Abstract: A method of providing a molded plastic component for a bipolar battery comprising a metal substrate subject to warpage upon molding to form a plastic frame about the periphery of the metal substrate, and the molded plastic component itself, comprises preheating the metal substrate and then injecting a plastic having shrinkage characteristics which match those of the heated metal substrate so as to provide a plastic frame wherein the plastic-metal interface has a reliable seal and is free from residual stresses.

Abstract: A molded plastic component for a bipolar battery comprises a metal substrate having a periphery which is embedded in the plastic and includes at least one surface suitable for accepting an active material paste, the plastic frame comprising a first set of opposed sides having a first thickness which defines the thickness of the active material paste which can be accepted and a second set having a thickness greater than that of the first set which provides a dam for the active material being applied, thereby achieving the ability to automatically paste such molded components on a commercial scale.