Low-cost high-power battery and enabling bipolar substrate
AssigneeYottaQ, Inc.
InventorsMartin R. Roscheisen, Brent J. Bollman, Hak Fei Poon, Zhengyu Wu, Boris Monahov, Sam Kao
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Abstract
A bipolar battery may include a substrate having a matrix made of a thermoset polymer formed from a liquid precursor. One or more conductive pellets can be disposed in the matrix to provide electrical connection between opposite sides of the matrix. Each conductive pellet has a characteristic thickness that is greater than a thickness of the matrix. Each of the one or more conductive pellets protrudes beyond first and second surfaces of the matrix.
Claims36
A substrate for a bipolar battery, comprising:
- a matrix made of a thermoset polymer formed from a liquid precursor;
- and
- one or more conductive pellets disposed in the matrix, wherein each conductive pellet has a characteristic thickness that is greater than a thickness of the matrix, wherein each of the one or more conductive pellets protrudes beyond first and second surfaces of the matrix.
A bipolar battery, comprising;
- one or more battery cells, wherein each cell comprises a substrate sandwiched between first and second acid glass mats, a positive active material disposed on the first active glass matt and a negative active material disposed on the second acid glass matt, wherein the substrate includes a matrix made of a thermoset polymer formed from a liquid precursor, one or more conductive pellets disposed in the matrix, and first and second conductive foils respectively attached to first and second surfaces of the matrix, wherein the first and second conductive foils respectively make electrical contact with portions of the conductive pellets that protrude beyond the first and second surfaces, wherein each conductive pellet has a characteristic thickness that is greater than a thickness of the matrix, wherein each of the one or more conductive pellets protrudes beyond the first and second surfaces of the matrix.
A method for fabricating a substrate for a bipolar battery, comprising:
- disposing one or more conductive pellets in a layer of a thermosetting polymer precursor;
- and
- irreversibly curing the thermoset polymer precursor to form a thermoset polymer matrix having the one or more conductive pellets embedded in the matrix, wherein each conductive pellet has a characteristic thickness that is greater than a thickness of the matrix, wherein each of the one or more conductive pellets protrudes beyond first and second surfaces of the matrix.
A substrate for a bipolar battery, comprising:
- a first polymer matrix having a first set of one or more conductive pellets disposed in the first polymer matrix, wherein each conductive pellet has a characteristic thickness that is greater than a thickness of the second polymer matrix, wherein each of the one or more conductive pellets in the first set protrudes beyond first and second surfaces of the matrix;
- a second polymer matrix having a second set of one or more conductive pellets disposed in the second polymer matrix, wherein each conductive pellet has a characteristic thickness that is greater than a thickness of the second polymer matrix, wherein each of the one or more conductive pellets in the first set protrudes beyond first and second surfaces of the second polymer matrix,
- a planar conductive member sandwiched between the first polymer matrix and the second polymer matrix in electrical contact with the conductive pellets of the first and second polymer matrices,
- wherein first and second sets of conductive pellets are laterally offset with respect to each other by an offset distance thereby increasing a corrosion path length for the substrate by an amount of the offset distance.
Dependencies are inferred from the claim text.