Abstract: Light-weight VRLA batteries comprise a thin lead substrate that is supported by non-conductive, preferably plastic frames that provide structural stability to accommodate stress and strain in the bipole assembly. In particularly preferred batteries, the plastic frames are laser welded together and phantom grids and electrode materials are coupled to the respective sides of the lead substrate. Where the phantom grid is an ultra-thin lead grid, the lead grid is preferably configured to provide a corrosion reserve of less than 10 charge-discharge cycles and the bipole assembly is charged in an in-tank formation process. Where the phantom grid is a non-conductive grid, the lead grid is preferably a plastic grid and the bipole assembly is charged in an in-container formation process. Consequently, weight, volume, and production costs are significantly reduced while specific energy is substantially increased.

Abstract: Contemplated bipolar lead acid batteries include a bipole assembly with a monolithic or composite current collector that is in contact with the PAM. Especially preferred current collectors have a substrate formed from pure lead and grid formed from a lead alloy, wherein the interface between the grid and substrate is formed via electroforming and/or resistance welding. Particularly preferred batteries are configured as deep cycle batteries and have a low ratio between the surface area of the grid and the weight of the PAM.

Abstract: A bipolar lead acid battery comprises a compression resistant separator in which the electrolyte is retained in a gelled form, and wherein quasi-bipolar electrodes are maintained in a cell stack under pressure. Most preferably, the negative active material further includes a compression resistant spacer structure and the battery is configured as a VR-BLAB where each single cell can independently vent gases during the charge cycle.