Prevention of air trap formation during bipolar stack battery fabrication

A method of forming a bipolar stacked battery that prevents air from becoming trapped during formation of the bipolar stacked battery comprising:

• forming an electrically and ionically insulating frame between each of the plurality of stacked battery cells of the bipolar stacked battery.

A bipolar stacked battery that prevents air from becoming trapped during formation of the bipolar stacked battery comprising:

• a plurality of stacked battery cells;
• and
• an electrically and ionically insulating frame formed between each of the plurality of stacked battery cells, wherein the insulating frame is positioned in each of the plurality of stacked battery cells so that at least one edge in each of the plurality of stacked battery cells is open so as not to completely seal each of the plurality of stacked battery cells, wherein a separator and an inner edge of the insulating frame of a respective stacked battery cell are similar in shape, wherein an area made by an outer edge of the insulating frame (Sf,outer) is greater than or equal to the area of a current collector (Scc), which satisfies 1≤(Sf,outer/Scc) for a respective stacked battery cell, wherein an area made by an inner edge of the insulating frame (Sf,inner) and an area of a separator (Ssep) of a respective stacked battery cell satisfy 0.8≤(Sf,inner/Ssep)≤1.43, wherein a thickness (T) of each respective stacked battery cell of the plurality of stacked battery cells, and the thickness of the insulating frame (t) satisfy 0.05≤(t/T)≤1.22.