Abstract: A grid plate for high power lead acid battery having a plate (14) covered with a conductive polymeric matrix (10) of preferably polyaniline and its derivatives, which is then coated with nanoscale particles of active material (14) such as lead sulfate and basic lead sulfate complexes.

Abstract: A positive electrode for a lead-acid battery having a heat-treated metal grid with an interconnected grain structure, wherein the grid is heat-treated after being at least partially coated with a paste containing lead. Also disclosed is a method of making a positive electrode for a lead-acid battery including applying a lead containing paste to a metal grid to produce a pasted grid, heating the pasted grid at a temperature and relative humidity sufficient to produce a cured grid, heat treating the cured grid at a temperature of at least about 125° C., for a period of time sufficient to produce an interconnected grain structure within the grid to produce a heat treated grid, and forming the electrode by assembling the heat treated grid into an electrochemical cell including a negative electrode and a sulfuric acid electrolyte, wherein an electric current is passed through the cell to convert at least a portion of the cured paste into lead dioxide.

Abstract: In a first process, an electrically conductive thin metal plate 7 is subjected to a press molding process employing a plurality of punches 3 in a primary molding block 1 and a plurality of dies 4 in a secondary molding block 2, so as to form therein a plurality of hollow projections 9 that project from one side of the metal plate 7, and bulges 14 that bulge out in a direction opposite to that of the projections 9, positioned between the projections 9. In a second process, the metal plate 7 on which have been formed the plurality of projections 9 and bulges 14 is subjected to either chemical etching or electrolytic etching, so as to form through holes 17 by corrosively removing thin-walled portions 11 from the tips of the projections 9, and, at the same time, to corrosively form innumerable fine irregularities 18 over the entire surface of the metal plate 7.

Abstract: An electrode core material has a substrate and at least one porous material layer diffusion-bonded to the substrate. The substrate is made of a metal foil processed into a three-dimensional structure which is substantially deformed from a major plane of the metal foil, preferably having bulge portions which protrude from at least one side of the metal foil, the bulge portions preferably having a curved, strip-shaped form between laterally spaced slits in the metal foil. The porous material layer is made of metal fine particles diffusion-bonded to each other, and the porous material layer has a three-dimensional structure which is substantially uniform in thickness and porosity. Methods are provided for producing the electrode core material by diffusion bonding the porous material layer to the substrate either before or after deforming the metal foil. The electrode core material may be used for the positive and/or negative electrode of an alkaline storage battery.

Abstract: The battery electrode plate includes a core member (1) which is densely coated with a mixture paste chiefly including an active material (2). The core member (1) is made of a metal sheet (3), which is formed with rows (8) of first and second bowed portions (4, 7) arranged along one direction (X) of the metal sheet so as to protrude alternately on the front and back sides of the metal sheet, the rows (8) of bowed portions arranged along the direction (Y) orthogonal to the direction (X) with flat parts (9) of a predetermined width interposed between each two rows. The battery electrode plate is produced by any of a reciprocating type continuous press method, a rotary type molding method, and an electrolytic deposition method.

Abstract: A device for manufacturing lead plates for a lead/acid battery, wherein lead electrode grates are filled with an active paste to form green lead plates to be cured, has at least three climate-controlled, connected chambers for curing the green lead plates. An inlet for introducing the green lead plates into a first one of the climate-controlled chambers is provided. The device has a transport device for moving the lead plates through the at least three climate-controlled chambers for curing. A removal device for removing the cured lead plates is provided. A control device controls temperature, humidity, and air movement in the at least three climate-controlled chambers.

Abstract: A process for enhancing chemical stability, corrosion resistance and for improved adhesion characteristics is described for use on metal or metal-alloy non-consumable electrodes, current collectors or other metallic articles used in electrochemical cells. The process includes peening of the article, optionally followed by an annealing treatment.

Abstract: It is an object of the invention to provide an apparatus for producing a grid for a battery plate which can improve the life performance of a lead storage battery, and in which a lead sheet 4 is prevented from being undulated or causing vibrations in a carrying-out portion of disk cutter rolls 2 and 3, and also a method of producing such a grid.

Abstract: A method for manufacturing a positive electrode for an alkaline storage battery that achieves excellent filing characteristics for an active material for the positive electrode and longer lifetime of the battery is provided. The method includes a first process of filling a paste of the active material for the positive electrode in a first porous metal sheet provided with a plurality of oblate pores whose major axes are arranged substantially in one direction, and a second process of pressing the first porous metal sheet that has undergone the first process using a roller press such that the one direction and a direction of a rotation axis of a roller in the roller press substantially are parallel, so as to produce a positive electrode sheet provided with a second porous metal sheet.

Abstract: Provided is a current collector substrate in an electrode of an alkaline secondary battery, which is advantageous not only in that it has excellent holding ability for a mixture for electrode, but also in that the utilization of an active material is improved, thereby enhancing the discharge characteristics of the battery, and an electrode and an alkaline secondary battery using the same. This current collector substrate has a plurality of openings formed within the surface of a metal powder sinter sheet which has a thickness (t) of 80 &mgr;m or less and is produced by a powdery calendering process, wherein the openings have periphery portions comprising burr portions protruding in the opposite directions.

Abstract: The present invention provides a current collector for a battery which comprises a lead or lead alloy substrate and a thin cladding of tin, batteries utilizing such a current collector and methods for manufacturing such batteries. Preferably the tin cladding is composed of substantially pure tin and the concentration of the tin cladding relative to the weight of the current collector (i.e., the combined weight of the substrate and cladding) is less than 4% by weight. The tin cladding forms a noncontinuous layer over the outer surface of the substrate such that there are interspersed regions of lead and tin at the current collector surface. Batteries utilizing such current collectors exhibit marked improvement in performance compared to similar cells composed of tin alloys. In particular, batteries using current collectors of the present design offer superior cycle life and shelf life performance.

Abstract: The present invention relates to a current collector for an electrochemical cell. The current collector is a substrate having a grid pattern comprising open areas converging at an imaginary focal point on a connector tab of the substrate. The openings are grouped into distinct regions with the larger openings immediately adjacent to the connector tab and the smaller openings distant there from. This provides more conductive pathways at greater distances from the tab.

Abstract: The invention provides a grid for a battery plate in which, when a metal sheet is formed into a grid-like shape, rupture due to torsion or stress concentration does not occur in a basal portion of a wire which is drawn out from a node of the grid, thereby preventing corrosion due to electrolyte from advancing so as not to cause a crack of corrosion in an early stage. The invention provides also a battery using the grid for a battery plate, a method of producing the grid for a battery plate, and a battery using it.

Abstract: A lug brushing assembly (10) that brushes the lugs of battery plates in an in-line manner so as to eliminate extra battery plate handling procedures. The lug brushing assembly (10) more effectively cleans the lugs of battery plates without causing excessive wearing of the brushes or abrasion on the lugs.

Abstract: The present invention discloses a sintered cadmium negative electrode for use in an alkaline storage battery having a porous sintered nickel substrate and an active material containing cadmium hydroxide, the active material impregnated in the porous sintered nickel substrate, sintered cadmium negative electrode in which a groove 3 having a depth of 0.1 to 20 &mgr;m is provided on a surface of the substrate so that a projected region and a depressed region are formed on the surface of the substrate. An alkaline storage battery employing the sintered cadmium negative electrode of the invention achieves, as well as a high capacity, an improved large current charge-discharge characteristic by increasing an oxygen gas absorbing performance.

Abstract: A base for an electrode plate that has an excellent ability to retain an active material and can be manufactured at a low cost, a method for manufacturing the same, and an alkaline storage battery using the same are provided. The method includes (i) forming a slurry containing water, a powder containing nickel, and a hollow particle formed of an organic compound, (ii) applying the slurry to a support made of metal, thereby forming a sheet, and (iii) burning the sheet, thereby forming a porous layer joined to the support by a metallic bond.

Abstract: The present invention is concerned with a protective coating with current applied on a metallic collector of an electrode. The protective coating comprises a mineral binder vitreous or partly vitreous and optionally an electronic conduction additive. This coating is applied in the form of a solution or dispersion on the collector of the electrode and dried, so that it coats and protects at least part of the surface of the metal of the collector to prevent the formation of passivation films generated by active species produced by other components of the generator.

Abstract: A coated positive grid for a lead acid battery is provided. The coated positive grid includes a strip lead or lead alloy and a coating of lead or lead alloy. The strip has first and second surfaces, and a linear elongated grain structure oriented parallel to the first and second surfaces. The coating is disposed on the first surface. The coating has a random grain structure. The random grain structure and the linear elongated grain structure conduct electrical current between the coated positive grid and an active material of the lead acid battery.

Abstract: A lead alloy coating for a positive grid of a lead acid battery is provided. The lead alloy coating includes a tin content of at least about 0.1%, but not more than about 3%; and a residual lead content. The lead alloy coating optionally includes a calcium content of at least about 0.01%, but not more than about 0.1%, with or without a silver content of at least about 0.01%, but not more than about 0.1%. Alternatively, the lead alloy coating optionally includes a barium content of at least about 0.01%, but not more than about 0.1%, with or without a silver content of at least about 0.01%, but not more than about 0.1%.

Abstract: The device includes a conveyor element for supplying separator strip in a first plane, a device for cutting sections from the separator strip, another conveyor element for preparing the separator strip sections at one folding site and a unit for supplying plates to be jacketed to the folding site in a second plane perpendicular to the first plane. Next to the plane in which the separator strip section is prepared at the folding site, there is a negatively pressurized roller as the device for tensioning the separator strip section prepared in the folding site. In the area of the folding site on the side of the plane in which a separator strip section is prepared at the folding site which is opposite the side from which the plate to be jacketed is supplied, there is a pair of folding rollers.

Abstract: An improved apparatus and method for making lead-acid storage battery plates comprising an alignment puncher for creating a plurality of alignment holes in a lead strip as the lead strip is progressively expanded and cut into a grid like pattern on an expander die system. The alignment of the lead strip is accomplished by inserting at least one alignment pin into at least one of the plurality of alignment holes that have been punched into the lead strip as the lead strip is progressively expanded and cut into a plurality of wire-like segments along opposing edges of the lead strip. After each cut, the alignment pin retracts while the lead strip is indexed.

Abstract: A pack-bonded, multiphase composite material is provided. The multiphase composite material has at least two layers of a matrix material pack-bonded with at least one layer of a reinforcement material. The reinforcement material is oriented in a pack-bonded direction such that the reinforcement material is uniformly dispersed between the matrix materials. Additionally, the matrix materials and the reinforcement material are chemically dissimilar. The matrix material is selected from the group consisting of lead and lead alloys, and the reinforcement material is a plurality of non-conductive, large length-to-diameter ratio, low-density fibers.

Abstract: In order to provide a nickel-metal hydride storage battery capable of preventing the formation of a minute chemical short circuit between the positive and negative electrodes while exhibiting an excellent self-discharge resistance, a nickel positive electrode plate is formed by filling an active material mainly composed of a hydroxide of nickel into a porous sintered nickel substrate, followed by further forming a layer of a manganese compound containing manganese with a valence of 2 or more on the surface thereof, and an alkaline storage battery is configured by using this nickel positive electrode plate.

Abstract: The electrode for a lithium secondary battery includes: a current collector; an interlayer containing Mo or W provided on the current collector; and a thin film composed of active material capable of lithium storage and release deposited on the interlayer.

Abstract: A porous metal sheet, for use in a battery electrode substrate, composed of a two-layer structure consisting of a first and second foamed metal layers or a structure having three or more layers consisting of the first and second foamed metal layer, a mesh metal layer and the like sandwiched between said first and second layer. The number of cells of the first foamed metal layer is smaller than that of the second foamed metal layer. The electrode plate is spirally wound with the second foamed metal layer located at a peripheral side and with the first foamed metal layer located at an inner peripheral side.

Abstract: A manufacturing method for a sintered substrate of alkaline batteries is provided. The manufacturing method includes a first step for mixing particles with a pore former and applying the mixture to a porous substrate, and a second step for sintering the porous substrate and the applied mixture. The particles are made of nickel or principally made of nickel, and the surfaces of the pore former particles each have a coating made of nickel or principally made of nickel. The pore former can be made from resin or any other materials if it disappears when sintered. The pore former particles should preferably have a spheric shape, but is does not matter whether the pore former particles are solid or hollow. Using such sintered substrate for an electrode, an alkaline storage battery can exhibit a high performance.

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: 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: Concave portions and convex portions are formed on a peripheral surface of a thin metal sheet by applying a pressing force thereto while the metal sheet is being embossed; pores are each formed on an apex of each of the concave portions and convex portions and burrs each projecting outward from a peripheral edge of each of the pores are generated by the pressing force; the metal sheets having the concave portions and convex portions formed thereon are layered on each other; the burr at the apex of each convex portion of a lower-layer metal sheet is interlocked with the burr at the apex of each concave portion of an upper-layer metal sheet adjacent to the lower-layer metal sheet to integrate the metal sheets with each other; and an active substance is charged into spaces between the upper-layer metal sheet and the lower-layer metal sheet through an aperture at the apex of each of the concave portions and convex portions.

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 metal sheet (1) which constitutes a non-sintered type electrode support is processed to have minute irregularities on its surface. The irregularities are formed by a mechanical method such that protrusions (9) and indentations (8) are configured with a center-to-center pitch (P) in the range of from 50 to 300 &mgr;m and such that the apparent thickness after processing is at least three times as large as the unprocessed material thickness.

Abstract: A battery plate stacker is delineated for enveloping expanded metal battery plates and stacking positive and negative plates in an alternating pattern, comprising, a battery plate feeder; a carrier coupled to the battery plate feeder; and a wire flattener module coupled to the carrier that conveys the expanded metal battery plates through the wire flattener module. The wire flattener module includes one or more pairs of rotatable members, each pair being aligned with a separate edge portion of an expanded metal battery plate while lying on the carrier. As the plate is conveyed through the pair(s) of members, they force any wires extending away from the surfaces of the plate back into positions flush with the plate surfaces, thereby avoiding puncturing of the separator material when it is crimped around the plate.

Abstract: A wet-chemical method of fabricating electrode foils for galvanic elements including dissolving at least two different fluorinated polymers in a solvent, mixing a highly conductive carbon black, whose BET surface area is between that of surface-minimized graphite and activated carbon and an electrochemically active material having a two-dimensional layer structure and an electronic conductivity of at least about 10−4 S/cm into which lithium can be reversibly incorporated and be reversibly removed therefrom with the least two polymers dissolved in the solvent, without additions of plasticizers, swelling agents or electrolyte, applying paste composition thus obtained to an electrode collector or a support foil, and drying the paste composition.

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 common carrier that supports two or more current collectors in a horizontal planar array with geometric features providing datums for positioning tooling and other processes related to the fabrication of battery electrodes.

Abstract: The method comprises the steps of: moving a strip through an expansion machine having at least one expansion punching tool and an associated complementary tool or matrix, causing the expansion machine to operate in synchronism with the movement of the strip so as to form a grid strip having an non-expanded central portion and two longitudinal grid portions adjacent the central portion, and forming, in the non-expanded central band, a plurality of openings or windows separated by transverse bridges which are to form the connection appendages or lugs of the plates. These openings or windows are formed, in the expansion machine, by punches operated in phase with the operation of the expansion punching tool.

Abstract: Microthin sheet technology is disclosed by which superior batteries are constructed which, among other things, accommodate the requirements for high load rapid discharge and recharge, mandated by electric vehicle criteria. The microthin sheet technology has process and article overtones and can be used to form thin electrodes used in batteries of various kinds and types, such as spirally-wound batteries, bipolar batteries, lead acid batteries silver/zinc batteries, and others.

Abstract: A sealed lead-acid cell and positive plate for a sealed lead-acid cell are provided. The positive plate comprises a grid supporting structure having a layer of active material pasted thereto, the grid supporting structure comprising a lead-based alloy consisting essentially of lead, from about 0.02% to about 0.05% calcium, from about 1.5% to about 3.0% tin, and from about 0.01% to about 0.05% silver. A positive plate in accordance with the invention has excellent mechanical properties, and is satisfactory for use in a lead-acid cell.

Abstract: An automated assembling machine for a positive electrode plate Ni-MH battery is provided.

Abstract: A method of forming battery grids or plates that includes the step of applying a lead alloy coating to a continuous strip of interconnected battery grids formed from a lead alloy grid material is disclosed. The battery grids may be formed by a continuous battery grid making process such as strip expansion, strip punching, or continuous grid casting. In one version of the method, the grid wires of a continuous strip of battery grids produced by a punching process are immersed in a melt of the lead alloy coating. In another version of the method, the grid wires of a continuous strip of battery grids produced by a punching process are deformed such that the grid wires have a cross-section other than the rectangular cross-section produced by the punching process and the strip of interconnected grids is immersed in a melt of the lead alloy coating. The method increases the cycle life of a battery.

Abstract: The present invention discloses a method for manufacturing an electrode for a battery by filling an active material into a three-dimensional porous metal substrate sheet and cutting said sheet to a certain size, comprising the steps of: pressing the portion to be cut and the periphery thereof in the substrate sheet; coating the portion to be cut and the periphery thereof in the substrate sheet with a resin; and/or impregnating the portion to be cut and the periphery thereof in the substrate sheet with a liquid containing a resin component, in addition to the steps of: filling an active material into the substrate sheet; and cutting the substrate sheet at the portion to be cut. This method prevents the occurrence of burrs and cuttings while the sheet is being cut and the coming off of the active material, thereby suppressing internal short circuit of the battery. As a result, a battery hardly suffering from a deterioration in preservation performance and charge-discharge cycle life can be obtained.

Abstract: An electrode for a lithium secondary battery in which an alloy thin film containing Sn (tin) and In (indium) is formed on the surface of a current collector having a surface roughness Ra of 0.1 &mgr;m or more, and a lithium secondary battery using thereof.

Abstract: A method employing a bonding layer is used to form active metal electrodes having barrier layers. Active metals such as lithium are highly reactive in ambient conditions. The method involves fabricating a lithium electrode or other active metal electrode without depositing the barrier layer on a layer of metal. Rather a smooth barrier layer is formed on a smooth substrate such as a web carrier or polymeric electrolyte. A bonding or alloying layer is formed on top of the barrier layer. Lithium or other active material is then attached to the bonding layer to form the active metal electrode. A current collector may also be attached to the lithium or active metal during the process.

Abstract: An alkali metal electrochemical cell, and particularly a lithium oxyhalide cell, is described. The oxyhalide cell also exhibits superior restart characteristics by the provision of a MANNIGLASS 1200 separator.

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: A method for making positive grids for lead-acid batteries from calcium-tin-silver lead-based alloys comprises casting an alloy strip and then rolling the strip at a temperature between about the solvus temperature and the peritectic temperature of the alloy, quenching the rolled strip, then, preferably, heat aging at a temperature of 200° F. to 500° F., and fabricating into the positive grid, such grids having enhanced mechanical and high temperature corrosion resistance characteristics.

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: A conductive porous body that has a conductive layer almost free from impurities and that enables a metallic porous body having extremely low resistance to be produced with high productivity and production efficiency, and a metallic porous body and a battery plate both produced by using the conductive porous body. The conductive porous body has a nickel conductive layer formed on the surface of the framework of a plastic porous body having a continuous-pore structure. The conductive layer is formed by the deposition of nickel from an aqueous solution containing nickel compounds with the use of a reducing agent containing titanium compounds. The metallic porous body can be obtained by forming a continuous metal-plated layer on the surface of the framework of the conductive porous body. The metal-plated layer is formed by electroplating with the conductive porous body serving as the cathode. The battery plate consists mainly of the metallic porous body.

Abstract: A method for producing a grid for a lead storage battery has a first step, a second step and a cooling step performed between the first and second step. In the first step, lead alloy is sequentially rolled over a plurality of rolls. In the second step, the rolled sheet obtained at the first step is machined to produce a grid for a lead storage battery. In the cooling step, the rolled sheet is cooled so that (1) the surface temperature thereof is 10° C. or lower at least once and (2) the total time during which the rolled sheet is exposed to an atmosphere of higher than 10° C. is 10 hours or less.

Abstract: A battery comprises a substrate having a cathode with a lower surface contacting the substrate and an opposing upper surface. A cathode current collector comprises conducting lines that contact the upper surface of the cathode. An electrolyte at least partially extends through the cathode current collector and contacts the cathode. An anode contacts the electrolyte, and optionally, an anode current collector contacts the anode. Also, because the cathode is formed on the substrate before the cathode current collector, the cathode current collector advantageously does not have to be fabricated out of a metal that is capable of withstanding further processing of the cathode, such as annealing of the cathode.