Fabrication process for polymer-based bipolar batteries via in-situ polymerization

A method of forming a battery via in situ polymerization, the method comprising:

• applying a first epoxy-based blocker composition precursor to select edge regions of at least one bipolar electrode, a terminal negative electrode, and a terminal positive electrode, the select edge regions of the at least one bipolar electrode defined by a first current collector, the select edge regions of the terminal negative electrode defined by a second current collector, and the select edge regions of the terminal positive electrode defined by a third current collector;
• assembling the at least one bipolar electrode, the terminal negative electrode, and the terminal positive electrode with at least two insulating interlayers disposed between electrodes of opposite polarities to form a stack defining a first side, a second side, a third side, and a fourth side, the first, second, and third current collectors each having a height that is greater than a height of the stack;
• reacting the first epoxy-based blocker composition precursor to form a first epoxy-based blocker composition sealing only the first side, the second side, and the third side that together define a fillable interior region, the fourth side being unsealed by the first epoxy-based blocker composition;
• injecting a precursor of a polymer electrolyte into the fillable interior region via the fourth side;
• applying a second epoxy-based blocker composition precursor to a terminal region of the fourth side;
• and
• concurrently reacting the precursor of the polymer electrolyte and the precursor of the second epoxy-based blocker composition to form a polymer electrolyte within the stack and a second epoxy-based blocker composition sealing the fourth side,
• the polymer electrolyte comprising a polymeric host comprising a polyalkylene oxide, bis(trifluoromethanesulfonyl)imide (LiTFSI) and lithium tetrafluoroborate (LiBF4), and a solvent mixture comprising ethylene carbonate (EC), diethylene carbonate (DEC), and ethylmethylene carbonate (EMC),
• the first epoxy-based blocker composition and the second epoxy-based blocker composition defining a sealed pouch that comprises the stack comprising the polymer electrolyte.

A method of forming a battery via in situ polymerization, the method comprising:

• applying a first blocker composition precursor to select edge regions of at least one bipolar electrode, a terminal negative electrode, and a terminal positive electrode;
• assembling the at least one bipolar electrode, the terminal negative electrode, and the terminal positive electrode with at least two insulating interlayers disposed between electrodes of opposite polarities to form a stack defining a first side, a second side, a third side, and a fourth side;
• reacting the first blocker composition precursor to form a first blocker composition sealing only the first side, the second side, and the third side that together define a fillable interior region, the fourth side being unsealed by the first blocker composition;
• injecting a precursor of a polymer electrolyte into the fillable interior region via the fourth side, the polymer electrolyte being a polymer gel electrolyte comprising, at least one lithium salt, at least one solvent, and a polymeric host selected from the group consisting of:
• polyvinylidene fluoride (PVdF), polyvinylidene fluoride copolymers, polyacrylonitrile (PAN), polymethylmethacrylate (PMMA), oligomers, copolymers, and combinations thereof;
• applying a second blocker composition precursor to a terminal region of the fourth side;
• and
• concurrently reacting the precursor of the polymer electrolyte and the precursor of the second blocker composition at greater than or equal to about 80° C. to less than or equal to about 90° C. to form a polymer electrolyte within the stack and a second blocker composition sealing the fourth side,
• the first blocker composition and the second blocker composition defining a sealed pouch that comprises the stack comprising the polymer electrolyte.