Abstract: A continuous process for making lead-acid grids and plates for a family of cells and batteries requiring grids with a particular plate width and varying plate heights comprises expanding and slitting a continuous strip to provide the desired width and a grid having at least one side frame bar and an interconnected expanded mesh, pasting the expanded mesh with active material, determining the grid height desired and then cutting the expanded mesh strip transversely of the direction of travel to provide plates of the desired height while forming a plate lug from one side frame bar.

Abstract: A current collector for an electrochemical cell is described. The current collector has both external and internal connection tabs which are preferably contiguous with each other and provide for increased flexibility in connecting a cell terminal lead directly to any contact point along the extent of the two connection tabs.

Abstract: An electrode plate including an active portion pasted with active material and a plate head including a connection tab. The plate head is constituted by the same metal foam as the plate support, but the density of the metal foam in the plate head is not less than 2.5 times the density of the metal foam in the remainder of the electrode plate, the higher density of the plate head coming from an operation in which the foam of the support is compressed, the tab of the plate head emerging from the middle of the thickness of the plate and being derived from compression of the support in two directions: compression firstly in the direction of its height; and compression secondly in the direction of its thickness. Such an electrode plate is made from a plate of metal foam whose top edge is compressed so as to form the plate head.

Abstract: A three-dimensional substrate material for use in constructing battery electrodes comprises a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, and a porous covering layer of a polymeric mesh material, flexible metal screen or metal fibers, bonded to at least one surface of the matrix material to retain the sintered matrix material substantially within the planar surface of the surface of matrix material during spiral-wounding of the chemically loaded matrix material.

Abstract: A method of making metal hydroxide plate blanks for use in an electrochemical cell which includes compressing a porous metal web in at least one compression zone to a substantially non-porous state, attaching at least one a non-porous strip of the same metal to the porous metal web in the area of the compression zone, impregnating the porous metal web with a coating of electrochemically active material to form an impregnated web, removing excess coating from the impregnated web, drying the impregnated web, and dividing the dried web into plate blanks in the area of the metal strip. The metal is selected from the group consisting of nickel, silver and copper, with the preferred metal being nickel.

Abstract: Described is a support for electrodes of primary or secondary electric cells, said support comprising an open-mesh, three-dimensional network structure composed of plastics threads coated unbrokenly with one or more efficiently conducting, thin metal coats and, to form the three-dimensional structure, being provided with humplike depressions and/or elevations which are distributed over its surface and in whose region the distance between the plastics threads is increased, wherein at least the outer metal coat of the plastics threads consists of a valve metal. Also described are electrodes comprising such a support and a process for producing the articles mentioned.

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. In the process of the invention, the conductive tab area of an electrode plate coated with active material is pierced with opposing, offset piercing plates having raised surface probes which penetrate the conductive tab area. The resulting area is cleared of active 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 method of continuously making plates for a lead-acid battery, and the resulting battery, comprise providing an electrically conductive strip of a lead or lead alloy which is fed into a grid expander which converts the strip into a continuous mesh having a top and bottom bar, feeding the continuous grid mesh into a tab blanker to form the lug for each plate in the top bar and notching the top and bottom bars at spaced locations so that what becomes the corners of the top and bottom frame bars are notched, thereafter pasting the continuous grid mesh with active material paste and then dividing the continuous grid mesh into individual plates, the method disclosed providing a process capable of being reliably run at commercial rates of speed with minimal scrap rates due to separator punctures and the like, the process thus providing sufficiently wide processing latitude which, in the preferred embodiment, can even significantly minimize out-of-specification grids that would otherwise would have to be scrapped.

Abstract: In an expanded mesh of this invention, a latitude skeletal element composing a mesh has a length which is substantially not elongated from a state of a sheet-shaped material. For this reason, the expanded mesh is not bulged like a barrel. Namely, it is flat. Since a longitudinal skeletal element is inclined acutely relative to straight portions as compared with a conventional expanded mesh, the expanded mesh will become a grid with good current collecting efficiency when a lug of current collector plate is formed on an inclining direction side.

Abstract: A storage battery having various cell constructions to increase the surface-to-weight ratio of active material exposed to electrolyte ions, to reduce internal resistance, and to extend the life of the battery is provided. One configuration for the battery cell utilizes pleated positive and negative plates which are monolithically coupled to respective electrodes. Another configuration for the battery cell utilizes a single positive plate and a single negative plate which are interrelated in, for example, a serpentine configuration.

Abstract: A method of fabricating electrodes suitable for use in electrochemical cells is provided. Each electrode has a perforated current collector and a tab which form an integral unit. The method can be adapted for batch, semi-continuous, or continuous fabrication of electrodes having electrode material laminated onto one or both surfaces of the current collector.

Abstract: A continuous cast positive grid of lead having substantially improved corrosion resistance and decreased growth in a positive plate of a lead-acid battery and a continuous cast negative grid of lead having substantially increased tensile strength for a lead-acid battery. A web of lead is continuously cast with a series of succeeding grid blanks of uniform thickness which are cold worked to reduce the positive grid thickness by at least 3:1 and the negative grid thickness in the range of about 1.5:1 to 2.8:1 preferably by passing through the nip of each of a plurality of successive compression rollers. Electro-chemically active paste is applied to the reduced webs, preferably flash dried, and individual pasted grids are cut from the reduced and pasted webs to provide positive plates and negative plates for a lead-acid battery.

Abstract: A continuous cast positive grid of lead having substantially improved corrosion resistance and decreased growth in a positive plate of a lead-acid battery and a continuous cast negative grid of lead having substantially increased tensile strength for a lead-acid battery. A web of lead is continuously cast with a series of succeeding grid blanks of uniform thickness which are cold worked to reduce the positive grid thickness by at least 3:1 and the negative grid thickness in the range of about 1.5:1 to 2.8:1 preferably by passing through the nip of each of a plurality of successive compression rollers. Electro-chemically active paste is applied to the reduced webs, preferably flash dried, and individual pasted grids are cut from the reduced and pasted webs to provide positive plates and negative plates for a lead-acid battery.

Abstract: The invention provides a zinc battery anode, comprising a substantially planar skeletal frame including conductive metal and having a portion of its surface area formed as open spaces, and further comprising an active zinc anode component encompassing the skeletal frame, the active anode component being formed of a slurry of porous granules comprising zinc, impregnated with and suspended in an electrolyte, and compacted under pressure to the skeletal frame.

Abstract: A porous metal body is produced by forming a coating film of one or more metal capable of forming a eutectic alloy at temperatures not higher than the melting point of Al on a foamed resin skeleton having a three-dimensional network structure according to the plating, vapor deposition, sputtering, CVD or other vapor phase process, impregnating the foamed resin having the coating film formed thereon with a paste comprising powdery Al, a binder and an organic solvent as principal components to thereby obtain a paste-coated composite and heating the composite at a temperature ranging from 550.degree. C. to 750.degree. C. in a nonoxidizing atmosphere. The resultant porous metal body has a large effective surface area and a high space utilization factor and exhibits excellent performance in uses in filters and battery plates.

Abstract: A method for making a molded plastic component for a bipolar battery, such as a lead-acid battery, comprises molding a plastic frame about a thin electrically conductive substrate, embedding the periphery of the substrate in the plastic frame and then removing the warpage resulting from the molding by a suitable surface reformation step, as by die stamping, to restore a surface that will allow desirable electrical performance to be achieved when the bipolar battery is used in service.

Abstract: A battery electrode (12) for use in an electrolytic bipolar battery (10) comprises a structurally rigid and electrically conductive core member (18), at least one corrosion resistant layer (20), an interface layer (22), a positive-side active layer (14) and a negative-side active layer (26). The corrosion resitant layer (20) is in intimate contact with and is interposed between one surface of the core member (18) and the interface layer (22). The corrosion resistant layer is comprised of a material which can participate in a corrosive electrochemical reaction with the material of the positive active layer, but does so less effectively than does the interface layer. The interface layer (22) is in intimate contact with and is interposed between the corrosion resistant layer (20) and the positive-side active layer (14). The negative-side active material (26) is in intimate contact with the surface of the core member opposite the core member surface carrying the corrosion resistant layer.

Abstract: An improved battery plate and method of making for an electric storage battery. The battery plate comprises a plurality of metallic fibers of a single or plural diameters randomly oriented and sintered to provide a conductive battery plate with a multiplicity of pores defined therein. The metallic fibers are formed by cladding and drawing a plurality of metallic wires to provide a fiber tow. The fiber tow is severed and the cladding is removed to form metallic fibers. The metallic fibers are arranged into a web and sintered to form the battery plate.

Abstract: Bipolar battery cells, bipolar batteries, and related methods are disclosed. The disclosed bipolar plate comprises a composite of long carbon fibers and a filler of carbon particles and a fluoroelastomer. A fluoroelastomeric sealant for placement between adjacent cells is also disclosed.

Abstract: A method for forming an electrode plate which includes an active portion pasted with active material and a plate head which includes a connection tab. The plate head is constituted by the same metal foam as the plate support, but the density of the metal foam in the plate head is not less than 2.5 times the density of the metal foam in the remainder of the electrode plate, the higher density of the plate head coming from an operation in which the foam of the support is compressed, the tab of the plate head emerging from the middle of the thickness of the plate and being derived from compression of the support in two directions: compression firstly in the direction of its height; and compression secondly in the direction of its thickness. Such an electrode plate is made from a plate of metal foam whose top edge is compressed so as to form the plate head.

Abstract: Disclosed are methods for enhancing the adhesion of composite electrodes onto metal foils (i.e., current collectors), to metal foils prepared by these methods and to electrolytic cells produced from these metal foils.

Abstract: The electrode comprises a metal substrate and a coated layer of an active material provided on one or both faces of the substrate. The metal substrate is a metal sheet having a plurality of punched holes. The punched holes have burrs along their peripheries so that the apparent thickness including the burrs is at least twice the original thickness of the metal sheet. The burrs improve the engagement between the metal substrate and the coated layer.

Abstract: An energy compression device includes at least one bipolar element comprising a positive electrode formed of cobalt disulfide, a negative electrode formed of a lithium alloy, an inert porous separator disposed between and in contact with the electrodes, and a lithium cation salt dispersed through the separator and in contact with, and preferably dispersed through, the electrodes.

Abstract: An aqueous cadmium oxide paste of high flowability for the vibration filling of foam-structure and fiber-structure electrode plaques is characterized by a cadmium oxide content of about 25 to 35% by volume, a pH of about 10 to 12.5, a content of about 0.5 to 2.5% by weight, based on cadmium oxide, of one or more dispersants from the group comprising the water-soluble salts of polyphosphoric acids, di- and polyphosphonic acids and their derivatives, gluconic acid or of antimonyl tartrate. The paste has a plastic viscosity of about 0.1 to 1 Pa.s and also a yield value of between about 10 and 120 Pa. This cadmium oxide paste makes it possible to fill foam-structure and fiber-structure electrode plaques completely in one operation.

Abstract: Metallization by deposit under vacuum of metal on a face of a support film of synthetic resin at a thickness of 0.005 to 0.1 micron, followed by the electrochemical deposit of an additional metallic layer, whose thickness is between 0.1 and 4 microns. A coating of an electrode of a generator is then applied on the surface of the collector thus prepared. The assembly is characterized by the adhesion of its components and its facility of mechanized handling during the steps of assembling the complete generator.

Abstract: A battery plate for lead acid storage batteries using a grid prepared by expanding a lead-calcium-tin (Pb--Ca--Sn) alloy sheet, is made by expanding a Pb--Ca--Sn alloy sheet having a tensile strength of 6.0 kg/mm.sup.2 or lower and an Sn content of 0.6-1.8% by weight to make a grid,filling this grid with an active material paste, and then aging the grid to increase the tensile strength of the expanded grid to 7.0 kg/mm.sup.2 or higher. The workability in expanding of the Pb--Ca--Sn alloy sheet can be improved and furthermore, concentration of stress strain on the nodes of the grid can be inhibited and thus, corrosion of the nodes can be inhibited. The aging can provide a battery pate having a high tensile strength and a lead acid storage battery having an excellent charge-discharge cycle life characteristics.

Abstract: Methods for fabricating battery plates for lead/acid batteries are provided. The battery plates that are fabricated may be positive plates, negative plates, or bipolar plates. The principal active constituent of the battery plates is elemental lead in the case of negative plates, lead oxide in the case of positive plates, or elemental lead on one face and lead oxide on the other face of bipolar plates. In any event, the battery plate comprises a thin layer of lead (which may later be oxidized, at least at its surface), where the thin layer of lead is surface treated so as to form a plurality of closely spaced depressions therein. By the surface treatment, the exposed active surface area of the plate is increased to at least 150% of its projected area. The surface treatment may be by embossing the lead, or micro-machining the lead using a laser. When the plate is a bipolar plate, a core element is provided between a pair of opposed thin layers of lead, one of which will subsequently be oxidized.

Abstract: A process for producing a lightweight electrode grid by exposing a compred, heated mat of dense graphite fibers to Ni(CO).sub.4 gas wherein the Ni(CO).sub.4 decomposes upon contact with the graphite fibers depositing a nickel metal coating on the graphite fibers which strongly bonds the fibers together to form a compressed mat or grid of nickel metal coated fibers.

Abstract: A co-doped lead oxide for use in the manufacture of storage battery plates, the use of such lead oxides improving the efficiency of lead-acid batteries, comprising, as co-dopants, based upon the total weight of the lead oxide, copper in an amount of from about 0.01 to 0.1% and either tin in an amount of from about 0.008 to 0.1% or antimony in an amount of from about 0.005 to 0.08%.

Abstract: Bipolar electrode is provided with a conductive support/separator perforated on a part which is free from active material with at least one opening which communicates by a gaseous environment in a battery between elements assembled in series. The opening prevents the passage of electrolyte from one conductive support/separator to another, and may include an advantageously hydrophobic material, which also contains an opening therethrough, and is arranged on at least one side of the opening. The bipolar electrodes are particularly applicable to sealed batteries.

Abstract: Methods for fabricating cored structures are provided. The cored structures may particularly find usefulness as cored battery plates for use in lead/acid batteries. A pre-formed core element is provided, and on its surfaces there is placed a thin layer of an active surface material. That active surface material is one which may enter into a chemical or electrochemical process when in use and in the presence of an electrolyte or other agent which will promote such chemical or electrochemical process. In the case of lead/acid batteries, the active surface is lead or lead oxide. The core element is generally one which does not bond with the active surface material, but will if the active surface material is ion bombarded or neutral atom embedded into the surface of the core, and where the amount of bombardment or embedment is determined by controlling the accelerator voltage.

Abstract: Discrete locations of an electrode web or electrode segment based on a porous metallic carrier framework, which are intended to receive the take-off conductor, are briefly heated to about 450.degree. C. and then cleared of active mass with compressed air. The heating, for which a stream of hot air is particularly suitable, has the effect of destroying the organic binder present in the active material. Following such treatment, a clean metal surface is made available for the welded attachment of the take-off conductor, of a size which is limited to the precise dimensions necessary for the connection.

Abstract: A method and apparatus for filling fibrous-structure electrode plaques for rechargeable batteries with an active compound paste, with simultaneous sizing of the plaque. The fibrous-structure electrode plaque is fed by means of a conveyor device to a roll mill whose roll nip is uniformly filled with a flowable active compound paste over the nip width. As the plaque passes through the roll nip, it is filled with active compound paste from both sides, simultaneously sized for thickness, its surface is smoothed and excess paste is removed from the main surface.

Abstract: A process for producing a lightweight electrode grid by exposing a heated t of dense graphite fibers to Ni(CO).sub.4 gas wherein the Ni(CO).sub.4 decomposes upon contact with the graphite fibers depositing nickel metal coating on the graphic fibers. The nickel coated graphite fibers are then sintered to form the grid. Nickel or cadmium electrodes are made by attaching a current collector to the grid and impregnating the grid with the appropriate nickel or cadmium active material.

Abstract: An electrode strip comprising a perforated conductive carrier, such as a nickel mat, coated with an electrochemically active material and wherein a selected area of the carrier free of the electrochemically active material is secured to a conductive tab on one side and a second conductive tab on the other side. The invention also relates to a method for producing the electrode strip.

Abstract: A method for manufacturing an expanded mesh sheet, includes the steps of: forming a plurality of slits on a strip at predetermined pitches to simultaneously form a plurality of strip-shaped lift portions and connecting portions connecting the strip-shaped lift portions to each other in a lattice pattern, the slits each being intermittently formed in a longitudinal direction of the strip and the intermittent pattern of adjacent slits in a widthwise direction of the strip being offset from each other in the longitudinal direction of the strip; and expanding the strip in the widthwise direction thereof. An apparatus for manufacturing the sheet, includes: a pair of rolls in coacting meshing engagement with each other, each roll having a plurality of disk-shaped cutters; and a driving device for rotating the rolls. Each cutter has cutting edge portions and reliefs on a periphery thereof at predetermined pitches.

Abstract: A method and an apparatus for expanding a preslit deformable mesh sheet and an improved battery grid are disclosed. The method comprises the steps of positioning the lateral edges of the deformable strip with the same horizontal plane; laterally expanding the preslit portion of the strip while maintaining the lateral edges within the said horizontal plane; and vertically expanding the preslit portion of the strip selectively and concurrently with the lateral expansion thereof while maintaining the lateral edges in the horizontal plane. The apparatus comprises means for diverting one lateral edge from the other and laterally expanding the preslit portion of the deformable strip, while maintaining the lateral edges within the same horizontal plane, and means for vertically expanding the preslit portion of the deformable strip selectively and concurrently with the lateral expansion.

Abstract: This invention provides a lead-acid battery plate and its manufacturing method. In a lead-acid battery plate making use of an expanded metal comprising copper or copper alloy electroplated with lead or lead alloy for its grid; this invention is characterized by that a protector is provided on a side of the grid. And in a manufacturing method for a lead acid battery plate in which the expanded metal comprising copper or copper alloy electroplated with lead or lead alloy is used for its grid, and a plate lug comprising lead or lead alloy is connected by casting to an upper part of the grid; this invention is characterized by that the plate lug is first connected by casting to the upper part of the copper expanded metal, and lead or lead alloy is then electroplated on the copper expanded metal to which the plate lug is connected.

Abstract: A simple device for the vibration filling of porous fiber structure electrode plaques for voltaic cells includes a vibrating plate having a principal extension arranged substantially vertical within a filling chamber. An electrode plaque is arranged with a principal surface substantially parallel to the principal surface of the vibrating plate at a distance of about 2 to 50 mm from the vibrating plate (when swung in to the maximum extent). The distance of the vibrating plate from the base of the filling chamber is at least about 1 mm. It is possible to fill a series of electrode plaques with one charge of the filling chamber, the filling operation for the electrode plaque proceeding very rapidly and with considerably less noise then known devices, in which the entire filling vessel is vibrated.

Abstract: An Sn or Pb/Sn alloy heat-treated at 170.degree. C. or higher for a given period of time is applied to the surface of a collector to make a lead storage battery which is improved in terms of its chargeability upon left overdischarged.

Abstract: An automatically operating apparatus and method for producing cathodes for ry-cell batteries, especially lithium batteries. A strip-like carrier material to which cathode material is fed in a dosed manner is transported on an endless, continuously rotating conveyor belt system. After passing a pasting mechanism, which includes a roller, and after passing a possibly provided cleaning mechanism for exposing the contact locations for the current shunting, the cathode material subsequently passes into a pressing mechanism that includes two rotating belts. Following the pressing mechanism is a cutting device that, just like the cleaning mechanism, moves synchronously with the conveyor belt system during processing, and that cuts the carrier material in conformity with the cathode lengths. Subsequently, the current shuntings are attached.

Abstract: A method for the manufacture of lead-acid batteries and associated apparatus and a lead-acid battery design resulting therefrom is disclosed. The method involves providing a battery grid and pasting the grid with a battery paste such that a profiled and tapered battery plate is formed. This battery plate is wrapped onto a coil and cured in curing apparatus. A battery element is formed using coils of the finished plate stock, separator material, and winged end plate. After this, several battery elements are then placed into a battery container.

Abstract: There is disclosed a method of laser treating lead-containing battery grids such that virtually instantaneous melting and solidfication occurs, thereby yielding an improved fine-grained microstructure even with such normally immiscible (in lead) metals as aluminum. The invention also permits a high aluminum content without the metal vaporization and oxidation, or the coarse grain structure, normally encountered. The fine grain structure of the treated product provides a battery grid having improved weight, electrical, mechanical and corrosion-resistant properties.

Abstract: A method for the vibration filling of foam-structure or fiber-structure electrode plaques for galvanic cells, particularly for electrical accumulators, totally immerses one or more electrode plaques in a vibrating paste of active mass which has an active mass content of about 25 to 60 vol %, a maximum granulometry of the active particles of about 0.04 mm and in the unvibrated state a yield value of about 10 to 120 Pa and a plastic viscosity of about 0.1 to 1 Pas at 20.degree. C. The paste is preferably set in vibration with a frequency of about 40 to 125 Hz and an amplitude of about 0.1 to 1.5 mm by a vibration transmitter fitted inside the tank containing the paste.

Abstract: The present invention provides a process for producing a grid for use in lead acid batteries which comprises superposing, on a sheet bar of a lead-calcium alloy, a sheet or a foil of a lead-silver-tin alloy consisting of 0.01-1.0% by weight of tin and a residual quantity of lead and having a thickness smaller than that of the sheet bar, pressure-bonding both the materials by cold rolling to prepare an elementary sheet, and subjecting the elementary sheet to an expanding process or a punching process.The grid obtained according to the process of the invention is improved in the charge-discovery characteristics after overdischarging and standing and does not deteriorate the maintenance-free characteristic of lead-calcium-tin alloy.

Abstract: A method and apparatus for applying paste to a battery grid. An endless conveyor belt pulls a grid through a pasting zone where paste is impressed into the grid. The grid is further passed through a fixed orifice, after being impressed with paste to impart a predetermined thickness to the grid. The orifice may be defined by two plates.

Abstract: A plate for a bipolar battery includes a planar substrate of plastic conductive material, with a mesh of metallic wire disposed therein, the surfaces of the wires exposed above the substrate surface. This divides the substrate surface into discrete areas.

Abstract: A paste hopper control system in which the weight and thickness of lead oxide paste applied to a stream of battery grid material from a hopper are independently controlled in response to in-line weight and thickness measurements obtained downstream of the paste hopper. Paste weight is independently controlled on the two sides of the stream by separately driving transversely spaced, independently rotatable hopper paddles in accordance with weight measurements obtained on the respective sides of the stream. Plate thickness is independently controlled on the two sides of the stream by adjusting the heights of the ends of a trowel roller in accordance with downstream thickness measurements and by adjusting the height of the hopper as a unit.

Abstract: An apparatus for dividing a multi-unit battery plate grid into individual battery plate grids and for subsequently applying paste to the individual battery plate grids, which apparatus comprises a pasting device for applying paste to the grids, a parter located upstream of the pasting device for dividing multi-unit battery plate grids into individual battery plate grids prior to pasting thereof, and a conveyor for feeding multi-unit battery plate grids through the parter and for thereafter feeding the individual battery plate grids through the pasting device. Also disclosed herein is a method of dividing a multi unit battery plate grid including at least two connected individual battery plate grids into separated individual battery plate grids and of subsequently pasting the separated individual battery plate grids, which method comprises the steps of dividing the multi-unit battery plate grid into separated individual battery plate grids, and thereafter pasting the individual separated battery plate grids.

Abstract: A high tensile strength fibrous material is coated with an extruded, corrosion-resistant metal to form a composite wire which is used in the formation of a grid element for a battery.