Abstract: A bipolar stacked battery that prevents air from becoming trapped during formation of the bipolar stacked battery has a plurality of stacked battery cells. An electrically and ionically insulating frame is formed between each of the plurality of stacked battery cells.

Abstract: A method of forming a stacked bipolar battery laminates a plurality of layered cells of the stacked bipolar battery together at a single time.

Abstract: A method for forming a bipolar battery may form a mixture of conductive material and non-conductive material. The method may compress an area of the mixture so the conductive material of the mixture comes into contact to form a conductive region and the mixture that is uncompressed form an insulative region of a current collector of the bipolar battery.

Abstract: A current collector for a bipolar battery has a conductive region. An insulating region is formed around the conductive region to shield the conductive region.

Abstract: A method for forming a bipolar battery may apply a cathode layer to a current collector, comprising: providing a cathode mixture; and feeding the cathode mixture through a plurality of cathode calendar rolls. The method may apply an anode layer to the current collector, comprising: providing an anode mixture; and feeding the anode mixture through a plurality of anode calendar rolls. The cathode mixture and the anode mixture are fed into the plurality of cathode calendar rolls and the plurality of anode calendar rolls asymmetrically.

Abstract: A bipolar stacked battery has a plurality of bipolar electrodes. Each of the bipolar electrodes has a current collector. A cathode layer containing a cathode active material is formed on a first surface of the current collector. An anode layer containing an anode active material is formed on a second surface of the current collector. A separator layer is formed on the cathode layer and the anode layer, wherein the separator layer extends past opposing side edges of the cathode layer and the anode layer. An insulator is formed on exposed side edges on at least one side of the current collector and extends past the current collector. A pair of terminal stacks is provided, wherein one of the pair of terminal stacks is formed at a higher voltage side of the bipolar stacked battery and a second of the pair of terminal stacks is formed on a lower voltage side of the bipolar stacked battery.