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.

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 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: Provided are an apparatus and method for manufacturing a current collector for a secondary battery. In the current collector manufacturing method, a current collector source material is first prepared, pre-treated and then passed between rollers, one of which has patterns shaped like openings to be formed in the source material to then coat a pattern forming composition. Then, the resultant is dried and etched to form the openings, thereby completing the current collector. The current collector manufacturing apparatus includes a main roller, a guide roller coupled to the main roller so that the current collector passes therebetween, and a pattern forming composition storage unit, installed under the main roller, for supplying the pattern forming composition to a patterned portion.

Abstract: A primed current collector for use in an electrochemical cell comprising a current collector having a first surface and a second surface, and a primer applied to at least a portion of the first and/or second surfaces of the current collector, wherein the primer comprises a uniform layer of lithium polysilicate.

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 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: To provide a process for producing lead grids, with which the waste rate can be reduced, materials can be saved, volume corrosion can be largely eliminated or at least reduced and the geometric designs made can be expanded, a process is proposed for producing lead grids for lead electrodes to make storage batteries in continuous manufacture, wherein grid blanks are produced by pouring a material containing lead that can be hardened and then ausformed by rolling, with the addition of heat, at a temperature under the melting point.

Abstract: A fibrous-structure electrode plate has a metal thickness which increases continuously towards the current discharge lug and the resultant low-loss current carrying. To produce the fibrous-structure electrode framework plates according to the invention, textile substrate can be reinforced by electrodeposition. For the subsequent use of the textile substrate which has been reinforced by electrodeposition as an electrode framework of fibrous structure, a diaphragm system is introduced into the electrodeposition bath between each anode and the premetallized web of a textile substrate which is to be reinforced by electrodeposition. In this way, it is possible to distribute the metal applied to the substrate, specifically without previously cutting the web to size.

Abstract: The present invention relates to an assembling machine for Ni-MH batteries and an assembly process thereof, more particularly, to an automated assembling machine for a negative electrode plate Ni-MH battery wherein the negative electrode plate for Ni-MH batteries can be made through an automated on-line production process so that cost, time, and reject rate of production thereof can be substantially reduced, and hence production efficiency can be maximized.

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 improved embossing expanded graphite sheet material comprises removing at least a portion of the gas from within the material by exposing the material to a pressure less than atmospheric pressure, and then embossing the material. Preferably, the pressure to which the material is exposed is less than or equal to about 400 torr. An improved apparatus for embossing expanded graphite sheet material at a pressure less than atmospheric pressure comprises: at least one embossing device; at least one compression device adapted to urge the embossing device against the material; an embossing chamber comprising the at least one embossing device and adapted to receive the material, and to be substantially gas-tight at least when the embossing device is urged against the material by the pressing device; and an evacuation device for reducing the pressure within the embossing chamber. The atmosphere within the embossing chamber may comprise an inert gas, such as, for example, nitrogen, helium and argon.

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 hydrophilic collector for alkaline secondary batteries is formed of a nonwoven fabric plated with nickel in which the nonwoven fabric is hydrophilized by sulfonation, a gaseous fluorine treatment, or vinyl monomer grafting. A method for making the collector includes a hydrophilizing step of a nonwoven fabric comprising at least one of a polyolefin fiber and a polyamide fiber, and a plating step of applying nickel plating to the hydrophilic nonwoven fabric. Preferably, the nickel plating is electroless plating, and the nonwoven fabric has a plurality of micropores extending from one surface to the other surface thereof. An electroplating film may be deposited on the electroless plated film, if necessary. This collector facilitates assembling a battery which exhibits improved high-rate discharge characteristics due to improved adhesiveness of the plated nickel film to the nonwoven fabric.

Abstract: A workpiece, in which a lead is laid on top of a three-dimensional porous metal body, is placed between an ultrasonic horn and an anvil with a lead portion facing the ultrasonic horn. A support is raised so that the lead portion of the workpiece is pressed between the ultrasonic horn and the anvil. While being rotated around a central shaft with a motor, the ultrasonic horn vibrates at a frequency of 20 kHz in the shaft direction. Thus, the workpiece is advanced continuously, so that the lead is bonded ultrasonically to the three-dimensional porous metal body (i.e., metal-to-metal bonding is established). It is possible to provide a battery electrode that can be produced continuously at a lower running cost, reduce the faulty welding with a current collecting plate, and prevent short-circuits.

Abstract: The present invention relates to coiled electrode assemblies having conductive tabs, methods of attaching the conductive tabs to the coiled electrode, and electrochemical cells employing such assemblies. An electrode plate which is coated with active material has a designated area for tab attachment. The conductive tab area's active material is pierced with opposing, offset piercing plates which have raised surface probes which penetrate the conductive tab area's coating and substrate. This tab area is cleared of active material and reinforced with a reinforcing material and a conductive tab is welded to the thus treated area resulting in an electrode plate having a strong integrated tab assembly.

Abstract: A lead-acid storage battery uses as a current collector an expanded grid produced by processing a belt shaped material formed of lead or lead alloys. Strand of a grid for negative electrodes have a twist. The extent of the negative electrode's grid is larger than that of the positive electrode's grid. Accordingly, degradation of output characteristics in the domain deep in the depth of discharge is prevented and further high rate discharge cycle life characteristics are improved.

Abstract: After joining strips of lead plates in a lengthwise direction to a strip of porous metal sheet having a three-dimensional structure, the metal sheet is rolled entirely or in the vicinity of the lead plates. The porous metal sheet is then cut into several electrode substrates, which are coated with active materials and further cut into several electrode plates having a lead plate on one side thereof.

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 belt-shaped spongelike organic high polymer sheet is subjected to stretching forces in the longitudinal and lateral directions so as to transform the approximately spindle-shaped organic high polymer units which compose the organic high polymer sheet. After this, a metal is put into voids inside the organic high polymer sheet. Then, the organic high polymer is eliminated by baking it, and the metal is sintered. As a result, a spongelike metal substrate is completed whose carbon content is 0.5% by weight or less and whose metallic lattices have a longer length/shorter length ratio of 1.7 or below. The spongelike metal substrate is filled with electrode active material to form an electrode, which is combined with a counter electrode and a separator, and coiled in the direction of the longer lengths of the lattices to form a coiled electrode assembly. The electrode assembly is used to manufacture an alkali storage cell.

Abstract: The present invention relates to coiled electrode assemblies having conductive tabs, methods of attaching the conductive tabs to the coiled electrode, and electrochemical cells employing such assemblies. An electrode plate which is coated with active material has a designated area for tab attachment. The conductive tab area's active material is pierced with opposing, offset piercing plates which have raised surface probes which penetrate the conductive tab area's coating and substrate. This tab area is cleared of active material and reinforced with a reinforcing material and a conductive tab is welded to the thus treated area resulting in an electrode plate having a strong integrated tab assembly.

Abstract: A lead acid battery grid made from a lead based alloy containing calcium, tin, and silver having the following composition: calcium above 0.06 and below 0.082%, tin above 1.0% and below 1.2%, silver between 0.005 and 0.020%, and optionally containing up to 0.025% aluminum. To enhance corrosion resistance and reduce grid growth, the grid optimally may contain 0.005 to 0.05% copper as an alloying element complementary to and as a replacement for part of the silver, provided the silver content does not fall below 0.005% and no more than a trace of aluminum is present.

Abstract: According to the present invention, an inexpensive iron sintered substrate used for alkaline storage batteries which has three-dimensionally intercommunicating spaces is improved, and inexpensive alkaline storage batteries using the substrate are provided. The electrode used for the alkaline storage batteries includes an iron powder sintered substrate having three-dimensionally intercommunicating spaces and plated with nickel and an active material powder filled in the space of the substrate, wherein an oxide film obtained by previously oxidizing iron per se is formed on the surface portions of the substrate which are not plated with nickel.

Abstract: A manufacturing method for an expanded grid includes the steps of: (a) supplying a thin plate of band form from the longitudinal direction, (b) forming a plurality of intermittent cuts parallel to the edge in a first region, excluding the central portion, of the thin plate of band form, (c) bending the central portion at a desired angle, and (d) expanding and developing the cuts in the width direction, while moving sequentially in the longitudinal direction the thin plate having the first region forming the plurality of cuts and the central portion not having the cuts, in which the first track distance of the outermost side portion of the first region having the cuts developed and formed is nearly the same distance as the track distance of the central portion. The plane distortion of the grid is eliminated, the width dimension of the grid is stable, and the quality of the electrode plate using such grid is enhanced. Further, local stress concentration of the grid is suppressed.

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: A metal foam support, plus an electrode comprising same, as well as methods of making both, are disclosed, in which there is provided for both the support and the electrode a metal foam member with at least one stacked edge. The stacked edge has a plurality of layers to which a metal connection tab member can be secured. Such an electrode can serve as a negative electrode for a secondary battery.

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 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: A lithium-ion battery cell assembly includes a negative electrode having a negative current collector contacting a negative electrode active material. The negative current collector is prepared by providing a piece of a negative current collector metal, thereafter oxidizing the piece of the negative current collector metal, and thereafter reducing the piece of the negative current collector metal. The negative electrode is assembled with a positive electrode with an intermediate separator. An electrolyte saturates the electrodes and the separator, and provides a lithium ion path between the negative electrode and the positive electrode.

Abstract: The apparatus comprises a reticulating machine (39) for simultaneously producing in metal sheet (2) of strip form a plurality of slits (67) disposed in a continuous and zigzag arrangement extending in the lengthwise direction thereof, and an expanding machine (40) for expanding in the lateral direction the metal sheet (2) in which slits (67) have been formed in order to produce a lozenge-shaped mesh configuration. The expanding machine (40) comprises two endless conveyor elements (44) disposed at the two lateral edges of the metal sheet (2), chuck members (47), a plurality of which are provided in an equally-spaced arrangement to the endless conveyor elements (44), and a center guide member (91) for conveying the metal sheet (2) while guiding the transverse central portion such that it is deflected to one side in the direction of thickness of the metal sheet (2).

Abstract: An apparatus and method for producing expanded mesh sheets provides for forming fine slits in a metal sheet at a slit section by plate cutters, but excluding portions in a center and both sides in a widthwise direction of the metal sheet. The areas where the slits have been formed are drawn out at an expanding section thereby opening the slits and obtaining a mesh sheet which has solid portions in the central portion and on both sides. The mesh sheet is flattened at a rolling device to obtain the expanded mesh sheet. An electrode sheet is prepared by applying an active material onto mesh portions of the expanded mesh sheet, and collectors for a battery are cut out from the electrode sheet such that lead connecting portions thereof are located at the solid portion of the mesh sheet where there are no openings.

Abstract: A lithium ion secondary electrochemical cell includes an anode comprising both a material capable of reversibly incorporating an alkali metal, and a copper current collector, a cathode capable of reversibly incorporating an alkali metal, and an electrolyte which includes a solution of an alkali metal salt dissolved in a polar organic solvent. A method of preventing the electrochemical dissolution of the copper current collector in the lithium ion battery electrolyte includes charging the lithium ion cell immediately after its assembly. By immediately charging the freshly assembled lithium ion cell, lithium will be intercalated into carbon. The copper current collector, therefore, will be at the lithium-carbon potential and thus will be cathodically protected, and will not electrochemically dissolve in the lithium ion battery electrolyte.

Abstract: A porous metal material (22) is manufactured by a method comprising a step of utilizing a magnetic field to orient numerous metal staple fibers (3), and holding these metal staple fibers (3) on the metal substrate sheet (9) in a state of being more or less perpendicular thereto by means of an adhesive (19) supplied to the metal substrate sheet (9), and a step of removing the adhesive (19) by pyrolysis, and integrally joining the metal staple fibers (3) and metal substrate sheet (9) by sintering.

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 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: In a positive electrode for an alkaline storage battery, a layer is formed between a porous substrate as a core material and an active material including nickel hydroxide filled into the porous substrate. The layer includes an oxide containing cobalt and nickel and/or a hydroxide containing cobalt and nickel. In the hydroxide, the average of an oxidation number of a metal is more than +II. The layer has a high electric conductivity while keeping the high corrosion resistance. A utilization rate of the active material can be improved due to the high electric conductivity. An alkaline storage battery including such an electrode has a good cycle property.

Abstract: A lead acid cell including a positive plate or grid has been discovered involving Pb/Ca/Sn/Ag alloy. An interaction between tin and silver which leads to optimum tin and silver levels which are substantially different than those indicated in the prior art. The described optimum tin and silver levels results in a positive alloy with superior mechanical properties and improved corrosion resistance which leads to superior battery life in present day SLI applications. In a preferred manner, the alloy includes lead, tin in the range of about 0.8% to about 1.17%, and silver in the range of grater than 0 to about 0.015%, the percentages being based upon the total weight of the lead-based alloy.

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 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: 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: 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: In a system for applying material to a substrate, a first material is applied to the substrate and the substrate coated with the first material is drawn between a pair of rollers to form a material layer. The roller which contacts the first material is grounded and an electrostatic charging device sprays electrostatically charged particles of a second material onto the roller such that the particles are evenly dispersed on the surface of the roller. The particles of the second material on the roller tend to prevent the first material from adhering to the roller and are preferably incorporated into the second material.

Abstract: A method for manufacturing lead plates for a lead/acid battery includes the step of providing lead electrode grates and filling an active paste into the lead electrode grates to form filled lead plates. Subsequently the lateral surfaces of the filled lead plates are subjected to a continuous processing sequence of less than 6 hours under preselected processing parameters for time, temperature, humidity, and air movement. The processing sequence includes a curing step in which moisture is added to reach a first humidity value, a predrying step for reducing the amount of free lead in the active paste at a second humidity value that is lower than the first humidity value, and a final drying step.

Abstract: A lead-acid battery according to the invention contains an electrode grid structure that comprises dispersoid-containing lead having relatively high strength and good corrosion resistance. The dispersoid particles exemplarily are selected from the oxides, nitrides and carbides that are substantially insoluble in lead and in sulfuric acid of concentration suitable for use in a lead-acid battery. Significantly, the dispersoid-containing lead has average grain size of at least 20 .mu.m. In consequence of the relatively large grain size, the total length of grain boundaries exposed to electrolyte is relatively small, and corrosion resistance is improved. Exemplary techniques for forming the dispersoid-containing lead are disclosed.

Abstract: The use of a continuous process for making a directly cast strip to provide a thickness satisfactory for industrial cells and batteries for stationary and motive power applications is disclosed, the thickness of the strip being at least 0.060 inch, and the process providing a visually crack-free surface in the transverse direction of the directly cast strip, the strip being lead or a lead-based alloy, such as, for example, calcium-tin-silver.

Abstract: A belt-shaped spongelike organic high polymer sheet is subjected to stretching forces in the longitudinal and lateral directions so as to transform the approximately spindle-shaped organic high polymer units which compose the organic high polymer sheet. After this, a metal is put into voids inside the organic high polymer sheet. Then, the organic high polymer is eliminated by baking it, and the metal is sintered. As a result, a spongelike metal substrate is completed whose carbon content is 0.5% by weight or less and whose metallic lattices have a longer length/shorter length ratio of 1.7 or below. The spongelike metal substrate is filled with electrode active material to form an electrode, which is combined with a counter electrode and a separator, and coiled in the direction of the longer lengths of the lattices to form a coiled electrode assembly. The electrode assembly is used to manufacture an alkali storage cell.

Abstract: The primary object of the present invention is to provide an electrode for an alkali secondary battery, the electrode being capable of exhibiting high binding power and showing a high electrical conductivity without use of a binder. An electrode for an alkali secondary battery, the electrode comprising a molded product molded from a mixture containing an active material-containing powder and a flaky nickel powder which has lowered strain.

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: An improved current collector for use with lithium ion batteries includes an aluminum grid of the type used for making conventional current collectors that is plated with a layer of zinc, the outermost portion of which is oxidized to zinc oxide. The current collector is made by first cleaning an aluminum grid in an aqueous basic solution to remove its outer layer of alumina. The cleaned aluminum grid is then plated with zinc by contact with an aqueous solution of zinc oxide. The plated aluminum grid is rinsed and dried in air to oxidize the outer surface of the zinc and form an outer layer of zinc oxide. The resulting zinc-plated current collector can be made into a battery with a higher conductivity at the interface between the current collector and the electrode active materials than a battery made with a conventional aluminum current collector. It also has a rough outer surface which improves its adhesion to the polymeric layers used in constructing a plastic lithium ion battery.

Abstract: A two-level IR detector imaging array of high fill-factor design. The upper microbridge detector level is spaced above and overlie the integrated circuit and bus lines on the substrate surface below.