Abstract: The invention includes battery electrode core plates utilizing an expanded foil processed to reduce protrusions on the strands of the expanded foil. Expanded foils may be metal or metal-coated plastic. Reducing or eliminating protrusions on the expanded foil mitigate the risk of internal shorts due to protrusion cross-over or “hot spots.” Protrusion reduction may be achieved using chemical etching via various chemical or electrochemical processes that preferentially free or remove material from burrs and free chads, in addition to removing material from sharp edges of the expanded foil.

Abstract: A composite bushing substrate and method of producing the same are provided. The composite bushing substrate may include a clad metal, created by metallically bonding a high strength base layer and an interlayer. The surface of the interlayer may be textured or embossed to form a surface with a high surface area. A low friction surface material may be applied to the textured interlayer surface, resulting in a composite bushing material that can resist deformation of the surface material.

Abstract: An improved layered structure with an outer lightning protection surface is provided. The layered structure may include an expanded metal foil processed to reduce the number, severity, or the number and severity of stress concentration sites, thereby reducing micro-crack initiation sites. Chemical etching, mechanical micro-deburring processes, or both may be used to address stress concentration sites on the expanded metal foil.