Abstract: A bipolar lead acid battery with increased energy density is provided. The battery includes a number of lead acid wafer cell that each comprise a negative electrode having a negative electrode plate and a negative active material positioned on the negative electrode plate, as well as a positive electrode having a positive electrode plate and a positive active material positioned on the positive electrode plate. The positive electrode plate comprises a metal foil with a conductive film thereon, such as a titanium foil or substrate with a titanium silicide coating thereon. The lead acid wafer cell also includes a separator between the negative and positive electrodes, wherein the separator includes an electrolyte for transferring charge between the negative and positive electrodes.

Abstract: A solventless system for fabricating electrodes includes a mechanism for feeding a substrate through the system, a first application region comprised of a first device for applying a first layer to the substrate, wherein the first layer is comprised of an active material mixture and a binder, and the binder includes at least one of a thermoplastic material and a thermoset material, and the system includes a first heater positioned to heat the first layer.

Abstract: A system and method for providing a ceramic-based separator onto an electrode is disclosed. A separator is formed on the electrode via a dry, solvent-free application of a ceramic-based separator to the electrode. An electrode is provided to an application area via a feed mechanism and a separator layer is then applied to the electrode that is comprised of a binder including at least one of a thermoplastic material and a thermoset material and an electrically non-conductive separator material, with the separator layer being applied to the electrode via a dry dispersion application.

Abstract: A system and method for providing a ceramic-based separator onto an electrode is disclosed. A separator is formed on the electrode via a dry, solvent-free application of a ceramic-based separator to the electrode. An electrode is provided to an application area via a feed mechanism and a separator layer is then applied to the electrode that is comprised of a binder including at least one of a thermoplastic material and a thermoset material and an electrically non-conductive separator material, with the separator layer being applied to the electrode via a dry dispersion application.

Abstract: A bipolar lead acid battery with increased energy density is provided. The battery includes a number of lead acid wafer cell that each comprise a negative electrode having a negative electrode plate and a negative active material positioned on the negative electrode plate, as well as a positive electrode having a positive electrode plate and a positive active material positioned on the positive electrode plate. The positive electrode plate comprises a metal foil with a conductive film thereon, such as a titanium foil or substrate with a titanium silicide coating thereon. The lead acid wafer cell also includes a separator between the negative and positive electrodes, wherein the separator includes an electrolyte for transferring charge between the negative and positive electrodes.

Abstract: A solventless system for fabricating electrodes includes a mechanism for feeding a substrate through the system, a first application region comprised of a first device for applying a first layer to the substrate, wherein the first layer is comprised of an active material mixture and a binder, and the binder includes at least one of a thermoplastic material and a thermoset material, and the system includes a first heater positioned to heat the first layer.