involves removing the transfer sheet 103 and the paste 105, i.e., the anode 12, from the mold 101 and transferring it to a substrate 11. The anode 12 is disposed on a surface of the substrate 11 opposite the cathode 13. The first step 202 through the third step 206 can be performed before, after, or in parallel with the fourth step 208 through the sixth step 212. The battery plate 10 is assembled as a bipolar plate once the anode 12 and cathode 13 are disposed thereon. A seventh step 214 involves transferring and adding assembled battery plates 10 to the stack of battery plates. The first step 202 through the seventh step 214 may be repeated as many times as necessary until the desired stack size is reached. The final step 218 involves curing the assembled stack of battery plates. The stack may need to be moved, such as from an assembly line or station to a curing area.

[0075] 8A-8C show a sequence of steps for preparing a battery plate 10, such as a bipolar plate, using a mold 101 with a movable plate 102 to form the cathode 13 and anode 12. FIG. 8A shows the mold 101 with a transfer sheet 103 disposed on the movable plate 102. The transfer sheet 103 is disposed in a molding area 104 of the mold 101. FIG. 8B shows the injection of paste 105 into the molding area 104. The paste 105 is injected through an extrusion nozzle 106. The paste 105 is forced through an orifice by low pressure to fill the molding area 104 as the transfer sheet 103 passes by. The direction of movement of the mold 101 relative to the extrusion nozzle is indicated by arrow 107. FIG. 8C shows the movable plate 102 extending towards the substrate 11 so that the paste 105 comes into contact with the substrate 11. Thus, the paste 105 and transfer sheet 103 may be combined with the substrate 11 to form part of the battery plate 10. The paste 105 and transfer sheet 103 may be placed within the frame 20 of the substrate 11.

[0076] Figures 9 and 10 show a stack of battery plates 10 and separators 14 that form the battery assembly 1. Figure 9 shows a partially disassembled perspective view of the stack, while Figure 10 shows a perspective view of the stack. An end plate 25 is shown having a terminal hole 42 and a hole 39 for a post 17 in the form of a bolt and nut 19. Adjacent to the end plate 25 is a battery plate 10 that is a monopolar plate 43 having a frame 20 with a raised edge. The monopolar plate 43 has a raised insertion portion 41 that surrounds a hole 40 and a post 17 in the hole used to form a transverse channel 16. Adjacent to the monopolar plate 43 is a separator 14. The separator 14 has a frame 34 at its periphery. The separator 14 includes an absorbent glass mat 36 including a central portion within the frame 34. A formed insertion portion 35 surrounding a formed insertion hole 37 that forms the transverse channel 16 is shown. Adjacent to the separator 14 is a bipolar plate 44. The bipolar plate 44 includes a frame 20 at its periphery. The frame 20 is a raised surface. The raised insertion portion 41 is raised to form the transverse channel 16. The raised insertion portion 41 forms a raised insertion hole 40 for the transverse channel. Figure 10 shows a stack of the battery plate 10 and the separator 14. The end plate 25, the battery plate substrate frame 20, the separator frame 34, the post 17, and the nut 19 around the post 17 are shown. A battery terminal 33 is disposed in the terminal hole 42 of the end plate 25.

[0077] FIG. 11 shows a side view of a stack of battery plates 10 forming a battery assembly 1. The battery plates 10 include monopolar plates 43 at opposing ends of the stack of battery plates 10. Between the opposing monopolar plates 43 are a plurality of bipolar plates 44. Each of the battery plates 10 includes a substrate 11. Adjacent to each substrate 11 of the bipolar plates 44 is an anode 12 and a cathode 13. Disposed between each pair of anodes 12 and cathodes 13 is a separator 14. The separator 14 is shown as an absorbent glass mat that has absorbed liquid electrolyte. Each pair of anodes 12 and cathodes sandwiches the electrolyte between them to form an electrochemical cell. Also shown is a transverse channel 16. Disposed within the transverse channel 16 is a channel seal 15. The channel seal 15 is formed as a rubber tube. Disposed inside the channel seal 15 is a post 17. The post 17 is in the form of a threaded bolt. At the ends of the posts 17 there is overlap in the form of bolt heads 18 and nuts 19. Around the edges of the substrate 11 for both the monopolar plate 43 and the bipolar plate 44 is a frame 20.

[0078] 12 shows an end plate 25. The end plate 25 is disposed on the substrate 11 of the monopolar plate 43. The end plate 25 is disposed opposite the anode 12 or cathode 13 disposed on the substrate 11 of the monopolar plate 43. The end plate 25 is disposed over the exposed overlapping portion of the post 17, such as the nut 19. A seal 22 is disposed between the nut 19 on the post 17 and the monopolar plate 43. The seal 22 includes a sealing surface 23. The sealing surface 23 contacts the opposing surface 24 of the monopolar plate 43.

[0079] 13 shows the installation of the membrane 27 as part of the battery assembly 1. The membrane 27 is applied around the edges of the stack of battery plates 10. End plates 25 are shown with four spaced nuts 19 on the ends of the posts 17. An end plate 25 is shown on each end of the stack of battery plates 10. A frame 20 is disposed around the substrates 11. Between the frames 20 of the substrates 11 is a frame 34 of the separators 14. The membrane 27 is applied to the substrate frames 20 and separator frames 34 using sources of heat 26 and pressure 28 to seal the membrane 27 to the edges of the substrate frame 20 and separator frame 34 portions of the stack of battery plates 10.

[0080] FIG. 14 shows a battery assembly 1. The battery assembly 1 includes a stack of battery plates 10. The stack of battery plates 10 includes a frame 20 of substrates 11 interspersed with a frame 34 of separators 14. End plates 25 are shown. Four spaced nuts 19 are shown on one end plate 25. Vent holes 30 are also shown. The vent holes 30 are drilled into the electrochemical cells. A manifold 31 is fitted over the vent holes 30. The manifold 31 is fitted to form a common head space for the vent holes 30. A check valve 32 is also shown. The check valve 32 is placed on the manifold 31 in contact with the common head space, but this is not shown. Two terminal posts 33 are also shown. The terminal posts 33 are the negative and positive terminals of the battery assembly 1.

[0081] 15 illustrates separator 14. Separator 14 includes a frame 34. Frame 34 is integrally molded as part of separator 14. Separator 14 also includes four inserts 35. Inserts 35 are also integrally molded as part of separator 14. Inserts 35 include holes 37 therethrough. Holes 27 are adapted to form part of a plurality of transverse channels 16 (not shown). Frame 34 is disposed about absorbent glass mat 36.

[0082] 16 shows a battery assembly 1. The battery assembly 1 includes a post 38 molded therein, the post 38 having a molded head 47. The molded head 47 is disposed on the end plate 25.

[0083] 17 shows the battery assembly 1. Shown on the end plate 25 are posts 17 and nuts 19. The end plate 25 includes terminal holes 42 with terminals 33 disposed therein. The battery assembly includes a manifold 31 and a check valve 32. A membrane 27 is disposed on the periphery of the stack of battery plates 10 (not shown) as part of the battery assembly 1.

[0084] FIG. 18 shows a cross-section along the plane indicated by line AA in FIG. 17 through the transverse channel 16. A monopolar plate 43 is shown with a substrate 11 and a cathode 13, with a frame 20 at the end of the substrate 11. A separator 14 with a frame 34 on each end adjoins the cathode 13 of the monopolar plate 43. A bipolar plate 44 with an anode 12 adjoins the separator 14. On the substrate 11 is disposed the anode 12, on the opposite surface of which is the cathode 13, in this view disposed at the end with a frame 20. In this view there are several bipolar plates 44, arranged as described. Between the bipolar plates 44 there are separators 14. At the opposite end of the stack there is a monopolar plate 43, with a substrate 11 with a frame 20, in this view disposed at the end, and an anode 12 facing the separator 14. The pair of battery plates form an electrochemical cell within which a separator 14 is disposed. Also shown is a cross channel 16 within which a channel seal 15 and a post 17 are disposed, with a nut 19 at the end of the post 17. FIG. 19 shows a partial cross section of the end of the battery assembly 1 along line BB of FIG. 17. Vent holes 30 are shown. FIG. 20 shows a cross section of the assembly of FIG. 17 along section CC. Section CC is taken through the vent holes 30 to the electrochemical cells. Vent holes 30 for each electrochemical cell of the battery assembly 1 are shown.

[0085] Figure 21 shows the battery assembly 1. The battery assembly 1 includes a valve 50 in the end plate 25. The valve 50 communicates with an integrated channel 46 (not shown). The integrated channel 46 (not shown) communicates with a plurality of vent holes 30 (not shown). Figure 22 shows a cross-sectional view of the assembly of Figure 21 along the E-E section. The battery assembly 1 includes the integrated channel 46. The integrated channel 46 communicates with the vent holes 30. Each vent hole 30 communicates with an electrochemical cell. The integrated channel 46 communicates with the valve 50 at the end of the stack of battery plates of the battery assembly 1. Figure 23 shows a cross-sectional view of the assembly of Figure 21 along the F-F section. The F-F section passes through the integrated channel 46. The integrated channel 46 communicates with the vent holes 30.

[0086] Figure 24A shows the separator 14, and Figure 24B shows an enlarged view of the vent 51 of the separator 14. The separator 14 has an absorbent glass mat 36. The separator 14 includes a plurality of inserts 35 formed within the separator 14. Each insert 35 includes a hole 37 passing therethrough. One of the inserts 35 includes a vent (vent hole). The vent 51 communicates between the hole 37 of the separator and the absorbent glass mat 36. The frame 34 around the separator 14 is also shown. Figure 24B is an enlarged view of the insert 35 having the hole 37 and the vent 51. The vent 51 communicates between the hole 37 of the separator 14 and the absorbent glass mat 36.

[0087] Any numerical value recited in this application includes all values ​​from the lower value to the higher value in one unit increments, provided that there is a separation of at least two units between any lower value and any higher value. These are only specifically intended examples, and all possible combinations of numerical values ​​between the lowest and highest values ​​recited should be considered as being expressly set forth in this application as well. Unless otherwise stated, all ranges include both endpoints and all numerical values ​​between the endpoints. The term "consisting essentially of" describing a combination includes the specified elements, components, ingredients, or steps, and such other elements, components, ingredients, or steps that do not materially affect the basic and novel properties of the combination. The use of the terms "comprising" or "including" to describe a combination of elements, components, ingredients, or steps herein also contemplates an embodiment that consists essentially of the elements, components, ingredients, or steps. A plurality of elements, components, ingredients, or steps may be provided by a single integrated element, component, ingredient, or step. Alternatively, a single integrated element, component, ingredient, or step may be separated into a plurality of separate elements, components, ingredients, or steps. The disclosure of "a" or "one" describing an element, component, ingredient, or step is not intended to exclude additional elements, ingredients, ingredients, or steps.

Claims

1. a) a substrate having a first surface, an opposing second surface, and one or more non-planar structures; b) one or more active materials disposed on the first surface, the second surface, or both the first surface and the second surface; A battery plate comprising: The battery plate includes: i) one or more protrusions extending from the substrate and protruding beyond the active material, the one or more protrusions having a surface that is substantially free of the active material or dust of the active material; and ii) a frame on the periphery of the substrate, the frame or a portion thereof protruding beyond the active material in a direction transverse to the one or more surfaces on which the active material is deposited, the frame being substantially free of the active material or the dust consisting of the active material; Including, the battery plate is adapted to form a portion of one or more electrochemical cells in a battery assembly; and the one or more protrusions of the substrate are one or more inserts having one or more openings, the one or more openings extending through the one or more inserts, and the one or more inserts protruding beyond the one or more active materials.

2. the substrate is made of a non-conductive polymer; The battery plate of claim 1 , wherein the one or more protrusions and the frame are integral with the substrate.

3. the substrate includes a plurality of openings; The battery plate of claim 2 , wherein one or more of the openings are filled with a conductive material that provides a conductive path between the first surface and the second surface of the substrate.

4. 10. The battery plate of claim 1, wherein the battery plate includes one or more other protrusions extending from the first surface, the second surface, or both, of the substrate, the protrusions being disposed within the active material and not extending beyond the active material.

5. The battery plate includes: a) a monopolar plate, in which the one or more active materials are applied to the first surface of the substrate and the second surface is kept free of any of the active materials; b) a bipolar plate having the one or more active materials disposed on both the first surface of the substrate and the second surface of the substrate, the active material on the first surface functioning as an anode and the active material on the second surface functioning as a cathode; or c) a dual polar plate, wherein the one or more active materials are disposed on both the first surface of the substrate and the second surface of the substrate, and the active materials on the first surface and the second surface function as an anode, or the active materials on the first surface and the second surface function as a cathode; 2. The battery plate of claim 1, wherein the battery plate is one of the above.

6. one or more transfer sheets are bonded to the one or more active materials on a side opposite the substrate; each transfer sheet includes a porous material adapted to permit liquid electrolyte to pass through the transfer sheet while preventing the active material from passing through the pores of the transfer sheet; The battery plate of claim 1 .

7. the pores are between about 35 microns and about 2000 microns in size; 7. The battery plate of claim 6, wherein the one or more transfer sheets comprise a sheet of glass, polymer, or both that is woven, non-woven, extruded, or any combination thereof, such that the holes are formed therein.

8. the one or more active materials and the one or more transfer sheets have a cross-sectional area smaller than a cross-sectional area of ​​the interior of the frame such that the one or more active materials and the one or more transfer sheets are disposed inside the frame.

7. The battery plate of claim 6.

9. 10. The battery plate of claim 1, wherein the first surface, the second surface, or both, on which the one or more active materials are disposed are surfaces having one or more curved regions, convex regions, concave regions, one or more openings therethrough, or any combination thereof.

10. 5. The battery plate of claim 4, wherein the one or more other protrusions of the substrate disposed within the one or more active materials have a shape that enhances adhesion of the active materials to the first surface, the second surface, or both of the substrate.

11. one or more transfer sheets are bonded to the one or more active materials on a side opposite the substrate; the one or more inserts extend through the one or more active materials and one or more voids formed in the one or more transfer sheets, the voids having a cross-sectional area greater than an exterior cross-sectional area of ​​the one or more inserts; the one or more inserts protrude beyond the one or more active materials; The battery plate of claim 1 .

12. A battery assembly formed from a plurality of battery plates according to claim 1.

13. The battery assembly includes one or more stacks including a plurality of the battery plates, the one or more stacks including: a) one or more bipolar plates comprising the substrate, the substrate comprising: i) a first active material disposed on the first surface to function as an anode, the first active material having a first transfer sheet bonded to a side opposite the first surface; and ii) a second active material disposed on the second surface to function as a cathode, the second active material having a second transfer sheet bonded to a side opposite the second surface; the one or more bipolar plates having b) a first monopolar plate comprising the substrate having a first active material disposed on the first surface to function as an anode, the first transfer sheet being bonded to an opposite side of the first surface, the opposing second surface being devoid of the active material; c) a second monopolar plate comprising the substrate having the first surface free of the active material and a second active material disposed on the second surface to function as a cathode, the second active material having a second transfer sheet bonded to the side opposite the second surface; d) a liquid electrolyte disposed between each pair of adjacent battery plates, the liquid electrolyte functioning with the anode and the cathode disposed in the space between the battery plates of the pair to form an electrochemical cell; and Equipped with The plurality of battery plates are arranged such that a surface of the substrate on which the cathode is disposed faces a surface of another battery plate on which the anode is disposed, and the first and second monopolar plates are disposed at opposite ends of each battery plate stack; each transfer sheet includes a porous material adapted to permit the liquid electrolyte to pass through the transfer sheet while preventing the active material from passing through pores in the transfer sheet; The battery assembly of claim 12.

14. The one or more inserts protrude beyond the transfer sheet, the one or more inserts in the substrate are transversely aligned and interdigitated with one or more other inserts in one or more other substrates, separators, or both, to form one or more channels integral within the battery assembly. The battery assembly of claim 13.

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