Abstract: A battery assembly, such as a bipolar battery assembly can be fabricated using an optical welding process. For example, a stack of biplate assemblies can be assembled including aligning the biplate assemblies using a fixture, the fixture having at least one feature sized and shaped to engage a corresponding feature in a first casing portion in the stack of biplate assemblies. The stack of biplate assemblies can be compressed. A second casing portion comprising an optically-transmissive region can be mated to the first casing portion. An optically-absorbing region of the first casing portion can be irradiated through an optically-transmissive portion of the second casing portion to form a weld structure along at least one edge of the second casing portion.

Abstract: A battery assembly, such as a bipolar battery assembly, generally includes a first casing portion comprising an optically-absorbing region, and a second casing portion comprising an optically-transmissive region. The first and second features form a welded joint. Fabrication of such an assembly can include physically mating the first casing portion with the second casing portion, and irradiating, such as using a laser, the optically-absorbing region defining the first feature through the optically-transmissive region to form the welded joint.

Abstract: A current collector plate assembly including a polygon-shaped electrically conductive substrate having a first surface and a second, opposing, surface, and at least three edges. A frame is coupled to regions of the first and second surfaces near the at least three edges of the substrate. A first cladding of a positive active materials layer covers an area of the first surface of the substrate. A second cladding of a negative active materials layer covers an area of the second surface of the substrate.

Abstract: Apparatus and techniques such as can include a sealed bipolar battery assembly are described herein. For example, the battery assembly can using two or more sealing techniques, such as to provide a liquid-tight assembly. A sealed current collector assembly can be provided, such as by fitting compressible plastic seals to one or both side of a current collector. An adhesive seal can be applied to an edge or perimeter of the current collector. A plastic seal assembly can be used to anchor the seals or to provide an additional layer of leakage protection should electrolyte seep under hydrophobic plastic seals. Current collector assemblies including stackable casing frames can be assembled to provide a rigid casing. These casing assemblies can be stacked on top of one another to form bipolar cells comprising the battery assembly.

Abstract: A battery assembly, such as a bipolar battery assembly, generally includes a first casing portion comprising an optically-absorbing region defining a first feature, and a second casing portion comprising an optically-transmissive region, the second casing portion defining a second feature, the second feature sized and shaped to mate with the first feature. The first and second features form a hermetic seal comprising a welded joint. Fabrication of such an assembly can include physically mating the first casing portion with the second casing portion, and irradiating, such as using a laser, the optically-absorbing region defining the first feature through the optically-transmissive region to form the welded joint. The first or second casing portions can include one or more casing segments that can support a battery plate, such as comprising a conductive substrate. A gasket or seal can be used such as to provide a further seal at or near a perimeter of the conductive substrate.

Abstract: A current collector assembly, such as for a bipolar lead acid battery, can include an electrically-conductive silicon substrate and a frame bonded to the electrically-conductive silicon substrate. The substrate can be treated or modified, such as to include one or more thin films which render a surface substrate electrically conductive and electrochemically stable in the presence of a lead acid electrolyte chemistry. An interface between the frame and the electrically-conductive silicon substrate can be hermetically sealed. In an example, the frame can provide an edge-seal ring configuration. In an example, a casing assembly can include a spacer bonded to the substrate, along with a casing segment and a thermally-conductive rib, the spacer isolating the thermally-conductive rib from the electrically-conductive silicon substrate electrically.

Abstract: Apparatus and techniques are described herein for providing a battery plate assembly including a silicon current collector. The silicon current collector can include apertures. A lead layer or lead alloy layer can be formed on the silicon current collector. A monopolar battery assembly can be provided, such as including monopolar battery plate assemblies comprising silicon current collectors. The silicon can include a conductive metallurgical grade silicon, such as cast and cut to provide individual current collector substrates.

Abstract: An end contact, such as for a bipolar battery assembly, can be sized and shaped to provide a low resistance electrical bond between the battery cells and a terminal. In an example, a bipolar battery assembly can include a casing, at least one bipolar current collector housed within the casing, a first monopolar current collector, a first electrolyte region defined between the bipolar current collector and the monopolar current collector, and a first electrically-conductive end contact electrically coupled to the first monopolar current collector. The first electrically-conductive end contact can include a centrally-located hub region, a plurality of planar arms extending radially outward from a centrally-located hub region, and at least one planar brace comprising a first segment extending between two planar arms amongst the plurality of planar arms. A similar end contact can be used for opposite end of the battery assembly.

Abstract: Apparatus and techniques are described herein for providing a plate such as can be included as a portion of a hybrid energy storage device assembly. A hybrid device can include capacitor and battery structures, such as can include a sealed stack of hybrid bipolar plates comprising silicon wafers.

Abstract: Apparatus and techniques herein related battery plates. For example, a first battery plate can include a conductive silicon wafer. A first mechanical support can be located on a first side of the conductive silicon wafer. A first active material can be adhered to the first mechanical support and the first side of the conductive silicon wafer, the first active material having a first polarity. In an example, the battery plate can be a bipolar plate, such as having a second mechanical support located on a second side of the conductive silicon wafer opposite the first side, and a second active material adhered to the second mechanical support and the second side of the conductive silicon wafer, the second material having an opposite second polarity.

Abstract: A current collector assembly, such as for a bipolar lead acid battery, can include an electrically-conductive silicon substrate and a frame bonded to the electrically-conductive silicon substrate. The substrate can be treated or modified, such as to include one or more thin films which render a surface substrate electrically conductive and electrochemically stable in the presence of a lead acid electrolyte chemistry. An interface between the frame and the electrically-conductive silicon substrate can be hermetically sealed. In an example, the frame can provide an edge-seal ring configuration. In an example, a casing assembly can include a spacer bonded to the substrate, along with a casing segment and a thermally-conductive rib, the spacer isolating the thermally-conductive rib from the electrically-conductive silicon substrate electrically.

Abstract: Apparatus and techniques are described herein for providing a bipolar battery plate such as can be included as a portion of an energy storage device assembly, such as a battery. The bipolar battery plate can include a silicon substrate. A first metal layer can be deposited on a first surface of the rigid silicon substrate, and a different second metal layer can be deposited on a second surface of the rigid silicon substrate opposite the first surface. The first and second metal layers can be annealed to form a first silicide on the first surface and a different second silicide on the second surface of the rigid silicon substrate.

Abstract: Apparatus and techniques herein related battery plates. For example, a first battery plate can include a conductive silicon wafer. A first mechanical support can be located on a first side of the conductive silicon wafer. A first active material can be adhered to the first mechanical support and the first side of the conductive silicon wafer, the first active material having a first polarity. In an example, the battery plate can be a bipolar plate, such as having a second mechanical support located on a second side of the conductive silicon wafer opposite the first side, and a second active material adhered to the second mechanical support and the second side of the conductive silicon wafer, the second material having an opposite second polarity.

Abstract: Apparatus and techniques are described herein for providing a battery plate assembly including a silicon current collector. The silicon current collector can include apertures. A lead layer or lead alloy layer can be formed on the silicon current collector. A monopolar battery assembly can be provided, such as including monopolar battery plate assemblies comprising silicon current collectors. The silicon can include a conductive metallurgical grade silicon, such as cast and cut to provide individual current collector substrates.

Abstract: Apparatus and techniques are described herein for providing a bipolar battery plate such as can be included as a portion of an energy storage device assembly, such as a battery. The bipolar battery plate can include a silicon substrate. A first metal layer can be deposited on a first surface of the rigid silicon substrate, and a different second metal layer can be deposited on a second surface of the rigid silicon substrate opposite the first surface. The first and second metal layers can be annealed to form a first silicide on the first surface and a different second silicide on the second surface of the rigid silicon substrate.

Abstract: Apparatus and techniques such as can include a sealed bipolar battery assembly are described herein. For example, the battery assembly can using two or more sealing techniques, such as to provide a liquid-tight assembly. A sealed current collector assembly can be provided, such as by fitting compressible plastic seals to one or both side of a current collector. An adhesive seal can be applied to an edge or perimeter of the current collector. A plastic seal assembly can be used to anchor the seals or to provide an additional layer of leakage protection should electrolyte seep under hydrophobic plastic seals. Current collector assemblies including stackable casing frames can be assembled to provide a rigid casing. These casing assemblies can be stacked on top of one another to form bipolar cells comprising the battery assembly.

Abstract: Apparatus and techniques are described herein for providing a plate such as can be included as a portion of a hybrid energy storage device assembly. A hybrid device can include capacitor and battery structures, such as can include a sealed stack of hybrid bipolar plates comprising silicon wafers.