Patent WO-2019083382-A2 (WO)
Title: A composite lead-acid battery comprising current collectors based on shaped elements made of conductive porous carbon and processes for manufacturing
Inventor: Czerwiński Andrzej
IPC: H01M10/12
Filed: 2018-10-24
Abstract: The present invention discloses components of a CLAB-type composite lead-acid battery and a CLAB-type composite lead- acid battery having lightweight composite current collectors having non-lead substrates made of conductive porous carbon produced in the form of shaped elements with a specific desired target geometry, porosity and surface architecture. Current collectors have increased mechanical strength, increased electrical conductivity, increased ability to use the active mass filling the collector, and minimized the amount of lead used for their construction. The carbon substrates of current collectors can be produced in any shape, thanks to which it is possible to produce current collectors and CLAB-type batteries of any shape. By using the solution according to the present invention, vehicle designers or other devices requiring the use of a starter battery or an electrochemical energy source will not be limited by the need to use a standard, cuboidal battery chamber. A method for manufacturing of shaped elements made of conductive porous carbon, using the process of carbonization of polymeric materials, consisting of heating in a gaseous environment a polymeric material impregnated with a suitable resin or a mixture of resins, that undergoes thermal hardening followed by carbonization in an anaerobic or reducing atmosphere, according to the present invention is characterized in that a porous polymeric material is subjected to mechanical pre-treatment to obtain shaped elements made of a porous polymeric material having the desired geometry, taking into account the expected dimensional changes during the carbonization process, which are then impregnated with a resin or a mixture of resins, then the impregnated shaped elements are optionally subjected to further mechanical machining, and then the shaped elements are hardened, then embedded in the holder, the whole is placed in the carbonization chamber and carbonized, which results in formation of shaped elements made of conductive porous carbon of a desired, target geometry without the need for their further mechanical machining. A method for manufacturing of current collectors of a composite lead-acid battery, the collector having a substrate made of porous non-lead conductive material, coated at least partially with lead or lead alloy and having an electrical contact, according to the present invention is characterized in that the substrate made of porous non-lead conductive material used has increased mechanical strength, and was subsequently made in a form of shaped elements with a specific desired target geometry, dimensions, shape, spatial architecture, relief and porosity, in a way that does not require mechanical machining of the conductive material from which the substrate is made of. A method for introducing an active mass into the current collector of a positive or a negative electrode of lead-acid battery, which collector is equipped with an electrical contact made of lead or lead alloy, employing a form with an inner shape and depth identical with the target shape of said electrodes, which form is made of a material resistant to sulfuric(VI) acid, preferably of PTFE, characterized in that the active mass is introduced by gravitational shaking, and an excess of the paste located above the upper edge of the form is collected by means of a doctor blade; A lead-acid composite battery having at least one cell comprising at least one positive electrode, at least one negative electrode, electrolyte and means ensuring current flow, at least one electrode having a current collector made of porous non- lead substrate covered at least partially with a surface layer of lead or its alloy, and filled with an appropriate active, cathodic or anodic active mass, characterized in that the current collectors of the electrodes have substrates made of porous non-lead conductive material of increased mechanical strength, previously made in the form of shaped elements with a specific desired target geometry, dimensions, shape, spatial architecture, relief and porosity, in a way that does not require mechanical machining of the conductive material from which the substrate is made of.