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: The present disclosure provides an expanded metal having substantially isotropic electrical resistance in at least two dimensions. Also disclosed are a composite structure comprising an expanded metal as disclosed herein and a lightning protection system comprising the expanded metal. Methods for manufacturing the expanded metal are also disclosed.

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.

Abstract: The present disclosure provides a lightning protection system and a composite structure comprising such a lightning protection system, wherein the lightning protection system comprises a metal foil layer, a plastic layer, and a matrix material.