Abstract: A lead-acid battery electrode plate is manufactured by consecutively supplying a lead or lead alloy sheet; leaving a part in the vicinity of the center of the sheet as a non-expansion portion and expanding both sides like mesh to form a grid body; filling active material paste into the grid body; and cutting the grid body to predetermined dimensions. In the lead-acid battery electrode plate, the non-expansion portion forms a current collector part of the electrode plate along an expansion portion in an up and down direction of the electrode plate. One or more openings are made in a part of the non-expansion portion. A part of the non-expansion portion is projected above the position of an upper margin of the cut expansion portion as a current collector lug part. When the current collector lug part is placed upside, the expansion direction is the width direction of the electrode plate.

Abstract: An electrode comprises a porous three-dimensional conductive support and at least one reinforcing metal band fixed along a longitudinal edge portion of the support and having a coefficient of elongation to rupture equal to at least 20% in a direction parallel to the edge portion of the support. Two longitudinal edge portions of the band are bent against the same face of the band, at least part of whose surface is pressed against the support.

Abstract: An electrode component for an electrochemical cell or a capacitor is described wherein the electrode is produced by physical vapor depositing an electrode active material onto a substrate to coat the substrate. The thusly produced electrode is useful as a cathode in a primary electrochemical cell and as a cathode and an anode in a secondary cell, and as an electrode in an electrochemical capacitor and an electrolytic capacitor.

Abstract: Disclosed are a lithium battery and methods for the manufacture thereof. Such a lithium battery at least comprises a stack of a negative electrode (12), a separator (7), and a positive electrode (11). In the manufacturing methods, a pattern of holes is produced in the negative electrode (12) as well as in the positive electrode (11), and a polymeric material is caused to penetrate the holes, whereby the negative electrode, the positive electrode and the separator are sticked and pressed together. Moreover, the negative electrode and the positive electrode are provided with a pattern (4, 5, 6) which can be used for the purpose of aligning the electrodes. The presence of such a pattern facilitates the alignment of the layers with respect to each other.

Abstract: A lightweight, high-energy electrode plate for a lead acid battery, and method for making an electrode plate, comprising a highly conductive non-lead substrate having a specific gravity no greater than 70% that of lead, a pair of outer layers of thin sheets of imperforate conductive foil that is corrosive resistant to the electrolyte acids of the battery and that are welded together to encapsulate the non-lead substrate.

Abstract: A method of forming battery grids or plates that includes the step of mechanically reshaping or refinishing battery grid wires to improve adhesion between the battery paste and the grid wires. The method is particularly useful in improving the paste adhesion to battery grids formed by a continuous battery grid making process (such as strip expansion, strip stamping, continuous casting) that produces grid wires and nodes with smooth surfaces and a rectangular cross-section. In a preferred version of the method, the grid wires of battery grids produced by a stamping process are deformed such that the grid wires have a cross-section other than the rectangular cross-section produced by the stamping process. The method increases the cycle life of a battery.

Abstract: A lead-acid storage battery includes a positive electrode, a negative electrode and an electrolyte material. The foregoing negative electrode has a first grid with a first grid geometry and a first active material provided on the above first grid. The foregoing positive electrode has a second grid with a second grid geometry and a second active material provided on the above second grid. A first mesh area of the foregoing first grid is smaller than a second mesh area of the foregoing second grid, thereby achieving an excellent high rate discharge cycle life.

Abstract: An electrochemical generator comprising thin films including a positive electrode and its collector, and a sheet of a host metal intended to later on constitute a negative electrode, as well as an electrolyte which is conductive towards alkaline ions and also a source of alkali ions. The sheet of the host metal has voids whose quantity and arrangement are capable of locally absorbing any lateral expansion of the sheet of host metal and thereby substantially preventing all cumulative change in the plane of the sheet of host metal when there is an initial formation of alloy in the sheet between the host metal and an alkali metal which is brought about by the alkaline ions. A method of manufacturing such a generator is also described.

Abstract: A composite electrode for an electrochemical device wherein the current collectors and carriers are incorporated into at least one of the electrodes, which are used in alkali metal electrochemical devices, and alkali metal-ion electrochemical devices, which current collectors and carriers are a net of metallized glass or ceramic fibers which may be plasma etched prior to metallizing, and which are woven or non-woven.

Abstract: A novel air cathode and the metal air cells made therewith are provided. With a conductive air diffusion layer of carbon black and polymeric materials, the current collecting substrate is disposed on one side of the air diffusion layer while the active layer is on the other side of the air diffusion layer. The current collecting substrate is in good contact with both the air diffusion layer and the cathode can of the cell, and it has absolutely no direct contact with the active layer. The performance of cells made therewith are significantly improved in high drain discharge situations and the internal impedance of the cells is reduced.

Abstract: A battery grid, suitable for use in a lead-acid battery, with a grid upper portion having a grid wires defining a first grid pattern, and a grid lower portion electrically connected to the grid upper portion. The grid lower portion having grid wires defining a second grid pattern, wherein the first grid pattern is different from said second grid pattern to improve the conductivity of the grid.

Abstract: The present invention provides a substrate for a secondary battery electrode having excellent bonding strength of a sintered porous metal to a ground metal plate so that the sintered porous metal does not peel off from the ground metal plate when the substrate for a secondary battery electrode is rolled up and fixed into a cylindrical battery. For this purpose, a layer of metal having a melting point lower than that of the ground plate is formed at least on one side of the ground plate, and a porous layer is formed by forming a layer of powdered metal having a melting point higher than that of the layer of metal on the layer of metal and sintering the powdered metal at a temperature not less than the melting temperature of the layer of metal and not more than those of the ground plate and the powdered metal.

Abstract: In a process for the production of an electrode for cell, a three-dimensional porous metal substrate is filled with an active material filler containing an active material. Then, heat and ultrasonic vibration is applied in order to denature or deform the active material filler to the substrate at a predetermined point where a collector leading portion is formed to remove the active material filler.

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: The invention pertains to an electrode grid for lead batteries with a rectangular grid frame, pasting accessory rails arranged on it, and a group of grid cross members which form the skeleton to hold the active mass, the pasting accessory rails extending on both sides of the electrode grid solely in the pasting direction and, especially on the front and back side of the electrode grid, are arranged offset from each other.

Abstract: A stamped grid for a lead-acid battery having a grid pattern that is optimized for electrical performance. The stamped grid includes an electrically conductive grid body having opposed top and bottom frame elements, opposed first and second side frame elements and a plurality of interconnecting grid wire elements forming a grid pattern. The grid wire elements include a plurality of vertical wire elements connected to both top and bottom frame elements, a plurality of vertical wire elements connected to the top frame element and one of either the first or second side frame elements and a plurality of cross grid elements that interconnect the vertical wire elements. Each of the vertical grid elements that is connected to the top frame element and one of either the first or second side frame elements includes a plurality of the cross frame elements connected thereto at a substantially 90° angle.

Abstract: A cylindrical alkaline storage battery including a spiraled electrode body composed of a pair of opposed electrodes spirally rolled up through a separator and coupled within a cylindrical casing, at least one of the electrodes being in the form of a non-sintered type electrode composed of an active material retention substrate of three dimensionally meshed structure impregnated with paste of an active material, and a current collector formed with a disc portion for connection to one end portion of the non-sintered type electrode and a lead portion for connection to a terminal, wherein the one end portion of the non-sintered type electrode is formed without impregnation of the paste of the active material, and wherein a perforated sheet metal welded to the one end portion of the non-sintered type electrode is welded at its side edge to the disc portion of the current collector.

Abstract: In a dispersoid-reinforced electrode with a net-like open pore structure and a ceramic and a metallic meshwork, ceramic particles with an average particle diameter of less than 100 nm are homogeneously distributed in the metallic network thereby reinforcing the electrode.

Abstract: A battery has an organic electrolyte, a negative electrode having at least one metal out of alkaline metal and alkaline metal alloy, and a positive electrode including a conductive core having at least one metal out of porous metal plate and metal mesh, wherein an active material covers the core. At least a part of one side of the core is exposed from the active material at a position confronting the negative electrode, and the width of narrowest part of the metal is greater than the thickness of the negative electrode. In this constitution, the discharge reaction is delayed in the exposed portion of the core of the positive electrode. By this delay in discharge reaction, the electric connection of the negative electrode is maintained up to the end of discharge. Hence, voltage drop at the end of discharge is suppressed. As a result, the battery having an excellent discharge capacity up to the end of the discharge is obtained.

Abstract: A method and apparatus for producing lead storage batteries are provided. sentially grid-shaped lead electrodes are produced and are provided with a pasty, active mass. Immediately thereafter separator material is provided on both sides of the electrodes. The electrodes are stacked, electrically connected, and placed in a housing to form a cell unit, which is subsequently stored to effect curing of the pasty, active mass.

Abstract: A current collector in the form of a conductive substrate subjected to a special chemical etch on both major surfaces to provide a "basket weave" structure, is described. The basket weave structures has a lattice construction surrounded by a frame and comprising first strand structures intersecting second strand structures to provide a plurality of diamond-shaped openings or interstices bordered by the strands. The strand structures intersect or join with each other at junctions thereby forming the current collector as an integral unit.

Abstract: A rectangular battery having an electrode group which is inserted in a battery case having an airtight structure. The electrode group is formed by alternately stacking positive electrodes and negative electrodes via separators. The battery case is rectangular had has a closed bottom and an open part that is airtightly sealed by a cover. The outermost electrodes, which are located on both faces of the electrode group, are coated with an active material on a surface of a core. Furthermore, the outermost electrodes have the same polarity and the cores thereof directly contact an inside surface of the outer battery case. In one embodiment, the capacity of the outermost electrodes is smaller than the capacity of the inwardly disposed electrodes of the same polarity.

Abstract: A plate-like current collector and the method of producing the same, said collector comprising a metal foil having a plurality of bowl-like projections, each projection projecting downwardly from the front side thereof to the reverse side thereof and having a penetrated hole in the center of the projection, a turning peripheral portion of the central penetrated hole formed to curve upwardly to a level positioning beneath the front side of the metal foil, wherein the penetrated hole may be enlarged or contracted using the elastic deformation of the turning peripheral portion.

Abstract: An anode for use in an electrochemical cell, wherein the electrochemical cell includes a metallic casing, an electrolyte, a cathode, and an anode within the metallic casing. The anode comprises at least one perforated electrochemical zinc based sheet conductively attached to the metallic casing. A process for fabricating an electrochemical cell comprises the steps of fabricating an anode having at least one perforated electrochemical zinc based sheet conductively attached to a casing, associating a cathode with the electrochemical cell, associating an insulating microporous separator between the anode and cathode, and introducing an alkaline electrolyte to the anode and cathode through the microporous separator.

Abstract: A battery plate and a battery including the plate, the plate being a rigid reticulated conductive metal structure comprised of rigid elongated tendrils many of which meet in continuous intersections (apexes) of the tendrils to form dodecahedrons which form a conductive structure with pores and volumes to receive electrolyte. If desired a coating of battery materials can be adhered to the structure, still leaving open pores and volumes.

Abstract: A method of treating a copper current collector (copper mesh and/or copper foil) for use in Li-ion and/or Li-ion polymer batteries, comprising the steps of: positioning a copper current collector within an electrolytic solution adjacent an anode plate, the electrolytic solution comprised of about 2 to about 25 grams/liter of Cu.sup.+2, and about 30 to about 100 grams/liter of H.sub.2 SO.sub.4 ; energizing the system to have a predetermined current density; maintaining the current density of the system for about 0.5 to about 3.0 minutes; and removing the copper current collector from the electrolyte solution and rinsing the same.

Abstract: A battery grid has a thickness which is greater at the top than at the bottom to achieve a uniform compressive force on a grid stack exerted by the side walls of a battery container.A plastic wedge is disposed between the side walls of the battery container and the stack of grids to improve the distribution of compressive forces.

Abstract: A slit is formed in a clad sheet integrating a thin layer of lead alloy containing at least one of tin and antimony at least on one side ot a parent material made of lead or lead-calcium system alloy. The clad sheet is processed by expanding to twist the rib of the formed grid, and the thin layer of the lead alloy containing at least one of tin and antimony is spirally oriented in multiple directions, as the positive electrode plate. An expanded grid is thus formed. In this manner charging reception characteristics after long-term storage following deep discharge at high temperature ot a lead-acid battery are improved.

Abstract: After a band-like nickel fiber felt is joined to the surface of a belt-shaped punching metal having a large number of openings and sintered, the positive electrode active material is carried on the nickel fiber felt to fabricate a positive electrode.

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: A current collector for an electrode with two halves. The current collector has a first layer positioned on the first half of the electrode, a second layer positioned on the second half of said electrode, and a third layer positioned between the first and the second halves of the electrode.

Abstract: A stamped grid for a lead-acid battery having a grid pattern that is optimized for electrical performance. The stamped grid includes an electrically conductive grid body having opposed top and bottom frame elements, opposed first and second side frame elements and a plurality of interconnecting grid wire elements forming a grid pattern. The grid wire elements include a plurality of vertical wire elements electrically connected to both top and bottom frame elements, a plurality of vertical wire elements connected to the top frame element and one of either the first or second side frame elements and a plurality of cross grid elements that interconnect the vertical wire elements. Each of the vertical grid elements that is electrically connected to the top frame element and one of either the first or second side frame elements includes a plurality of the cross frame elements connected thereto at a substantially 90.degree. angle.

Abstract: To obtain a lithium ion secondary battery having excellent charge and discharge characteristics in which electric connection between active material layers and a separator can be maintained without requiring a strong armor metal case, so that it can be made into thin forms having large energy density. Convex parts and concave parts are formed on at least two surfaces among surfaces of a positive electrode active material layer 7 and a negative electrode active material layer 9 both adjacent to a separator 4 and surfaces of the separator 4 facing both of the active material layers 7, 9, and these three means are bonded and closely adhered by an adhesive resin layer 11 and electrically connected by keeping a lithium ion-containing electrolytic solution in the separator 4 and voids 12 formed by a bonded surface 11a of the convex parts and the concave parts.

Abstract: A current collector for a molten salt battery using liquid sodium as an anode active material, which current collector has excellent electrolyte resistance and low electrical resistance and is able to be produced simply and rapidly at a low cost, and includes a current collector material in which a carbon composite material obtained by calcining a mixture of expanded powder with a thermosetting resin under a non-oxidizing atmosphere is bonded to a porous carbon material having a porosity of 99 to 30% and an average pore diameter of 0.5 mm to 5 .mu.m. The above current collector is produced by a process including bonding a carbon composite material obtained by calcining a mixture of an expanded graphite powder with a thermosetting resin under a non-oxidizing atmosphere, to a porous carbon material having a porosity of 99 to 30% and an average pore diameter of 0.5 mm to 5 .mu.

Abstract: An alkaline secondary battery comprising a positive electrode, a negative electrode, and an alkaline electrolyte, wherein the positive electrode comprises a conductive substrate and a mixture held by the conductive substrate, the mixture containing nickel hydroxide and a conductive cobalt compound, and the positive electrode has pores, substantially all of the pores each having a diameter with a range of 0.0001 .mu.m to 10 .mu.m.

Abstract: Positive grids for lead-acid batteries for SLI, industrial battery, and electric vehicle batteries are disclosed in which the positive active material paste pellet openings have a reduced area and the number per square inch of the grid area are increased, the individual areas and the number of paste pellets varying with the intended application, and the preferred embodiments including reduced distances from the center of the paste pellet to the adjacent grid wires, as well as an optimized amount of positive active material per area of the grid wire surface area so as to allow enhanced electrical performance, if desired, or substantial savings in grid weight while achieving electrical performance commensurate with conventional lead-acid cells and batteries.

Abstract: Pb-Ca battery grids are dipped into a bath of molten Pb-Sn or Pb-Ag to prolong the useful life of the battery as determined by the high temperature SAE J240 test.

Abstract: Disclosed is a secondary battery, which comprises a cylindrically wound laminate consisting of a positive electrode plate, a negative electrode plate and a separator plate interposed therebetween, the negative electrode plate including an electrolytically active substance, a perforated support plate for supporting the electrolytically active substance and serving as an electron collector, the electrolytically active substance being applied to both side surfaces of the support plate, a protective can for enclosing the cylindrically wound laminate, and an electrolyte, wherein the perforation density of the perforated support plate is made greater in the outer portions more than in the central portion, so that the binding forces between the support plate and the electrolytically active substance become substantially uniform throughout the support plate and the conductivity of the support plate is considerably increased.

Abstract: A secondary battery has a cylindrically wound laminate made up of a positive electrode plate, a negative electrode plate, and a separator plate interposed therebetween. The wound laminate is enclosed within a protective can, which also encloses a volume of electrolyte. The negative electrode plate includes a support member, an electrolytically active substance disposed on at least one surface of the support member, and a supplementary support embedded in the electrolytically active substance. The supplementary support is in the form of an electrically conductive network formed from a plurality of entangled and interconnected conductive members, and is used to improve the electrical conductivity of negative electrode.

Abstract: A non-sintered type nickel electrode comprising an electrode substrate coated at its opposite surfaces with an active material for a cell; the electrode substrate comprising a metal member in the form of one of a metal plate and a metal foil, the metal member being worked into a corrugated shape, and an apparent thickness of the corrugated metal member being not less than three times larger than the thickness of the metal member before the working; and a microscopically-irregular layer being formed on each of opposite surfaces of said metal member generally over an entire area thereof, the microscopically-irregular layer being composed of one of nickel, cobalt and a mixture thereof.

Abstract: An improved anode for use in non-aqueous active metal secondary cells include a substrate current collector, a layer of active metal anode material on said current collector and a relatively narrow peripheral band of material capable of accepting reversible insertion of the active metal for capturing dendrite material formed in charging the anode on said current collector surrounding said layer of active metal anode material.

Abstract: Lightweight current collectors and carriers for incorporation into at least one of the electrodes which are used in alkali-metal polymer electrolyte electrochemical devices, which current collectors and carriers are of expanded metallized plastic film.

Abstract: A lead-acid battery includes a compartmented case and a polarity of electrochemically lead-acid cells serially connected via respective positive and negative terminals. Each cell includes planar positive and negative plates and resides in one compartment of the case. The battery further includes an electrochemically inactive cell serially connected with the electrochemically active cells and being intermediately disposed respecting the electrochemically active cells. Plates of the inactive cell preferably have connecting lugs extending therefrom which align with corresponding connecting lugs of the positive and negative plates of the active cells. Rigid homogeneous foam separates the inactive cell plates from one another and fills the inactive cell compartment thereby providing support for the inactive cell plates.

Abstract: An electrochemical cell has a cathode material formed into a pellet shape which expands as the cell is discharged. A cathode current collector circumferentially surrounds the cathode pellet and is in contact with the peripheral edge of the cathode pellet to prevent peripheral cathode expansion. The peripheral cathode current collector maintains a stable cell impedance during cell discharge.

Abstract: The present invention relates to an alkaline secondary battery improved in the structure of the plate substrate, and provides an alkaline secondary battery which uses a three-dimensional porous substrate which is inexpensive, improved in stability in electrolyte and inhibited from shrinkage at sintering. The battery has such a construction comprising a sealed case containing positive electrodes mainly composed of a nickel oxide, negative electrodes mainly composed of a hydrogen-absorbing alloy or a cadmium oxide, an alkaline electrolyte containing at least one component selected from the group consisting of potassium hydroxide, lithium hydroxide and sodium hydroxide and separators, the substrate used for at least one of the positive electrode and the negative electrode being a three-dimensional porous iron sintered body on the surface of which is provided a nickel coating layer.

Abstract: Conducting plastic electrodes and methods of preparing such electrodes are disclosed. The electrodes comprise a thermo-plastic polymer, an elastomeric polymer, and a conductive filler material.

Abstract: The invention provides long life alkaline storage batteries free from short-circuiting using plates having a punching metal as a substrate. In the alkaline storage batteries of the present invention, at least one of the positive plate and the negative plate comprises a punching metal as a substrate, the size thereof is different from that of another plate, and the plates are arranged so that the cut side of the plate having the punching metal substrate at which the substrate is cut through the punched portions does not overlap the side of the adjacent plate of opposite polarity. The plates having such a construction prevents needle-shaped projections produced by cutting the substrate through the punched portions from causing the short-circuiting with the adjacent plate of opposite polarity.

Abstract: A continuous cast positive grid of lead having substantially improved corrosion resistance and decreased growth in a positive plate of a lead-acid battery and a continuous cast negative grid of lead having substantially increased tensile strength for a lead-acid battery. A web of lead is continuously cast with a series of succeeding grid blanks of uniform thickness which are cold worked to reduce the positive grid thickness by at least 3:1 and the negative grid thickness in the range of about 1.5:1 to 2.8:1 preferably by passing through the nip of each of a plurality of successive compression rollers. Electro-chemically active paste is applied to the reduced webs, preferably flash dried, and individual pasted grids are cut from the reduced and pasted webs to provide positive plates and negative plates for a lead-acid battery.

Abstract: An improved battery grid for use in lead-acid batteries has been formed which has resistance to the detrimental effects of grid growth. The improved battery grid has been formed to relieve stress at predetermined locations. Specifically, stress is released by having an overdeveloped reticulum and/or flexible junctions including where the reticulum meets the frame and/or by having either no borders or borders which are released from the reticulum through use of the battery. This battery grid can be a positive grid formed on a continuous casting machine and has a growth relief mechanism to accommodate the condition of imperfect grain formation without interruption of the reticulum.

Abstract: A lead-acid cell includes a case, positive and negative plates within the case, microporous separator material between adjacent plates and electrolyte in a starved amount, with the case having jar and covers joined by a weldment along overlapping cover and jars. The positive plates include a grid frame with an intermediate member extending between spaced apart generally peripheral portions of the frame, with pasted active material on the grid frame separated substantially into two portions by the intermediate member. Compressive force is adjustably continuously applied to the positive and negative plates within the case. The plates are suspended within the case at positions removed from the wall of the case, while plate growth is permitted in a manner that plate shorting is avoided.