Patent Publication Number: US-10312549-B2

Title: Bipolar battery and plate

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of application Ser. No. 13/229,251 with priority to Sep. 9, 2011, entitled “Bipolar Battery and Plate,” which is currently pending and incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to a battery and in particular to a bipolar battery having a series of bipolar battery plates. 
     BACKGROUND 
     A conventional bipolar battery generally includes electrodes having a metallic conductive substrate on which positive active material forms one surface and negative active material forms the opposite surface. The active materials are retained by various means on the metal conductive substrate which is nonconductive to electrolyte ions. The electrodes are arranged in parallel stacked relation to provide a multi-cell battery with electrolyte and separator plates that provide an interface between adjacent electrodes. Conventional mono-polar electrodes, used at the ends of the stack are electrically connected with the output terminals. Most bipolar batteries developed to date have used metallic substrates. Specifically, bipolar lead-acid systems have utilized lead and alloys of lead for this purpose. The use of lead alloys, such as antimony, gives strength to the substrate but causes increased corrosion and gassing. 
     In most known plates for bipolar batteries, the positive active material, usually in the form of a paste is applied to the metallic conductive substrate on one side while the negative active material is similarly applied to the opposite side. The plates may be contained by a frame which seals the electrolyte between plates so that it cannot migrate through the plate. 
     In U.S. Pat. No. 4,275,130, a bipolar battery construction  20  is disclosed having a plurality of conductive biplates  21 . Each bipolar plate  21  may include a composite, substrate sheet  34  including a continuous phase resin material, which is nonconductive to electrolyte ions. The composite substrate sheet  34  also includes uniformly distributed, randomly dispersed conductive fibers  33  embedded in the material. The binder resin is a synthetic organic resin and may be thermosetting or thermoplastic. The composite substrate sheet  34  has substantially flat opposite side faces  35  which include at their surfaces exposure of portions of the embedded graphite fibers  33 . The embedded graphite fibers not only provide electrical conductivity through the substrate sheet  34 , but also impart to the thermoplastic material a high degree of stiffness, rigidity, strength and stability. Substrate sheet  34  may be made in any suitable manner such as by thoroughly intermixing the thermoplastic material in particle form with the graphite fibers. The mixture is heated in a mold and then pressure formed into a substrate sheet of selected size and thickness. After the sheet has been cured, the substantially flat side faces  35  may be readily treated or processed, as for example by buffing, to eliminate pinholes or other irregularities in the side faces. 
     As disclosed, lead stripes are bonded to the composite substrate sheet  34  by known plating processes. On the positive side face  35 , the facial areas between lead stripes  38  are covered by a coating of corrosion resistant resin  36  suitably a fluorocarbon resin such as Teflon (polytetrofluoroethylene) which protects against anodic corrosion of the adjacent graphite fibers and polyethylene of the substrate  34 . On the negative side face  35 , facial areas between lead stripes  37  may be protected by a thin coating of resin impermeable to electrolyte such as a polyethylene coating  36   a . In fabrication of the bipolar plate  21  and after the composite substrate sheet  34  has been formed, a thin Teflon sheet may be bonded to the positive side surface  35 . Prior to bonding, window like openings corresponding in length and width to the lead stripes are cut. Plating thereafter will bond the lead in stripes  38  to the exposed conductive graphite surfaces on the substrate side face  35 . The same fabrication process may be utilized on the negative side face  35  to coat the nonstriped areas with polyethylene or other like material. Plating of the negative stripes may be achieved as with the positive stripes. 
     A separator plate  23  serves to support the positive active material  24  and the negative active material  25  and may be made of a suitable synthetic organic resin, preferably a thermoplastic material such as microporous polyethylene. 
     Battery construction  20  includes a plurality of conductive bipolar plates  21 , peripheral borders or margins thereof being supported and carried in peripheral insulating casing members  22 . Interleaved and arranged between bipolar plates  21  are a plurality of separator plates  23  The separator plates carry positive active material  24  on one side thereof and negative active material  25  on the opposite side thereof. The casing members  22 , together with the bipolar plates  21  and separator plates  23 , provide chambers  26  for containing electrolyte liquid. At each end of battery construction  20 , standard bipolar plates  21  interface with current collecting plates, where  27  is the negative collector plate and  28  is the positive collector plate. Externally of end collectors  27  and  28  are provided pressure members  30  interconnected by rods  31  having threaded portions for drawing the pressure members plates together and applying axial compression to the stacked arrangement of bipolar plates and separator plates. 
     The bipolar plate  21  is lightweight, rigid, but includes joint lines between the lead stripe edges and protective coatings to resist corrosion and structural deterioration of the substrate. Furthermore, a plating process is required in order to bond the lead stripes  37 ,  38  to the conductive substrate having graphite fibers. Conductivity is limited by the size and amount type of graphite fibers in the substrate. Additionally, a plurality of bipolar plates  21  and layers are required to sit in separate casing members  22  and an external frame, all of which require further processing steps for more parts. The bipolar battery construction  20  is a complicated design having many layers of materials and substrates assembled in multiple chambers  26  and bodies  43  that are secured together by a complex external frame. 
     SUMMARY 
     It is an object of the present invention, among other objects, to provide a bipolar battery having a simplified bipolar plate design, wherein the active materials are encased within an insulated frame having a moldable substrate with perforations to improve conductivity between the active materials. Furthermore, the bipolar battery is inexpensive to produce and does not require a complex external frame to support the bipolar plates. 
     Each bipolar battery plate has a frame, a substrate positioned within the frame, a first lead layer positioned on one side of the substrate, a second lead layer positioned on another side of the substrate, a positive active material (PAM) positioned on a surface of the first lead layer, and a negative active material (NAM) positioned on a surface of the second lead layer. The substrate has a plurality of perforations and a plurality of standoffs integrally formed on opposing side surfaces thereof. The first and second lead layers are electrically connected to each other through the plurality of perforations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is explained in more detail below with reference to the Figures shown in the drawings, which illustrate exemplary embodiments of the present invention wherein: 
         FIG. 1  is a front view of a bipolar plate according to the invention; 
         FIG. 2  is a sectional view of the bipolar plate taken along the line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is a perspective view of a bipolar battery according to the invention; 
         FIG. 4  is an exploded perspective view of the bipolar battery of  FIG. 4 ; 
         FIG. 5  is a partial sectional view of the bipolar battery according to the invention having a casing; 
         FIG. 6  is another partial sectional view of the bipolar battery according to the invention without the casing; 
         FIG. 7  is a close up view of the bipolar plate according to the invention showing a perforation in a substrate of the bipolar plate; and 
         FIG. 8  is another close up view of the bipolar plate according to the invention, showing a non-conductive frame of the bipolar plate; and 
         FIG. 9  is another close up view of the bipolar plate according to the invention, showing another non-conductive frame of the bipolar plate. 
         FIG. 10  is a perspective view of the bipolar plate according to an additional embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
     The invention is explained in greater detail below with reference to the drawings, wherein like reference numerals refer to the like elements. The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the description will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art. 
     With respect to  FIGS. 1-10 , a bipolar battery  100  according to the invention includes a plurality of bipolar plates  10 , spacers  22  holding an electrolyte  20 , and terminal end sections  30 . Each of these components are stacked together to complete a bipolar battery  100  according to the invention, which is an adaptable design with minimal number of parts devoid a complex exterior support structure. 
     Now with reference to  FIGS. 1 and 2 , a bipolar plate  10  according to the invention is discussed. The bipolar plate  10  includes a frame  11 , a substrate  12 , a plurality of perforations  13  along and extending through a front and rear surface of the substrate  12 , lead foils  14 , a first active material  16 , and a second active material  18 . 
     In general, the substrate  12 , lead foils  14 , first active material,  16  and second active material are encased within the frame  11 , which provides support and protection for the bipolar plate  10 . The substrate  12  is positioned in a center of the frame  11 , the lead foils  14  are positioned on both sides of the substrate, and the active materials  16 ,  18  are then positioned over the lead foils  14 . The frame  11  is non-conductive. In the embodiment shown, the frame  11  is a moldable insulative polymer, such as polypropylene, acrylonitrile butadiene styrene (ABS), polycarbonate, copolymers, or polymer blends. Because the frame  11  is moldable, the number of shape and size configurations are abundant, which provides a bipolar plate  10  according to the invention that can be tailored to different uses. 
     In the embodiment shown, the frame  11  has a generally rectangular shape, which provides support for a substrate  12  when positioned in the frame  11 . The frame  11  is a casing for the bipolar plate  10 , as well as the bipolar battery  100 . The outer surface of the frame  11  is the outer surface of the bipolar plate  10  and bipolar battery  100 . The surface of the frame  11  is generally flat, and in particular, along the exterior surfaces of the frame  11 . The frame  11  supports itself, as well as the bipolar plate  10  when assembled with the spacers  22  and terminals sections  30 , especially when the bipolar plate  10  sits upright against a flat opposing surface. 
     The frame  11  further includes substrate receiving passageways  11   a  and material receiving passageways  11   b , as shown in  FIG. 2 . The substrate receiving passageways  11   a  are grooves or channels, while the material receiving passageways  11   b  are openings in the frame  11  that receive the lead foils  14  and active materials  16 ,  18  on both stackable side of the bipolar plate  10 . 
     The substrate receiving passageways  11   a  is a groove used to receive and secure the substrate  12 , when the substrate  12  is positioned within the frame  11 . Other configurations of substrate receiving passageways  11   a  are possible, including notches, indentations, recesses or any securing mechanism that secures the substrate  12  within the frame  11 . For instance, the substrate  12  could be secured to the frame  11  using a weld or by adhesive, or by a fastener. However, in the embodiment shown, the substrate  12  is secured in the substrate receiving passageways  11   a  during manufacturing the bipolar plate  10 . 
     Each material receiving passageway  11   b  is positioned in a substantial center of the frame  11  split from each other by the substrate  12 , when the substrate  12  is positioned within the substrate receiving passageways  11   a . Furthermore, the lead foils  14  and active materials  16 ,  18  are encased within an outer surface plane of the frame  11 . These pair of cavities are dimensioned to securely receive the lead foils  14  and active materials  16 ,  18  within the frame  11 . 
     In the embodiment shown, the substrate  12  is a separate piece of insulative material with respect to the frame  11 , with the substrate  12  is received and secured within the substrate receiving passageways  11   a  of the frame  11 . However, the frame  11  and substrate  12  can be formed together, as a monolithic structure, generally from the same material. During manufacturing, the frame  11  and the substrate  12  are constructed as one piece from the same material. This can be performed through a process such as injection molding, or other known methods. 
     The substrate  12  in the embodiment shown is an insulative plastic that is generally non-conductive, namely, polypropylene, acrylonitrile butadiene styrene (ABS), polycarbonate, copolymers, or polymer blends in the embodiment shown. As briefly discussed above, the substrate  12  may be prepared from the same material as the frame  11 , regardless if the frame  11  and substrate  12  are prepare from a one piece construction. 
     In an alternative embodiment, as shown in  FIG. 7 , the substrate  112  is generally nonconductive, being prepared from insulative plastic. However, conductive fibers and material are homogeneously dispersed throughout the insulative plastic. For instance, the substrate  112  may be prepared from a non-corrosive plastic sold by Integral Technologies, Inc, under the trade name Electriplast, which includes highly electrically conductive areas. The substrate  112 , as shown in  FIG. 7 , includes a non-conductive resin-based material or thermoplastic  112   a  with a micron powder(s) of conductor particles and/or in combination of micron fiber(s)  112   b  substantially homogenized within the resin or thermoplastic  112   a . As clearly shown in  FIG. 7 , the conductor particles or fibers  112   b  are homogenized throughout the body of the resin or thermoplastic  112   a . In this example, the diameter D of the conductor particles of the conductor particles or fibers  112   b  in the powder is between about 3 and 12 microns. The conductor fibers of the conductor particles or fibers  112   b  have a diameter of between about 3 and 12 microns, typically in the range of 10 microns or between about 8 and 12 microns, and a length of between about 2 and 14 millimeters. The micron conductive fibers of the conductor particles or fibers  112   b  may be metal fiber or metal plated fiber. Further, the metal plated fiber may be formed by plating metal onto a metal fiber or by plating metal onto a non-metal fiber. Exemplary metal fibers include, but are not limited to, stainless steel fiber, copper fiber, nickel fiber, silver fiber, aluminum fiber, or the like, or combinations thereof. Exemplary metal plating materials include, but are not limited to, copper, nickel, cobalt, silver, gold, palladium, platinum, ruthenium, and rhodium, and alloys of thereof. Any platable fiber may be used as the core for a non-metal fiber. Exemplary non-metal fibers include, but are not limited to, carbon, graphite, polyester, basalt, man-made and naturally-occurring materials, and the like. In addition, superconductor metals, such as titanium, nickel, niobium, and zirconium, and alloys of titanium, nickel, niobium, and zirconium may also be used as micron conductive fibers and/or as metal plating onto fibers. 
     The conductor particles and/or fibers  112   b  are substantially homogenized within the resin or thermoplastic  112   a . The substrate  112  includes controlled areas of conductive surfaces on the substrate  112 , wherein the conductive materials from the conductive particles or fibers  112   b  are exposed through the resin or thermoplastic  112   a , which are conductively connected by the homogenization process. The conductive surfaces of the substrate  112  are controlled by further manufacturing techniques, such as etching or abrasive blasting, wherein the surface is roughened by chemical or by propelling a stream of abrasive material against the surface under high pressure. The conductor particles and/or fibers  112   b  are then exposed, and conductive areas of the substrate  112  are provided. The process provides a substrate  112  having a controlled amount of conductivity, including the size and area of conductivity. 
     It is also possible that the substrate  112  includes a combination of both conductive particles, powders, and/or fibers  112   b , that are substantially homogenized together within an insulative resin or thermoplastic  112   a  during a molding process. The homogenized material is molded into a polygonal shape, as a substrate  112 , which accommodates various custom designs or properties required for the bipolar plate  10  according to the invention. The substrate  112  may then be molded with the frame  11  in a single manufacturing technique. This allows the bipolar plate  10  and bipolar battery  100  to be simplified, wherein minimal parts are used and production steps are eliminated. Furthermore, the properties of the substrate  112  and battery  100  may be focused by providing and controlling conductive areas along the surface of the substrate  112 . Since the frame  11  is insulative and the substrate  12 ,  112  is positioned in the substrate receiving passageways  11   a , the bipolar plate  10  can act as a frame of the bipolar battery  100  when assembled. 
     During manufacturing, the substrate  12  is either insert molded into the substrate receiving passageways  11   a , or the frame  11  is over molded over the substrate  12 . However, if the frame  11  and the substrate  12  are moldable together, i.e. insert or over molding two pieces together or injection molding one monolithic piece, the manufacturing steps of the bipolar plate  10  can be simplified, with less parts. Furthermore, this process allows the ability to customize the size and shapes of the bipolar plate  10  and bipolar battery  100  according to the invention. 
     Now with reference back to  FIGS. 1 and 2 , the substrate  12  and the substrate  112  shown in  FIGS. 4-8  includes perforations  13  along the surface of the substrate  12 ,  112 , and through the body extending through an opposite surface. In the embodiment shown, the perforations  13  are circular, but could otherwise be any shape. The perforations  13  are positioned in a symmetrical grid pattern. The perforations  13  are positioned in four quadrants of the shown substrate  12 ,  112 . Having a number of perforations  13  positioned in a symmetrical grid arrangement provides even conductions through the substrate  12 ,  112  when lead foils  14  are positioned on the opposite sides of the substrate  12 ,  112 . 
     Additionally, the substrate  112  includes conductive particles, powders, and/or fibers  112   b  along the surface and through the body of the substrate  112 , as clearly shown in  FIG. 5-9 . In general, there are surface areas of the substrate  112  are insulative, while other areas are conductive resulting from the conductive particles, powders, and/or fibers  112   b . As discussed above, the amount of conductive area can be controlled through manufacturing of the substrate  112 . For instance, the surfaces of the substrate can be roughened to expose conductive areas that may be custom in size and shape with respect to a whole exposed surface side of the substrate  12 , or the amount of conductive particles, powders, and/or fibers  112   b  can be controlled with respect to the amount of insulative resin or thermoplastic  112   a . In the embodiment shown in  FIGS. 5-9 , the whole exterior surface of the substrate  112  has been roughened to expose conductive particles, powders, and/or fibers  12   b . Hence, the substrate is conductive on the exposed surface sides of the substrate and the lead foils  14  are positioned on the conductor particles, powders, and/or fibers  112   b.    
     Now with reference to  FIGS. 1, 2, 7, and 8 , the lead foils  14  will be discussed, which are positioned within the material receiving passageway  11   b , on opposite sides of the substrate  12 ,  112 . The lead foils  14  are conductive and connect with each other through the perforations  13 . More specific, the lead foils  14  are mechanically and electrically connected to each other in the embodiment shown. The substrate  12 ,  112  generally is insulative, or only includes a limited area or conductivity based on conductor particles and/or fibers  112   b  in the insulative resin or thermoplastic  112   a . As a result, perforations  13  are used to connect the lead foils  14  with each other in the bipolar plate  10 , notably for a bipolar plate  10  having substrate  12  prepared exclusively from insulative material. The lead foils  14  are welded together, as shown in  FIG. 2 , by resistance welding or other process known to the art. On the other hand, a bipolar plate  10  having a substrate  112 , as shown in  FIG. 7 , which includes the conductor particles or fibers  112   b  homogenized in the resin or thermoplastic  112   a , may also include perforations  113 , which allow for further control and efficiency in conductivity between the lead foils  14  and active materials  16 ,  18  in the bipolar plate  10  according to the invention. 
     In either case, the perforations  13  can vary in size, shape, or grid pattern, but are large enough that the lead foil  14  can be positioned in and through the perforations  13  and connected to an adjacent lead foil  14 . The perforations  13  can be molded or milled into the substrate  12  during manufacturing. With reference to  FIGS. 1, 2, and 8 , the lead foils  14  are shown, being positioned on the both exposed surfaces of the substrate  12 ,  112  respectively, and dimensions to fit within the material receiving passageways  11   b  of the frame  11 . The lead foil  14  is dimensioned to securely fit in the material receiving passageway  11   b , such that the frame  11  encases each lead foil  14  positioned on both sides of the substrate  12 ,  112 . The leads foils  14  are mechanically and electrically connected through the perforations  13 , as shown in  FIG. 7 . 
     As shown in  FIG. 9 , the lead foils  14  may be inserted into the substrate receiving passageways  11 , along with the substrate  12 ,  112  during manufacturing and assembly. The lead foils  14  may encased within the frame during insert molding, over molding, or similar manufacturing technique where the lead foils  14  and substrate  12 ,  112  are manufactured within the substrate receiving passageways  11   a . The lead foils  14  are positioned on opposite surfaces of the substrate  12 ,  112  and then either inserted or manufactured within the frame  11 . It is possible to apply the lead foils  14  by known plating, vapor deposition, or cold flame spray methods. 
     It is also possible that the lead foil  14  is a paste having lead, which is positioned along the front and rear surfaces of the substrate  12 ,  112 . The paste is spread across opposite surfaces (i.e. front and rear surfaces) of the substrate  12 ,  112  and within the perforations  13 . The paste connects both sides of the substrate  12 ,  112  through the perforations  13 . The paste would be thick enough to provide connectivity between the pastes on each side, but should not be thicker than the material receiving passageway  11   b , considering an active material  16 ,  18  is also positioned within the material receiving passageway  11   b.    
     With reference to  FIGS. 2 and 5-9 , the active materials  16 ,  18  are shown and positioned on exposed sides of the lead foils  14 , facing away from the substrate  12 ,  112 . The first layer of active material  16  is a positive active material paste (PAM) that is applied over one lead foil  14 , while a negative active material (NAM) is applied over the other lead foil  14 , which is the second active material  18 . In the embodiment shown, the positive active material paste (PAM) and the negative active material (NAM) are paste of lead or lead oxide mixed with sulfuric acid, water, fiber, and carbon. 
     The thickness of the active materials  16 ,  18  (i.e. NAM and PAM) should not extend outside the material receiving passageway  11   b  of the frame  11 . Rather, the overall thickness T m  of the substrate  12 ,  112 , lead foils  14 , and active materials  16 ,  18  is less than the thickness T f  of the frame  11 . 
     The frame  11  encases the substrate  12 ,  112 , lead foils  14 , and active materials  16 ,  18 . As a result, when assembled the bipolar battery  100  is assembled in stacks of bipolar plates  10 , the frame  11  acts as a support and exterior surface for the bipolar battery  100 . The number of assembly steps and parts can be minimized. Furthermore, the bipolar battery  100  and bipolar plate  10  can be easily customized for various applications, since the frame  11  and substrate  12  can be molded to various shapes and sizes. 
     Now with reference to  FIGS. 3 and 4 , spacers  22  are shown that stack and seal with the bipolar plates  10  according to the invention, and used to hold an electrolyte  20  for the bipolar battery  100 . 
     The spacer  22  is shown between stacking adjacent bipolar plates  10 . The spacer  22  is essentially a casing having similar dimensions as the frame  11  and includes an electrolyte receiving space  22   a , as shown in  FIGS. 3-6 . The electrolyte receiving space  22   a  is a hole through the electrolyte receiving space  22   a , positioned substantially in the center of the spacer  22  and holds an electrolyte  20 . When sealed between two adjacent bipolar plates  10 , the spacer  22  prevents the electrolyte  20  from leaking and allows the electrolyte  20  to provide conductivity between the bipolar plates  10 . 
     As shown in  FIGS. 5 and 6 , at least one electrolyte receiving channel  22   b  is provided in the spacer  22 , which is positioned on an outer surface of the spacer  22  and directed into the electrolyte receiving space  22   a . A user can provide electrolyte  20  through the electrolyte receiving channel  22   b  and into the electrolyte receiving space  22   a , after the spacer  22  is assembled and sealed with adjacent bipolar plates  10 . In general, the electrolyte receiving channel  22   b  is an opening in the spacer  22  that extends through the spacer  22  and into the electrolyte receiving space  22   a . However, other mechanisms or structures known to the art could be used to allow ingress of electrolyte  20  into the electrolyte receiving space  22   a . The receiving channel  22   b  can be plugged or obstructed in some capacity when not utilized, or used to vent gases from the electrolyte receiving space  22   a.    
     The electrolyte  20  may be a variety of substances, including acid. However, the substance should be a substance that includes free ions that make that substance electrically conductive. The electrolyte  20  may be a solution, a molten material, and/or a solid, which helps create a battery circuit through the electrolyte&#39;s ions. In the bipolar battery  100  according to the invention, the active materials  16 ,  118  provide a reaction that converts chemical energy to electrical energy, and the electrolyte  20  allows the electrical energy to flow from the bipolar plate  10  to another bipolar plate  10 , as well as to electrodes  36  of the battery  100 . 
     In the embodiment shown, the electrolyte  20  is an acid that is held in an absorbed glass mat (AGM)  21 , as shown in  FIGS. 4 and 5 . The electrolyte  20  is held on the glass mat  21  by way of capillary action. Very thin glass fibers are woven into the glass mat  21  to increase surface area enough to hold sufficient electrolyte  20  on the cells for their lifetime. The fibers that include the fine glass fibers glass mat  21  do not absorb nor are affected by the acidic electrolyte  20  they reside in. The dimension of the glass mat can be varied in size. However, in the embodiment shown, the glass mat  21  fits within the electrolyte receiving space  22   a , but has a greater thickness than that the spacer  22 . Additionally, the electrolyte receiving space  22   a , in the embodiment shown, includes additionally space for a portion of the electrolyte  20 , and more specifically the glass mat  21 . As a result, the design of the bipolar battery  100 , according to the invention, allows for the spacer  22  holding the glass mat  21  to uniformly stack with adjacent bipolar plates  10 , wherein the active materials  16 ,  18  sit on the glass mat  21  containing the electrolyte  20 . 
     It is also possible that the glass mat  21  is removed, and an electrolyte  20 , such as a gel electrolyte, is free to flow between adjacent active materials  16 ,  18  between adjacent stacked bipolar plates  10  on either side of the spacer  22 . 
     It is also possible, in other embodiments, that the spacer  22  is an extension of the frame  11 . In general, the frame  11  includes a deeper material receiving passageway  11   b  in order to encase the lead foils  14  and active materials  16 ,  18 , as well as electrolyte  20 . Furthermore, if the frame  11  may be dimensioned such that the material receiving passageways  11   b  of stackable bipolar plates  10  can also hold an fiber glass mat  21  between each other, enclosing an encasing the lead foils  14 , active materials  16 ,  18 , glass mat  21 , and electrolyte  20  within the stacked and sealed bipolar plates  10 . The frame  11  may include the electrolyte receiving channel  22   b  that extends through the frame and into the material receiving passageway  11   b . In this embodiment, the bipolar plates  10  can be stacked onto each other and sealed. 
     Now with reference to  FIGS. 4-6 , the terminal sections  30  of the bipolar battery  100  will be discussed, which cap the ends of the bipolar battery  100 . The terminal sections  30  stack on opposite sides of stacked bipolar plates  10 , the number of bipolar plates  10  stacked next to each other depends on the electrical potential required of a specific battery design and shape. 
     Each terminal section  30  includes an additional layer of active material  32 , a terminal plate  34 , an electrode  36 , and an end plate  38 . The end plates  38  are positioned on opposite ends of the stacked bipolar plates  10 , with the active material  32 , the terminal plate  34  and electrode  36  positioned within the end plate  38 . 
     The active material  32  is provided to increase electrical flow through the bipolar battery  100 , from one terminal section  30  to the other terminal section  30 . The active material  32  is made of material that interacts with an adjacent active material  16 ,  18  from an adjacent bipolar plate  10 . Since a spacer  22  and electrolyte  20 , as described above, is positioned on each stackable side of the bipolar plates  10 , a spacer  22  is positioned between the terminal section  30  and an outside bipolar plate  10 . As a result, ions can freely flow through the electrolyte  20  and onto the active material  32  of the terminal section  30 . 
     As shown in  FIGS. 5-6 , the terminal plate  34  is provided and encased within the terminal section  30 . The terminal plate  34  is conductive and generally a metal. The terminal plate  34  attaches to an electrode  36 , which either an anode or a cathode of the bipolar battery  100 . The anode is defined as the electrode  36  at which electrons leave the cell and oxidation occurs, and the cathode as the electrode  36  at which electrons enter the cell and reduction occurs. Each electrode  36  may become either the anode or the cathode depending on the direction of current through the cell. It is possible that both the terminal plate  34  and the electrode  36  are formed as one piece. 
     As shown in  FIGS. 4-6 , the end plate  38  is non-conductive and provides structural support to ends of the bipolar battery  100  according to the invention. The end plate  38  includes a terminal receiving passageway  38   a , which is a recess in which the terminal plate  34 , electrode  36 , and active material  32  are positioned. Additionally, like the material receiving passageway  11   b , the terminal receiving passageway  38   a  provides enough clearance for an amount of electrolyte  20  to be encased with the terminal section  30 , and specifically within the material receiving passageway  11   b  along with the active material  32 , terminal plate  34 , and electrode  36 . In the embodiment shown in  FIGS. 5 and 6 , the terminal receiving passageway  38   a  provides enough space to receive and enclose a portion of the glass mat  21 , as well. 
     With reference to  FIGS. 3 through 8 , the assembly of the bipolar battery  100  according to the invention will be further discussed. 
     The bipolar plate  10  is manufactured and assembled with the substrate  12 ,  112  secured with the frame  11 . The substrate  12 ,  112  includes perforations  13  and/or conductor particles or fibers  112   b , and is generally molded with the frame  11 , either as a single or separate component. Once the substrate  12 ,  112  is positioned within the frame  11 , the lead foils  14  are positioned with the material receiving passageways  11   b  of the frame  11  on both exposed surfaces of the substrate  12 ,  112 . The lead foils  14  are mechanically connected together through the perforations  13 , and electrically connected through conductor particles or fibers  112   b  provided in the substrate  12 ,  112 . A first active material  16  is then positioned in the material receiving passageways  11   b  on one side of the substrate  12 , while the second active material  18  is positioned on another side of the substrate within material receiving passageways  11   b . As a result, the frame  11  encases the substrate  12 , lead foils  14 , and active materials  16 ,  18  within surface boundaries of the bipolar plate  10 . 
     The bipolar plates  10  are stacked then next to each other with spacers  22  provided between each stacked bipolar plate. Electrolyte  20  is provided in the electrolyte receiving space  22   a , which is dimensioned similar to the material receiving passageway  11   b  of the frame  11 . A fiber glass matt  21  can be provided in the electrolyte receiving space  22   a , as well, and an electrolyte  20  is provided into the fiber glass matt  21  through the electrolyte receiving channel  22   b . The spacers  22  and bipolar plates  10  evenly stack one next to the other, and are subsequently sealed. Since the spacers  22  and stacked bipolar plates  10  include non-conductive outer surfaces, the spacers  22  and frames  11  of the bipolar plates  10  create an outer shell for the bipolar battery  100 . The frames  11  of the bipolar plates  10  and spacers  22  can be secured to each other by any method known to the art such that the touching surfaces of the spacers  22  and the frame  11  are secured to each other and sealed. For instance, an adhesive can be used to connect and seal the surfaces together. Additionally, once the terminal sections  30  are assembled, they may be positioned on the stacked bipolar plates  10  and spacers  22 , and then sealed in the same manner. 
     It is also possible, that the end plates  38 , the spacer  22 , and the frame  11  include securing mechanisms (not shown), such as joint technique or fastener, to connect the pieces of the bipolar battery  100  together. Then a sealant may be applied to provide a seal around the bipolar battery  100 , and more specifically, a seal around the connecting end plates  38 , spacers  22 , and frame  11 . 
     It is also possible, that the bipolar plates  10  are stacked and secured next to each other without a spacer  22 . However, the material receiving passageway  11   b  should be large enough to hold and encase the lead foils  14 , active materials  16 ,  18  and an electrolyte  20 , including a fiber glass mat  21 , when the stacked bipolar plates  10  are sealed together. Furthermore, the frame  11  should include at least one electrolyte receiving channel  22   b  positioned in an extension of the frame  11 , so that electrolyte  20  can be provided into the material receiving passageway  11   b  of the frame  11 , or allow venting of the electrolyte  20 . 
     The number of bipolar plates  10  used in the bipolar battery  100  is a matter of design choice, dependent upon the size of battery  100  and the electrical potential required. In the embodiment shown, there are at least three bipolar plates  10  stacked next to each other. On opposites ends of the stacked bipolar plates  10  and electrolyte  20  are terminal sections  30 , which include a layer of active material  32 , a terminal plate  34  and electrode  36 , as well as an end plate  38 . In the embodiment shown, the outer surfaces of the spacer  22  and the frame  11  are substantially flush with each other when stacked and sealed. This design provides a smooth outer support surface. However, it is possible that irregularities in the surface may exist. For instance, the spacer  22  may be larger than the frame  11 ; however, the electrolyte receiving space  22   a  cannot be larger than the frame  11 . Additionally, the material receiving passageway  11   b  cannot be larger than the spacer  22 . In either case, it may be difficult to seal the spacer  22  and bipolar plates  10 , and the electrolyte  20  could leak from the bipolar battery  100  after assembly and the electrolyte  20  is positioned between adjacent bipolar plates  10 . 
     Furthermore, when the end plate  38  is stacked next to an adjacent spacer  22  and/or frame  11  of an adjacent bipolar plate  10 , the outer surfaces of end plate  38 , the spacer  22  and the frame  11  should be substantially flush. However, it is possible that irregularities in the surface may exist. For instance, the end plate  38  may be a bit larger than the spacer  22 , which may be larger than the frame  11 . Nonetheless, terminal receiving passageway  38   a  should not be larger than the receiving channel  22   b  or the frame  11 . Additionally, the terminal receiving passageway  38   a  should not be larger than the material receiving passageway  11   b  or the frame, or the end plate  38  should not be smaller than then the spacer  22 . In either case, the electrolyte  20  may leak from the bipolar battery  100  after assembly and the electrolyte  20  is provided between stacked bipolar plates  10 . In general, the frame  11  supports the bipolar plate  10 , encasing the substrate  12 , lead foils  14 , and active materials  16 ,  18 , as well as electrolyte. When stacked, the bipolar plates  10 , with adjacent spacers  20  and stacked terminal sections  30  provide an outer support surface for the bipolar battery  100 . This construction provides a bipolar battery  100  having a simplified designed, having fewer manufacturing steps and fewer parts than required in the prior art. Since the frame  10 , spacer  22 , and end plate  38  are insulative plastic and moldable, the bipolar battery  100  can be customized to accommodate shape and size requirements dependent on electrical potential and use. 
     In another embodiment, as shown in  FIG. 5 , a protective casing  200  is further provided, that encloses the bipolar battery  100  according to the invention. The casing  200  would include body  202 , a cover  204 , and an electrode receiving space  206 , in order for the electrode  36  to extend out of the casing  200 . Unlike an external structure of the bipolar battery  100 , the casing  20  can be used to house the bipolar battery  100  and provide greater protection. 
     In another embodiment, as shown in  FIG. 10 , the bipolar plate  10  of the above embodiments may further include a plurality of standoffs  40  positioned on each side of the substrate  12 ,  112 . The standoffs  40  are integrally formed on each side of the substrate  12 ,  112 , and are spaced apart from the perforations  13 . In the embodiment shown in  FIG. 10 , the lead foils  14  positioned on the substrate  12 ,  112 , have holes  41  corresponding to the standoffs  40 , such that the lead foils  14  accommodate the standoffs  40  and are positioned on the surfaces of the substrate  12 ,  112 . 
     When the bipolar plates  10  with standoffs  40  are assembled into a bipolar battery, the frames  11  and standoffs  40  of one bipolar plate  10  are respectively attached to the frames  11  and standoffs  40  of another bipolar plate  10 , providing uniform spacing and structural integrity between the plates  10  of the bipolar battery assembly. The frame  11  of one bipolar plate  10  may be attached to the frame  11  of another bipolar plate  10  by any type of welding known to those with ordinary skill in the art including ultrasonic welding, chemical welding, solvent welding, spin welding, or hot-plate welding. The frame  11  may alternatively be attached to another frame  11  by any mechanical connection known to those with ordinary skill in the art including a hook and latch or a ball and socket connection. The standoffs  40  of one bipolar plate  10  may be attached to the standoffs  40  of another bipolar plate  10  by any type of plastic welding known to those with ordinary skill in the art including ultrasonic welding, chemical welding, solvent welding, spin welding, or hot-plate welding. The standoffs  40  may alternatively be attached to other standoffs  40  by any type of mechanical connection known to those with ordinary skill in the art including a hook and latch or a ball and socket connection. 
     The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents.