Bipolar Lead Acid Cell Architecture for Higher Energy Density

The patent removes traditional lead grids and conductive links from the battery structure. Instead, it uses bipolar cells where the separator with electrolyte provides both separation and electrical connectivity between adjacent cells, eliminating the need for separate current collectors and inter-cell connectors. This extraction of non-essential components directly increases energy density by replacing dead weight with active energy storage materials.

The separator in the bipolar cell configuration serves multiple functions simultaneously: it acts as the physical barrier between positive and negative electrodes, provides the electrolyte medium for ion transport, and serves as the current collector that conducts electricity between cells. This multi-functionality eliminates the need for separate components, reducing overall battery mass and volume while maintaining reliable operation.

The patent eliminates traditional conductive links including lugs, straps, and inter-cell connectors. Electrical connectivity is achieved through the bipolar cell architecture where the separator with electrolyte directly conducts current between adjacent cells. This removal of intermediate conductive components reduces the number of electrical interfaces and contact resistances, thereby lowering overall internal resistance and improving power delivery capability.

The patent merges the functions of the separator and the current collector into a single integrated component. The separator, saturated with electrolyte, simultaneously provides ion transport pathways and electrical conduction between cells. This consolidation eliminates the need for separate conductive links and reduces the total resistance by creating a more direct and fewer-numbered electrical pathway between cells.

The patent removes traditional heavy lead grids from the electrode structure. Instead, it employs thin bipolar plates with catalytic coatings that serve as current collectors. The active materials are applied directly onto these lightweight bipolar plates, which provide sufficient mechanical support and electrical conductivity without the excessive weight of conventional lead grids, thereby increasing the proportion of active mass and improving specific energy.

The patent uses composite bipolar plates consisting of conductive substrates with catalytic coatings. These composite structures provide the necessary mechanical strength and electrical conductivity while being significantly lighter than traditional lead grids. The catalytic coatings enhance the electrochemical activity at the bipolar plate surfaces, maximizing the utilization of active materials and improving overall specific energy.