Battery plates useful in bipolar battery assemblies and methods of preparation

1. A battery plate comprising:

a) a substrate having a first surface opposing a second surface and one or more nonplanar structures, wherein the substrate is comprised of a non-conductive polymer;

b) one or more active materials disposed on the first surface, the second surface, or both the first surface and the second surface;

c) one or more projections extending from the first surface, the second surface, or both of the substrate that are disposed within and do not extend beyond the one or more active materials, and wherein the one or more projections are integral with the substrate;

d) one or more transfer sheets which are bonded to the one or more active materials and located on an opposite surface which is bonded to the substrate, wherein each of the one or more transfer sheets comprises a porous material adapted to prevent the one or more active materials from penetrating a plurality of pores of the one or more transfer sheets while allowing a liquid electrolyte to pass through the one or more transfer sheets;

wherein the battery plate is adapted to form part of one or more electrochemical cells in a battery assembly; and

wherein the battery plate is one of the following:

i) a monopolar plate in which the one or more active materials is applied to the first surface of the substrate while the second surface remains free of any of the one or more active materials;

ii) a bipolar plate in which the one or more active materials are disposed on both the first surface of the substrate and the second surface of the substrate, the one or more active materials on the first surface functions as an anode, and the one or more active materials on the second surface functions as a cathode; or

iii) a dual polar plate in which the one or more active materials are disposed on both the first surface of the substrate and the second surface of the substrate, the one or more active materials on the first surface and the second surface function as the anode or the one or more active materials on the first surface and the second surface function as the cathode.

2. The battery plate according to claim 1 ,

wherein the plurality of pores of the porous material have a size of about 35 microns or greater to about 2,000 microns or less.

3. The battery plate according to claim 1 , wherein the one or more transfer sheets comprise a sheet made of glass, polymer, or both which is woven, non-woven, extruded, or any combination thereof.

4. The battery plate according to claim 1 , wherein the substrate has a frame about a periphery of the substrate; and

wherein the one or more active materials and the one or more transfer sheets have a cross-sectional area smaller than the cross-sectional area of an interior of the frame such that the one or more active materials and the one or more transfer sheets are located within the interior of the frame.

5. The battery plate according to claim 1 , wherein the first surface, the second surface, or both upon which the one or more active materials are disposed have a surface with one or more curved regions, convex regions, concave regions, one or more openings passing therethrough, or any combination thereof.

6. The battery plate according to claim 1 , wherein the one or more projections of the substrate which are disposed within the one or more active materials have a shape to enhance adhesion of the one or more active materials to the first surface, the second surface, or both of the substrate.

7. A battery assembly formed with a plurality of the battery plates according to claim 1 .

8. The battery assembly of claim 7 , wherein the battery assembly includes one or more stacks of a plurality of the battery plates comprising:

a) one or more bipolar plates comprising the substrate having:

i) a first active material disposed on the first surface to function as the anode with a first transfer sheet bonded thereto opposite the first surface; and

ii) a second active material disposed on the second surface to function as the cathode and a second transfer sheet bonded thereto opposite the second surface;

b) a first monopolar plate comprising the substrate having a first active material disposed on the first surface to function as the anode with a first transfer sheet bonded thereto opposite the first surface while the opposing second surface is free to any active material; and

c) a second monopolar plate comprising the substrate having a first surface free of any active material and a second active material disposed on the second surface to function as the cathode and a second transfer sheet bonded thereto opposite the second surface;

d) the liquid electrolyte disposed between each pair of battery plates which are adjacent, wherein the liquid electrolyte functions with the anode and the cathode located in a space between the pair of battery plates to form an electrochemical cell; and

wherein the plurality of the battery plates are arranged such that surfaces of the substrates having the cathode disposed thereon face the surface of another battery plate having the anode deposited thereon, and the first and second monopolar plates are located at opposite ends of each stack of battery plates.

9. The battery assembly of claim 8 , wherein the battery assembly includes a separator located between the anode and the cathode of the electrochemical cell.

10. The battery assembly of claim 8 , wherein one or more extending projections of the substrate include one or more inserts in each of the substrates having one or more openings extending therethrough and the one or more inserts project beyond the one or more active materials and the transfer sheet; and

wherein the one or more inserts of the substrate align and interlock with one or more other inserts of one or more other substrates, separators, or both in a transverse direction to form one or more channels integrated into the battery assembly.

11. The battery plate according to claim 1 , wherein the battery plate includes one or more extending projections extending from the substrate which project beyond the one or more active materials, and wherein the surface of the one or more extending projections beyond the one or more active materials is substantially free of the one or more active materials or a dust formed from the one or more active materials.

12. The battery plate according to claim 11 , wherein at least one of the one or more extending projections of the substrate are one or more inserts having one or more openings extending therethrough and the one or more inserts project beyond the one or more active materials.

13. The battery plate according to claim 11 ,

wherein the one or more extending projections of the substrate are one or more inserts which extend through one or more voids formed in the one or more active materials and the one or more transfer sheets and the voids have a cross-sectional area larger than an exterior cross-sectional area of the one or more inserts; and

wherein the one or more inserts project beyond the one or more active materials.

14. The battery plate according to claim 1 , wherein the battery plate includes a frame about a periphery of the substrate, wherein the frame or a portion thereof, in the direction transverse to the one or more surfaces upon which the one or more active materials is deposited, projects beyond the one or more active materials and is substantially free of the one or more active materials or a dust formed from the one or more active materials.

15. A battery plate comprising:

a) a substrate having a first surface opposing a second surface and one or more nonplanar structures, wherein the substrate is comprised of a non-conductive polymer;

b) one or more active materials disposed on the first surface, the second surface, or both the first surface and the second surface;

c) one or more projections extending from the first surface, the second surface, or both of the substrate that are disposed within and do not extend beyond the one or more active materials, and wherein the one or more projections are integral with the substrate;

d) one or more extending projections extending from the substrate which project beyond the one or more active materials, and wherein a surface of the one or more extending projections beyond the one or more active materials is substantially free of the one or more active materials or a dust formed from the one or more active materials;

e) one or more transfer sheets bonded to the one or more active materials opposite the substrate, wherein the one or more transfer sheets comprise a porous material adapted to prevent the one or more active materials from penetrating pores of the one or more transfer sheets while allowing a liquid electrolyte to pass through the one or more transfer sheets, wherein the one ore more transfer sheets include one or more voids formed therein through which the one or more extending projections extend through;

wherein the battery plate is adapted to form part of one or more electrochemical cells in a battery assembly; and

wherein the battery plate is one of the following:

i) a monopolar plate in which the one or more active materials is applied to the first surface of the substrate while the second surface remains free of any of the one or more active materials;

ii) a bipolar plate in which the one or more active materials are disposed on both the first surface of the substrate and the second surface of the substrate, the one or more active materials on the first surface functions as an anode, and the one or more active materials on the second surface functions as a cathode; or

iii) a dual polar plate in which the one or more active materials are disposed on both the first surface of the substrate and the second surface of the substrate, the one or more active materials on the first surface and the second surface function as the anode or the one or more active materials on the first surface and the second surface function as the cathode.