Abstract: A method of manufacturing a plate suitable for use as a bipolar plate 500 in a bipolar battery 1 is disclosed. The method comprises the steps of extruding a first polymer containing conductive particles to form a conductive polymer plate 505, cutting a conductive polymer core 512 from the conductive polymer plate 505, and overmoulding the conductive polymer core 512 with a second polymer to provide a non-conductive polymer surround 516. A bipolar battery 1 is also disclosed, as well as a method of making a bipolar battery 1.

Abstract: A bipolar battery (1) comprising a stack of multiple bipolar plates (9) sandwiched between two monopolar plates (6, 8) is disclosed. The bipolar plates (9) each comprise a conductive polymer core (22) and an integrally formed non-conductive polymer surround (4), a layer of cathode material (16) on a first side of the bipolar plate (9), and a layer of anode material (28) on a second, opposite side of the bipolar plate (9). The integrally formed non-conductive polymer surround (4) extends from the conductive polymer core (22) further on one side than the other, such that on one side a first recess (19) is defined for accommodating electrolyte material of the battery (1). The layers of anode material (28) and cathode material (16) are contained within a casing formed at least in part by the integrally formed non-conductive polymer surrounds (4) of all of the bipolar plates (9).