Polyaniline powder of high conductivity is prepared by chemical polymerization of aniline in solutions containing 0.10M aniline, 2M perchloric acid and 0.15M ammonium persulfate at 5°C. The powder is mixed with graphite and acetylene black for obtaining high conductivity. The chemically-synthesized polyaniline doped with perchloric acid is then used as a cathode in the construction of a bipolar rechargeable battery which employs anti-acid stainless steel as a conductive substrate for a bipolar electrode. The proposed battery contains electrochemically-synthesized zinc powder as an anode material and a solution which contains 1M Zn(ClO4)2 and 0.5M NClO4 and 1.0×10−4 M Triton-X100 at pH of 3.2 as a battery electrolyte. To prevent hydrogen reduction, 1wt.% of electrochemically-synthesized optalloy is mixed with zinc powder which contains 2wt.% MgO, 4wt.% ZnO and 1wt.% sodium carboxymethyl cellulose. To investigate the effect of separator thickness on battery efficiency, three batteries are constructed with one, two and three layers of separators. Each sub-cell from the battery has an open-circuit voltage of 1.6V. Two bipolar batteries with open-circuit voltages of 3.2 and 6.4V are constructed and tested successfully for 100 charge–discharge cycles. The batteries have a capacity of 110mAhg−1 and Coulombic efficiency of >90%.