Wafer-based bipolar battery plate
An example includes a method including forming a battery electrode by disposing an active material coating onto a silicon substrate, assembling the battery electrode into a stack of battery electrodes, the battery electrode separated from other battery electrodes by a separator, disposing the stack in a housing, filling the interior space with electrolyte, and sealing the housing to resist the flow of electrolyte from the interior space.
1. A conductive bipolar battery plate, comprising:
an electrically conductive silicon wafer;
a first battery electrode located on a first surface of the conductive silicon wafer;
a second battery electrode located on a surface of the electrically conductive silicon wafer opposite the first surface, the second electrode having a polarity opposite the first battery electrode; and
an active material disposed on the first surface of the conductive silicon wafer;
wherein the first surface of the conductive silicon wafer comprises a silicide.
2. The conductive bipolar battery plate of claim 1 , comprising a barrier layer between the silicide layer and the active material.
3. The conductive bipolar battery plate of claim 2 , wherein the barrier layer includes one or more of TiN, TaN, molybdenum selenide, tin, or chrome.
4. The conductive bipolar battery plate of claim 1 , wherein the active material is porous.
5. The conductive bipolar battery plate of claim 1 , wherein the conductive silicon wafer includes a roughened or cut surface.
6. The conductive bipolar battery plate of claim 1 , wherein the silicide layer includes nickel.
7. The conductive bipolar battery plate of claim 1 , wherein the silicide layer includes one or more of tungsten, titanium, or molybdenum.
8. The conductive bipolar battery plate of claim 1 , wherein the silicon wafer comprises a metallurgical grade conductive silicon wafer.
9. The conductive bipolar battery plate of claim 1 , wherein the silicon wafer comprises a multi-crystalline conductive silicon wafer.
10. The conductive bipolar battery plate of claim 1 , wherein the active material includes lead.
11. The conductive bipolar battery plate of claim 1 , wherein the active material includes a lead paste.
12. A conductive bipolar battery plate, comprising:
an electrically conductive silicon wafer;
a first battery electrode located on a first surface of the conductive silicon wafer;
a second battery electrode located on a surface of the electrically conductive silicon wafer opposite the first surface, the second electrode having a polarity opposite the first battery electrode;
an active material disposed on the first surface of the conductive silicon wafer, the active material including lead; and
a barrier layer between the silicide layer and the active material;
wherein the first surface of the conductive silicon wafer comprises a silicide.