Abstract: The invention concerns a composite plate for Pb/PbO2 batteries with bipolar electrodes, characterized by unidirectional electronic conduction provided by metal wires made at least at the surface of lead or lead alloy, arranged in a regular array and coated with a polymer, stable in an acid medium and capable of generating a strong bonding with the lead or lead alloy constituting the wire surface—the wire volume representing only at most 4% of the plate total volume at most. Hence the mass per unit area thereof remains of the order of 15 g/km2.

Abstract: A reduced weight lead-acid battery is produced incorporating light-weight negative battery plates each comprising an electrically-conductive open mesh grid formed from a strip of expanded, punched or cast metal, a pair of outer lower density support layers such as polymer or polymer-coated glass fibre or low density metal on each side of the central open grid, preferably arranged in a rectangular lattice, attached to each other through openings in the grid preferably by an acid-resistant adhesive, and an electrochemically-active paste saturating the void spaces thereof. An acid-resistant thermoplastic resin adhesive or ties or lugs may be used to attach the support layers together.

Abstract: Light weight, low resistance electrode plates for lead-acid batteries are formed from a highly conductive non-lead substrate such as aluminum or copper, coated with a continuous layer of a corrosive resistant conductive materials, such as lead, applied from a fused salt bath.

Abstract: A positive electrode for a lithium-sulfur battery that includes a sulfur-based positive active material, a conductive agent and a binder filled in a porous current collector. The lithium-sulfur battery having the positive electrode can improve capacity characteristics by enhancing the utilization of the sulfur-based positive active material, and also improve cycle life characteristics by inhibiting the detachment of the active material from the current collector.

Abstract: A process for the removal of galvanic electrolytic residues from galvanically reinforced fiber structure frames, where the fiber structure frame is produced through chemical metallization of a textile substrate based on fleeces or felts made of synthetic fibers and then through galvanic reinforcement of the metallized textile substrate in a galvanic bath containing a galvanic electrolyte. The invention provides that the galvanic electrolytic residues are removed by suction from the fiber structure frame. The fiber structure frame then makes contact at least once under high pressure with the wash liquid in a wash station, and subsequently the wash liquid is removed by suction from the fiber structure frame. In order to remove by suction, the galvanic electrolytic residues or the wash liquid, a belt-shaped porous supporting device is inserted between the suction port and a main area of the fiber structure frame.

Abstract: In one implementation, a bicell battery apparatus includes first and second counter electrodes and an intermediate electrode positioned therebetween. Respective end edges of the first and second counter electrodes are received outwardly beyond a respective end edge of the intermediate electrode at a region. A current collector extension extends from one of the end edges of the intermediate electrode within the region and extends outwardly beyond the respective end edges of the first and second counter electrodes within the region. A first substantially electrolyte impermeable insulative layer is received between the current collector extension and the first counter electrode. A second substantially electrolyte impermeable insulative layer is received between the current collector extension and the second counter electrode.

Abstract: This invention provides a polymer rechargeable battery, which is obtained by integrally holding a separator, which comprises a polymer and a plasticizer, between positive and negative electrodes and then replacing the plasticizer with an electrolyte solution. The positive and negative electrodes are provided with current collectors obtained by etching metal-foil base materials, respectively. This invention also provides such current collectors. The polymer rechargeable battery according to this invention is excellent in impedance characteristic, load characteristic and the like.

Abstract: In one embodiment, the present invention relates to a third electrode for use in a metal-air tricell comprising a support structure coated with a layer of a lanthanum nickel compound and at least one metal mixture, wherein the mixture is adhered to the support structure without the use of an adhesive. In another embodiment, the present invention relates to a metal-air tricell comprising: an air electrode; a metal electrode; and a third electrode, wherein the third electrode comprises a support structure coated with a mixture of a lanthanum nickel compound and at least one metal, wherein the mixture is adhered to the support structure without the use of an adhesive.

Abstract: Improved electro-chemical power generation devices (e.g., metal-air fuel cell battery devices) having metal-fuel realized in the form of a metal-fuel card including a plurality of electrically-isolated metal-fuel elements (e.g., strips) disposed on the surface of substantially rigid and planar non-electrically-conductive substrate. The metal-fuel elements are in electrical contact with the anode contacting elements of the power generation device when the metal-fuel card is spatially registered to anode contacting elements of the electro-chemical power generation device. In another aspect of the present invention, an aperture formed in the substrate provides electrical contact between the metal-fuel element disposed on the first side of the substrate and the anode contacting element disposed on the second side of the substrate when the metal-fuel card is spatially registered to the anode contacting element.

Abstract: A primed current collector for use in an electrochemical cell comprising a current collector having a first surface and a second surface, and a primer applied to at least a portion of the first and/or second surfaces of the current collector, wherein the primer comprises a uniform layer of lithium polysilicate.

Abstract: A hydrophilic collector for alkaline secondary batteries is formed of a nonwoven fabric plated with nickel in which the nonwoven fabric is hydrophilized by sulfonation, a gaseous fluorine treatment, or vinyl monomer grafting. A method for making the collector includes a hydrophilizing step of a nonwoven fabric comprising at least one of a polyolefin fiber and a polyamide fiber, and a plating step of applying nickel plating to the hydrophilic nonwoven fabric. Preferably, the nickel plating is electroless plating, and the nonwoven fabric has a plurality of micropores extending from one surface to the other surface thereof. An electroplating film may be deposited on the electroless plated film, if necessary. This collector facilitates assembling a battery which exhibits improved high-rate discharge characteristics due to improved adhesiveness of the plated nickel film to the nonwoven fabric.

Abstract: Positive electrode and special lead accumulator for use at high temperatures, which is provided with a holder based on a special lead alloy with improved behavior against corrosion, The alloy comprises from 1 to 5% of antimony, from 0.5 to 3% of tin, from 0.05 to 0.50% of arsenic, from 0 to 0.05% of copper and from 0 to 0.02% of bismuth.

Abstract: A battery element of a lead acid battery including a negative plate, a positive plate and a separator having a metal inhibiting additive associated with a plate that reduces the detrimental effects of at least one impurity on the negative plate.

Abstract: An electrode grid for use in a lead acid battery comprising a reticulate part made of an organic or inorganic compound and not having a lead coating applied thereto, and an electricity leading part made of lead of a lead alloy and provided on the reticulate part. This structure reduces the weight of the electrode and increases energy density per weight of the lead acid battery.

Abstract: An electrical battery has a positive electrode having a positive active mass; an electrolyte; a negative electrode separated by the electrolyte from the positive active mass; and a vessel forming a housing of the battery, the positive active mass being arranged as a horizontally extending element.

Abstract: The invention provides a treatment for edge surfaces and faces of metallized fiber structure framework plates for use in electric accumulators. The edge surfaces and faces, except for the starting portion of the current tapping tab, are mechanically, thermally or chemically freed of projecting metallized fiber ends and fiber bundles in order to avoid short circuits or soft shorts caused by dendrites penetrating the cell separator or by metallized fiber ends. The mechanical, thermal or chemical treatments can take place individually or in combination with one another.

Abstract: Melting and recrystallizing the surfaces of a wrought Pb--Ca--Sn alloy strip from which positive Pb-acid storage battery grids are punched or expanded. The alloy also contains an alloyant such as silver which, upon recrystallization, provides a higher concentration of alloyant-rich grain boundaries on the surface of the grid than the wrought grid for enhancing the conductivity of any oxidation layer formed on the surface of the grid during high temperature cycling of the battery.

Abstract: In an organic electrolyte battery, resistor layers having higher resisting values than those of electric conducting substrates retaining active material of an electrode are formed on the substrate surfaces.

Abstract: A lithium ion battery includes a thin film of an electrical insulating material such as resin, a positive collector made of an electrically conductive thin film provided on one side of said electrically insulative thin film, a positive compound layer provided on said positive collector, a negative collector made of an electrically conductive thin film provided on the other side of said electrically insulative thin film, a negative compound layer provided on said negative collector, and an electrolyte film provided in contact with at least one of said positive compound layer and said negative compound layer.

Abstract: An electrode plate for a battery is constructed from a porous metal body having at least one low-porosity part selectively arranged therein. A porous resin core is coated with a paste having a metal component, passed through rolls provided with at least one recess to thereby form at least one low-porosity part and sintered. The resultant electrode plate for battery is not only ensured with respect to strength and capable of improving battery performance but also advantageous in that it is available at lowered cost and free from apprehension of supply of raw materials.

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 bipolar cell, such as a lead-acid cell, comprising bipolar plates having a conductive metal substrate with a pre-cured active material grid comprising a mesh and positive active material in contact on one side of the conductive substrate and a negative active material grid unadhered to the conductive substrate and positioned in contact on the opposite side from the positive active material grid.

Abstract: Disclosed is a novel non-aqueous battery comprising a spirally wound electrode assembly comprising a cathode, an anode and a separator which are spirally wound so that the cathode and anode active material layers are arranged opposite to each other through the separator, wherein the battery has a cathode-equipotential metallic segment provided in association with the cathode, wherein the segment has on at least one side thereof a portion free of a cathode active material layer to provide a cathode-equipotential, exposed metallic portion (.alpha.) longitudinally extending over a length of one wind or more of the spirally wound structure, the portion (.alpha.) being positioned opposite to an anode-equipotential, exposed metallic portion (.beta.) which is provided, in association with the anode, over a length of one wind or more of the spirally wound structure.

Abstract: The invention relates to a nickel electrode of the pasted type for a storage cell having an alkaline electrolyte, the electrode including a current collector and a paste. The electrode is manufactured by coating the collector with the paste which contains:a) an active material in powder form, having a nickel hydroxide base;b) a conductor constituted by a mixture of conductive particles and conductive fibers, the conductive particles having an average dimension D1 not greater than D/20, D being the average diameter of said active material, and the conductive fibers having an average dimension D2 not greater than D, and an average length L2 not less than 25 times the value of D2; andc) at least one polymer binder.

Abstract: An electrical battery has a negative electrode, a positive electrode, an electrolyte including a sulfuric acid solution, a positive active mass, and a cuvette disposed horizontally and composed of a material which does not interact with the sulfuric acid solution, the positive active mass being placed in the horizontally disposed cuvette.

Abstract: An electrode plate for a battery is constructed from a porous metal body having at least one low-porosity part selectively arranged therein. A porous resin core is coated with a paste having a metal component, passed through rolls provided with at least one recess to thereby form at least one low-porosity part and sintered. The resultant electrode plate for battery is not only ensured with respect to strength and capable of improving battery performance but also advantageous in that it is available at lowered cost and free from apprehension of supply of raw materials.

Abstract: A lithium battery and process of making same involves employing alternate layers of a lithium anode and an aluminum foil or NiAl expanded metal supported cathode assembly with a gel electrolyte contacting the alternate layers. The electrolyte includes a quantity of N-methyl-2-pyrrollidone and lithium contained within a polyimide matrix and the entire assembly is contained within a sealed polyimide casing. Separate electrical contacts are provided for each of the lithium anode assembly and the aluminum foil or NiAl supported cathode assembly. An out-gassing vent tube extends from the sealed polyimide casing and is sealed a predetermined time after battery construction.

Abstract: Proposed is an improvement in the method for the preparation of a battery electrode consisting of a spongy metal sheet to serve as a substrate having a three-dimensional skeletal structure with intercommunicating open pores and an active material filling the open pores of the skeletal structure of the substrate.

Abstract: A spirally coiled electrode assembly has positive and negative electrodes each including a web-like collector coated with an active material on opposite surfaces thereof, and separators disposed between the positive and negative electrodes. A plurality of rectangular leads extend from opposite sides of the web-like collectors in directions perpendicular to a direction in which the positive and negative electrodes and the separators are wound. Positive and negative terminals are connected to the rectangular leads extending from the respective opposite sides of the web-like collectors. The spirally coiled electrode assembly, the rectangular leads, and the positive and negative terminals are housed in a cylindrical casing whose opposite ends are closed by respective caps. The positive and negative terminals are fixed to the caps, respectively.

Abstract: A method of preparing an electrochemical cell wherein the composite electrode material adheres to the metal current collector to create good electrical contact is provided. The electrode/current collector comprises a current collector, a layer of an electrically conductive adhesion promoter formed on at least one surface of the current collector which comprises an electrically conductive material and an adhesive polymer; and a composite electrode selected from the group consisting of composite cathode and composite anode, wherein the thickness of said electrically conductive adhesive promoter is sufficient to bind the composite electrode to said current collector.

Abstract: Electrodes, particularly useful in bipolar plates of lead-acid batteries, include a metal-containing substrate, an electrically conductive material secured to the first side of the substrate, an electrically conductive layer including a polymer secured to the second side of the substrate; and a metallic layer secured to the electrically conductive layer so that the electrically conductive layer is located between the metallic layer and the substrate. Bipolar plates are provided and include an electrically conductive electrode element, a grid spaced apart from the electrode in proximity to the first side of the electrode element, positive active material in contact with the first side or second side of the electrode element and negative active material in contact with the first side or second side of the electrode element which is not in contact with the positive active material.

Abstract: An electrode substrate, for a battery, as a support for an active material used in a collector for a battery, comprising a metallic porous structure possessing interconnecting pores with a porosity of not less than 90% and a number of pores per cm of not less than 10 and having an Fe/Ni two-layer structure wherein Fe constitutes the interior of a skeleton of a porous body constituting the porous structure with the surface portion of the skeleton coated with Ni. Preferably, Fe constituting the interior of the skeleton has a purity of not less than 98% by weight, and the thickness of the nickel coating layer having an Fe content of not more than 10% by weight is 0.1 to 10 .mu.m. The ratio of thickness of the Fe-diffused layer to the thickness of the Ni coating layer is regulated to not more than 0.65 by forming a metallic porous body of Fe using a porous resin as a substrate, plating the metallic porous body with Ni, heat treating the plated body.

Abstract: A three-dimensional substrate material for use in constructing battery electrodes comprises a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, and a porous covering layer of a polymeric mesh material, flexible metal screen or metal fibers, bonded to at least one surface of the matrix material to retain the sintered matrix material substantially within the planar surface of the surface of matrix material during spiral-wounding of the chemically loaded matrix material.

Abstract: A double layer structure for use as a capacitor or battery electrode, for use in other electrochemical systems, includes in one embodiment a first layer containing conductive transition metal oxides and a second layer which includes conductive carbon embedded in a suitable binder. For capacitor and lead-acid battery applications the transition metal containing material is used as the negative terminal substrate. Another embodiment includes a carbon layer on an electrode surface, the electrode being made from the transition metal oxide in a binder. The last mentioned carbon layer is thin, inexpensive and more conductive than a laminate layer in which the carbon is imbedded in a self-supporting binder.

Abstract: Described is a support for electrodes of primary or secondary electric cells, said support comprising an open-mesh, three-dimensional network structure composed of plastics threads coated unbrokenly with one or more efficiently conducting, thin metal coats and, to form the three-dimensional structure, being provided with humplike depressions and/or elevations which are distributed over its surface and in whose region the distance between the plastics threads is increased, wherein at least the outer metal coat of the plastics threads consists of a valve metal. Also described are electrodes comprising such a support and a process for producing the articles mentioned.

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.

Abstract: A three-dimensional substrate material for use in constructing battery electrodes comprises a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, and a porous covering layer of a polymeric mesh material, flexible metal screen or metal fibers, bonded to at least one surface of the matrix material to retain the sintered matrix material substantially within the planar surface of the surface of matrix material during spiral-wounding of the chemically loaded matrix material.

Abstract: The present invention is directed to a method of manufacturing battery grids. In particular, a method of simultaneously casting multiple battery grid strips on a continuous casting machine is provided. The mold includes a bipartite grid cavity having a pair of adjacent grid cavity segments which communicate with each other through a common groove such that the resultant dual grid strip formed thereon includes a corresponding pair of grid strip segments that are interconnected by a series of flexible or frangible nodes. A dual grid strip can be folded along the flexible or frangible nodes to form a layered grid strip. The layered grid strip is then pasted with an active material and cut into individual battery plates.

Abstract: A solid state electrochemical device comprising (i) an anode, (ii) a cathode, (iii) interposed between the anode and cathode, a polymeric electrolyte, and (iv) adjacent to either the anode or the cathode, on a side opposite to the polymeric electrolyte, a current collector comprising (a) an aluminum or copper foil and (b) on a side of the aluminum foil facing the cathode or the anode, a layer of a cured polymer, in an amount effective to prevent corrosion between the cathode or anode and the aluminum foil, which (1) is conductive, (2) is pin-hole free and (3) adheres to said aluminum foil. The layer of cured polymer provides corrosion resistance to the current collector.

Abstract: A rechargeable electrochemical cell comprising a first electrode capable of reversibly incorporating on the surface thereof an alkali metal, a second electrode capable of reversibly incorporating therein ions of the alkali metal, and an electrolyte in contact with the first and second electrodes, the cell being characterized in that prior to charging the surface of the first electrode is substantially free from the alkali-metal.

Abstract: A method is provided for making a flexible primary battery suitable for microelectronics applications, and more particularly, for use with self-contained self-powered portable devices (SSPD) such as RF-ID tags. The method generally employs photolithography and etching techniques to minimize the thicknesses of metal foils required in the structure of the battery, as well as packaging methods which yield a flexible and durable battery having a thickness of not more than about 0.5 millimeter, and preferably about 0.3 millimeter or less, and a relatively small size on the order of a few square centimeters in surface area.

Abstract: An electrochemical cell includes an electrode (10) having a microporous polymeric substrate (12) upon which is deposited the first and second layers (18 and 22) of an electrochemically material. Disposed between said first and second layers of electrochemically active materials is a current collecting layer adapted to electrically couple the electrode with a battery cell can. Two or more of such electrodes (40 and 60) may be stacked one atop the other in order to affect a positive and negative electrode as used in conventional cylindrical cells.

Abstract: An anode for use in an electrochemical cell comprising a current collector layer having a thickness less than about 10 mils, and desirably less than about 4 mils, and a rigid support extending adjacent one side of the current collector layer so that the current collector layer is sandwiched between the anodic layer of the anode and the rigid support. The rigid support maintains the current collector layer in the original configuration of the current collector layer during discharge and recharge cycles of the cell. A cell containing the anode is also disclosed. The rigid support for the anode current collector can be mounted in the electrochemical cell case so as to allow for the release from the cell of gas produced at the anode.

Abstract: Metallization by deposit under vacuum of metal on a face of a support film of synthetic resin at a thickness of 0.005 to 0.1 micron, followed by the electrochemical deposit of an additional metallic layer, whose thickness is between 0.1 and 4 microns. A coating of an electrode of a generator is then applied on the surface of the collector thus prepared. The assembly is characterized by the adhesion of its components and its facility of mechanized handling during the steps of assembling the complete generator.

Abstract: The present invention provides improved processes for forming anti-corrosion layers, particularly barium metaplumbate, on lead, lead alloy-, and lead oxide-containing substrates. The processes of the invention are used to form corrosion-resistant current collectors which are assembled into lead-acid batteries. The inventive methods used to form barium metaplumbate employ a salt solution which includes a barium compound and a solvent salt. In a first embodiment, a substrate material having at least a surface comprising elemental lead reacts with a salt solution to form barium metaplumbate. The salt solution includes a barium compound and an oxidizing agent. The solvent salt or barium compound may themselves be oxidizing agents, or an additional oxidant may be added to the solution. The molten salt solution is applied to the substrate in any known manner such as dipping, spraying, and brushing.

Abstract: A current collector which uses a conductive primer layer under an electrode layer to improve the contact and adhesion of the electrode layer to a supporting member, wherein the conductive primer layer is composed of a polymeric material having pendant carboxylic acid groups crosslinked with a multifunctional crosslinking agent, and a conductive filler. The current collector may be used inter alia for making batteries.

Abstract: Disclosed are methods for enhancing the adhesion of composite electrodes onto metal foils (i.e., current collectors). Also disclosed are electrochemical cells produced from these metal foils.

Abstract: An electrochemical cell providing full consumption of electrochemically active particles in a nonpacking, electrolyte-permeable bed has a tapered cell cavity bounded by two nonparallel surfaces separated by a distance that promotes bridging of particles across the cavity. The gap/particle size ratio is maintained as the particles are consumed, decrease in size, and travel from the point of entry to the narrower end of the cell. A cell of this configuration supports a bed of low packing density maintained in a dynamic steady state by alternate formation and collapse of particle bridges across the gap and associated voids over the entire active area of the cell. The cell design can be applied to refuelable zinc/air cells and zinc/ferrocyanide storage batteries.

Abstract: Metal is deposited on a three-dimensional network plastic substrate having internal open cells by a gas phase plating technique to form a metal layer covering all three-dimensional network lattice surface to form a support. An active material is carried on the support to form an electrode. The electrode is improved in active material-support adhesion, allows the amounts of conductive agent and binder to be reduced, and provides a cell with improved performance. It is especially useful in a secondary lithium cell.

Abstract: A process for cutting a moving strip to form a series of plates, such as battery plates, includes the initial step of transporting the strip past a rotary divider including a cutter having radial blades configured to cut the strip into the plates. The cutter further has a set of blades for cutting individual pieces from the strip, which pieces are not part of the plates. As the cutter blades cut the strip to form the plates and pieces, a vacuum system applies suction to draw the pieces cut from the strip inwardly into the cutter through holes in the cutter, and then out of the cutter. The holes are each located adjacent each one of the corresponding blades and are shaped and positioned to permit the cut-away piece to pass through. In a preferred embodiment, the vacuum system includes a pair of vacuum manifolds that apply suction at opposite ends of the cylindrical cutter. An apparatus for carrying out the foregoing process accordingly includes a rotary divider as described above provided with a vacuum system.