Reinforced bipolar battery assembly

Abstract

An article having (a) one or more stacks of a plurality of electrode plates include: (i) one or more bipolar plates having a substrate having an anode on one surface and a cathode on an opposing surface; (ii) a separator and a liquid electrolyte located between each of the electrode plates; (b) a first end plate having a first end plate internal reinforcement structure, attached at an end of the one or more stacks; (c) a second end plate having a second end plate internal reinforcement structure, attached at an opposing end of the one or more stacks as the first end plate; wherein the first end plate and the second end plate reinforce the plurality of electrode plates during a charge cycle, a discharge cycle, or both the charge cycle and the discharge cycle.

1 . A battery assembly comprising:
 (a) one or more stacks of a plurality of electrode plates comprising:
 (i) one or more bipolar plates comprising a substrate having an anode on one surface and a cathode on an opposing surface; 
 (ii) a first monopolar plate having a first substrate with a cathode deposited on one surface and located at an end of the one or more stacks; and 
 (iii) a second monopolar plate having a second substrate with an anode deposited on one surface and located at an opposing end of the one or more stacks as the first monopolar plate; 
   (b) a liquid electrolyte disposed between each pair of electrode plates, wherein the liquid electrolyte functions with an anode and cathode pair to form one or more electrochemical cells;   (C) one or more separators located between the anode and the cathode of the one or more electrochemical cells; and
 wherein the first monopolar plate and the second monopolar plate each include an internal reinforcement structure integrated into the first substrate and the second substrate. 
   
     
     
         2 - 20 . (canceled) 
     
     
         21 . The battery assembly of  claim 1 , wherein the internal reinforcement structure of the first monopolar plate is molded into the first substrate; and
 wherein the internal reinforcement structure of the second monopolar plate is molded into the second substrate.   
     
     
         22 . The battery assembly of  claim 1 , wherein the first substrate and the second substrate are comprised of a thermoplastic polymer, elastomeric polymer, thermoset polymer, or a combination thereof. 
     
     
         23 . The battery assembly of  claim 1 , wherein the internal reinforcement structure includes one or more rib structures. 
     
     
         24 . The battery assembly of  claim 23 , wherein the one or more rib structures project from the first monopolar plate and the second monopolar plate away from the one or more bipolar plates. 
     
     
         25 . The battery assembly of  claim 23 , wherein the one or more rib structures include a plurality of intersecting ribs. 
     
     
         26 . The battery assembly of  claim 25 , wherein the one or more rib structures include a plurality of rib structures in a lattice pattern, grid pattern, honeycomb pattern, or a combination thereof. 
     
     
         27 . The battery assembly of  claim 1 , wherein the battery assembly includes one or more openings in each of the one or more bipolar plates, the first monopolar plate, the second monopolar plate, and the one or more separators which are aligned with each other in a transverse direction to form one or more channels. 
     
     
         28 . The battery assembly of  claim 27 , wherein the internal reinforcement structure includes a plurality of rib structures; and
 wherein one or more of the plurality of rib structures intersect, merge, or both with the one or more openings, one or more inserts within one or more openings, or both of the first monopolar plate and the second monopolar plate.   
     
     
         29 . The battery assembly of  claim 27 , wherein the one or more openings include one or more inserts molded therein which are aligned and form the one or more channels such that the one or more channels are integrated into the one or more stacks of the plurality of electrode plates and pass through the liquid electrolyte while the one or more inserts prevent leakage of the liquid electrolyte into the one or more channels. 
     
     
         30 . The battery assembly of  claim 29 , wherein one or more of the inserts in the separators have vent holes which communicate between the one or more channels and the one or more electrochemical cells. 
     
     
         31 . The battery assembly of  claim 27 , wherein one or more posts are located in one more of the channels and extend from the first monopolar plate to the second monopolar plate. 
     
     
         32 . The battery assembly of  claim 31 , wherein the one or more posts have on each end an overlapping portion which engages the outside surfaces of the first monopolar plate and the second monopolar plate so that the overlapping portion applies pressure onto the outside surfaces. 
     
     
         33 . The battery assembly of  claim 1 , wherein the first monopolar plate is attached about a periphery and an inner surface within the periphery to one of the bipolar plates which is adjacent to the first monopolar plate; and
 wherein the second monopolar plate is attached about a periphery and an inner surface within the periphery to one of the bipolar plates which is adjacent to the second monopolar plate.   
     
     
         34 . The battery assembly of  claim 33 , wherein the inner surface within the periphery of the first monopolar plate is heat-staked to one of the bipolar plates adjacent to the first monopolar plate; and
 wherein the inner surface within the periphery of the second monopolar plate is heat-staked to one of the bipolar plates adjacent to the second monopolar plate.   
     
     
         35 . The battery assembly of  claim 33 , wherein the periphery of the first monopolar plate and the periphery of the second monopolar plate are interlocked with one or more raised edges of one or more of the bipolar plates. 
     
     
         36 . The battery assembly of  claim 1 , wherein the first monopolar plate and the second monopolar plate are attached to one more of the bipolar plates so that the one or more bipolar plates are prevented from substantially deforming when the battery assembly is vacuum-filled during a charge cycle. 
     
     
         37 . The battery assembly of  claim 1 , wherein the first monopolar plate and the second monopolar plate are configured to reinforce the plurality of electrode plates during an evacuation of about 5 psi to about 30 psi prior to filling with the liquid electrolyte to prevent inward deformation of the plurality of electrode plates. 
     
     
         38 . A battery assembly comprising:
 a) one or more stacks of a plurality of electrode plates including:
 i) one or more bipolar plates comprising a substrate having an anode on one surface and a cathode on an opposing surface; 
 ii) a first monopolar plate having a first substrate with a cathode deposited on one surface and located at an end of the one or more stacks; and 
 iii) a second monopolar plate having a second substrate with an anode deposited on one surface and located at an opposing end of the one or more stacks as the first monopolar plate; 
   b) a liquid electrolyte disposed between each pair of electrode plates, wherein the liquid electrolyte functions with an anode and cathode pair to form an electrochemical cell;   c) one or more separators located between the anode and the cathode of the electrochemical cell;
 wherein the first monopolar plate and the second monopolar plate each include an internal reinforcement structure integrated into the first substrate and the second substrate; 
 wherein the internal reinforcement structure includes a plurality of rib structures which are intersecting and which are in a lattice pattern, grid pattern, honeycomb pattern, or any combination thereof; and 
 wherein the first monopolar plate and the second monopolar plate reinforce the plurality of electrode plates during both a charge cycle and a discharge cycle, wherein the charge cycle includes vacuum-filling the battery assembly with the liquid electrolyte. 
   
     
     
         39 . The battery assembly of  claim 38 , wherein the battery assembly includes one or more openings in each of the one or more bipolar plates, the first monopolar plate, the second monopolar plate, and the one or more separators which are aligned with each other in a transverse direction to form one or more channels;
 wherein the one or more openings include one or more inserts molded therein which are aligned and form the one or more channels such that the one or more channels are integrated into the one or more stacks of the plurality of electrode plates and pass through the liquid electrolyte while the one or more inserts prevent leakage of the liquid electrolyte into the one or more channels; and   wherein one or more of the plurality of rib structures intersect, merge, or both with the one or more openings, one or more inserts within one or more openings, or both of the first monopolar plate and the second monopolar plate.