Electric Batteries.
Year: 1887

page_text: Date of Application, 22nd Mar., 1887
Specification Accepted, 21st Oct., 1887
Electric Batteries.
I, WILLIAM MAIN of 856 Marcy Avenue, Brooklyn, County of Kings, New York,
United States of America, Electrician do hereby declare the nature of this invention
and in what manner the same is to be performed, to be particularly described and
ascertained in and by the following statement:-
My invention relates to that form of battery which may be used for storing up the
energy of an electric current for subsequent re-distribution and use. The simplest
battery of that form, as is well known, is that of Planté. To "form" the electrodes
for this battery, two plates of lead are placed near each other, but not in contact,
immersed in an electrolytic bath, and subjected to the action of an electric current
passing through them and the bath; the effect of the current being the formation of
peroxide of lead on the surface of one plate by the union of oxygen, released from the
electrolytic fluid, with the lead of the plate, and the union with, or occlusion in, the
other plate, of the liberated hydrogen. Two plates were thus obtained, one of which
had a coating of peroxide of lead, and the other held a certain amount of hydrogen
within its exposed surface; and which, as they returned to a condition of mutual
equilibrium, would exhibit a secondary .current; but one which was weak and of
short duration. To increase the depth of the active layer on the plates, and thus
secure a more powerful and enduring battery, it was found necessary to reverse
the current several times in forming the plates, the reversed current drawing away
the oxygen from the former oxygen plate, (this oxygen uniting with the hydrogen
released from the electrolytic fluid, to form water.) leaving there a surface of spongy
lead and forming the peroxide on the former hydrogen plate. On the second reversal,
the coating of peroxide was thrown back to the original oxygen plate, now a plate of
spongy lead, and, therefore, capable of receiving a larger amount of oxygen than
before, the oxygen penetrating the plate further and forming a thicker layer of
peroxide. Repetitions of this process increased the depth of the active layers on
both plates, and, consequently, the efficiency of the battery, to a very considerable
degree.

page_text: It was also found that the depth of the layer of peroxide could be increased by
employing a succession of currents, separated from each other by considerable intervals
of time. This was due to the fact that delay permitted the oxygen to penetrate,
lowering the oxidization of the oxygenized layer, but opening up an increased
thickness of metal to the action of the next following current.
By the use of these methods a battery of some strength could be at length obtained;
but its cost was excessive, and its operation in some respects unsatisfactory. It
was costly because of the mass of lead required to furnish a sufficiently substantial
support to the comparatively small active surface; because of the large quantity
of electrical energy expended in the several reversals of the current; and because
of the liability of the layers of peroxide and spongy lead, when made so thick, to
scale off, and of the plates themselves to become distorted, to break, or to scale.
These latter results were caused by the warping of the plates, consequent upon the
alternate expansion and contraction of the active layer, as the oxygen successively
united with it and withdrew from it; these repeated distortions acting upon and in
conjunction with irregularities in the structure and form of the plates, and other
irregularities consequent thereon in the active layers, to the injury of both the active
and supporting parts.
In operation this battery was unsatisfactory for the reason that, in the first place,
its internal resistance proved to be too great, especially after the battery had been
partially discharged. This was due to the resistance offered by the thick layer of
peroxide of lead, which is a poor conductor, especially when partially reduced; and
to the large amount of pure water formed in, and held within, the layer of active
material by the process of reduction, pure water being also a poor conductor.
It was found to be unsatisfactory for the further reason that when lead plates are
freely exposed to the action of an electrolytic fluid containing sulphuric acid, con-
siderable quantities of sulphate of lead will be formed in the active layers, whenever the
battery is allowed to stand inactive. When the active layers are thick, the sulphate so
formed is practically cut off from the action of the charging current, when the battery
is next used, because of the imperfect conduction of the peroxide between it and the
supporting plate; and it results that the battery is permanently clogged and practi-
cally disabled the action of the current upon the plate, under the inactive sulphate,
frequently even causing the oxidized layer to peel off, wholly or in part. Thus is
explained the well known liability of batteries of this class to be ruined by standing,
when discharged, with the plates in the liquid.
;
For the purpose of overcoming these several difficulties and defects, various modi
fications of the original Planté battery have been suggested. Thus it has been proposed
to artificially hasten the formation of the electrodes by mechanically attaching an outside
layer of lead or other active material to the plates. Red lead so applied to the oxygen
plate is readily converted into peroxide by the union with it of the liberated oxygen,
while that attached to the hydrogen plate is reduced to spongy lead by the union
of the liberated hydrogen with its oxygen, forming water this process being
comparatively cheaper and quicker than the process of forming the active layers solely
by the action of the current upon pure lead plates. The active material used for this
purpose has been applied to the plates in two general ways. It has been painted,
cemented, or otherwise attached in thin layers to the surface of flat plates; and it has
been packed into interstices, holes, spaces between ribs, and other cavities and
receptacles of various shapes and arrangements formed in and upon the surface of the
plates; or placed in masses between plates riveted or otherwise fastened together.
Both methods have disadvantages. The thin layers applied to the surface of the
plates, having no intimate union with the lead, readily scaled and dropped off; and it
became necessary to devise mechanical means of various sorts, such as retaining
aprons of cloth, wood or other inactive material, to prevent the active substance from
becoming diffused throughout the mass of electrolytic fluid. Even this means,
cumbrous, clumsy, and inconvenient as it was, was found to be insufficient, unless
supplemented by a union between the active material and the plates, effected by a
number of reversals of the current in "forming" the plates. The desired advantage of

page_text: avoiding the use of the large quantities of electrical energy formerly necessary was
therefore only partially attained by this means.
On the other hand, the method of connecting masses of active material with the
plates by packing it in holes and piling it on shelves of various forms was found
5 to be open to most of the disadvantages heretofore enumerated with reference to
thick, electrically formed active layers. The liquid would only penetrate the masses
partially and imperfectly, and to the extent to which they were penetrated the con-
duction of electricity was poor, and, therefore, the efficiency of the battery relatively
small. Sulphate of lead was formed in large quantities whenever the action of the
battery was temporarily arrested, and frequently even during the activity of the
battery, owing to the practical suspension, in places, of electrical action, by the non-
conducting masses of partially oxidized lead. Batteries formed on this and all
analogous plans, like the original Planté battery, have been practically failures,
because they have disregarded the principle that it is only the surface of the plates
which is active and efficient to any considerable degree.
It has been proposed to form electrodes of scraps and shavings of lead, in order to
increase the active surface; but batteries so made have been found to be subject to
all the disadvantages arising from imperfect conduction,—clogging by sulphate,
scaling and breaking, above enumerated.
It has also been proposed to improve the original Planté battery by the use of
electrodes made of thin sheets of lead, offering a large active surface în proportion to
weight and size; it being apparent that if such a battery could be formed it would be
simpler, more readily charged and stronger and more efficient in proportion to
weight, size, and cost than a battery wherein a deep layer of active material is
electrically formed by repeated reversals of current, or one in which the active
material is mechanically attached to the plates.
It is to this general class of batteries that my invention belongs,-it being my
purpose to devise a battery of this plan, which I believe to be the best, and which
shall avoid the difficulties and defects attached to the Planté battery, above
enumerated.
Electrodes made of sheet lead have heretofore been proposed, in which it has been
thought necessary to separate the sheets by the interposition of various materials,
such as paper, parchment, various metallic oxides, powdered coke, sand, powdered
glass, graphite, and similar materials. It has also been proposed to separate the
plates by corrugating each second plate. It has been proposed to hold these
bundles of plates together by the use of parchments or cloth sacks, bands of India
rubber, or other inert material, or by soldering their edges.
But these various processes have been found to avoid the difficulties only to an
indifferent extent. Many of the materials used for separating the plates had a
chemical effect upon the battery which was injurious. The electrolytic fluid having
free access to the surface of the plates, sulphate of lead was freely formed, with its
accompanying disadvantages. There was nothing to prevent the plates from buckling
and breaking, and the active layers from scaling off the separating media occupied
much valuable space; and a still more serious difficulty was encountered in regard
to the inferior conducting capacity of the plates when partially consumed, the layers
of peroxide being, as before stated, poor conductors, especially after partial dis-
charge of the battery. Moreover, the means used for retaining the plates together
vere cumbrous, taking up valuable space and in no respect aiding the chemical
ction of the battery. Other serious defects of electrodes so made is the difficulty of
eeping the thin plates, at all points, far enough apart to permit access of the fluid,
specially if the plates are made of any considerable size; the liability of the passage
etween them to become clogged, to the subsequent uncertain action of the battery.
On the whole, batteries so constructed have had hitherto little stability, strength, or
ractical value.
In experimenting with a view to constructing a practical battery of this general
lass, I have discovered that it is not advantageous to separate the sheets of lead or
ad foil from each other, but that they may much better be allowed to rest face to

page_text: face, giving, when so used, an electrode of greater efficiency, relative to size, than any
hitherto made. I find that with this construction the electrolytic fluid will be
drawn up between the plates by capillary attraction, in quantities amply sufficient
to oxidize them, and yield maximum results as regards the storing of energy, it
being only necessary to provide passage ways for the electrolytic fluid by means of 5
holes, or other channels, passing through the plate from side to side at sufficiently
frequent intervals.
These perforations may be made of any shape whatever, if only they permit the
liquids to pass freely through them, and should be as numerous as is in practice found
desirable for the kind of battery required for the particular use.
A battery desired 1
to be quick in its action, and intended to give up its charge within a short period
of time, should have a greater number of perforations in its electrodes than one
designed for more sluggish action. It will probably be found best to place the
perforations in regular patterns throughout the electrodes, in order that the latter
may be at all points equally accessible or as nearly so as practicable-to the action
of the electrolytic fluids, but I do not limit myself to such arrangements, nor to
any other in particular.
I propose to provide against the difficulty experienced in the use of electrodes
made up of thin plates, in that, as the plates are consumed, the conduction of the
current is not properly provided for, by placing at intervals, between the thin layers,
other plates of sufficient thickness to certainly withstand the action of the current
for a considerable length of time, and thereby offer a reliable channel for the passage
of the current to and from the active surfaces.
I also propose to increase the surface and promote the activity of the thin sheets by
puncturing or perforating them, passing them under pressure between sheets of sand
paper, or between rollers especially designed for that purpose, or effecting the
puncturing by other suitable means. The cavities or holes thus formed in the sheets
may or may not pass entirely through them. The activity and sensitiveness of the
electrodes is materially increased by this treatment, for the reason that points are thus
provided at which the chemical action on the plates will begin more readily than on a
smooth surface. The roughening, moreover, increases the absolute surface area of the
plate, and also increases the strength of the capillary action. This function is entirely
different from that of the recesses provided in inactive supporting plates for receiving
and retaining active material. I propose to attach the plates to each other by rivets
of the same material as the plates; this construction dispensing with the use in the
battery of every material whatever which is not chemically effective, though I do not
limit myself to the use of such material for rivets.
The plates may be riveted together before they have been subjected to any
electrolytic action; but I find that time is saved in charging the battery if they are
first oxidized. Likewise, the perforations may be made in the electrodes either
before or after they are joined together; and if the plates are oxidized before being
joined, either before or after they are so treated.
Electrodes formed as above described entirely avoid the difficulties heretofore
experienced, arising from the formation of sulphate of lead while the battery is in
action. The surface area is so great that the layer of active material nowhere
penetrates the body of the metal and therefore the sulphate-even that formed on the
outer surfaces of the electrodes- can never become electrically detached from the
conducting portion of the electrodes so as to escape reduction by the next charging
current. This battery has therefore the great advantage over other practical batteries
that it may be allowed to stand with the plates in the liquid, charged or discharged,
without suffering any permanent injury.
I wish it understood, that the use of rivets to bind the plates together, the puncturing
of the thin plates and the interposition at intervals of comparatively thick plates, are
features of iny construction, which may or may not be employed; the gist of the
invention consisting in the making of an electrode of a number of superimposed
lamine of suitable metal, provided with channel ways through them for the flow of
the electrolytic fluid, and its great advantage lying in the fact that an electrode so

page_text: made combines enormous surface area with solidity and compactness of a heavy plate
electrode.
I do not limit my invention to the use of lead plates; any other suitable material
may be used, and if made up into electrodes in a similar way, the battery so formed
will be within my invention.
In addition to the improvements above described, my invention includes details in
the construction of a secondary battery cell, hereinafter fully described and pointed
out in the claims. In the drawings annexed hereto and forming a part of this
specification;
Figure 1 is a vertical sectional view of a secondary battery cell, showing in elevation
an electrode made according to my invention.
Figure 2 is a plain view of a cell of which a part of the top has been broken away
to show the edges of the electrodes or plates.
Figure 3 is an edge view of one of the plates, the lower part being shown in cross
section.
Figures 4, 5, and 6, represent modifications in the shape and arrangement of the
channels through the plates from side to side, and
Figure 7 represents a side view of the surface of one of the plates, showing the
roughened or punctured surface.
The electrodes A are made up of a number of thin sheets of lead, platinum or other
suitable metal, B, between which at intervals are hung plates or sheets of conducting
metal C, these sheets being placed face to face, and united to each other by rivets D,
a suitable number of which are used to hold the sheets firmly and durably together.
The electrodes or plates thus made up are provided with a large number of perforations
or channel ways, E, cut through them from side to side. These channel ways could
be made round, as shown in Figs. 1, 4 and 5, oblong, as some of them are shown in
Fig. 6, or of any other form desired, it being only necessary to provide passage ways
through which the electrolytic fluid may have free access to all the plates at a large
number of points. I have found it convenient to vary the size of the channel ways,
as shown in Figs. 4 and 5, placing small perforations at intermediate points between
larger ones, as at E' and E. These small perforations I find are sufficient as starting
points for the penetration of the fluids between the plates. I prefer to roughen or
puncture all the interior surfaces of the plates, as shown in Fig. 7, and I may also
similarly prepare the two outside surfaces. The heavier plates C, if made of metal
which is not subject to electrolytic action, may be as light and thin as desired, it being
only necessary that they should furnish a certain and permanent conducting path for
the current to the active surfaces. I consider it best to make them of active material,
as this gives, of course, so much more active surface in the electrode ; but when so
made it is necessary that they should be heavier than the other plates, in order that
there may certainly be a proper conducting path for the current as long as the
electrode lasts.
To the top edge of each compound plate are soldered two projecting lugs, F, provided
with base pieces, F, these lugs serving to sustain the plates in the cell, and furnish
the means for making electrical connection therewith. These lugs project up through
holes made for them in the cover, G, of the battery cell, washers, H, preferably of
asbestos soaked in parafine, being placed between the base pieces, F, and the cover, G;
this cover being made of hard rubber or similar material. The electrodes A are, of
course, arranged in positive and negative pairs, as shown, and the lugs of the positive
and negative electrodes, respectively, are arranged in separate transverse ranges, as
shown in Fig. 2, so that the lugs of the same pole may be conveniently connected to
each other by the strips I and I, fitted over the projecting ends of the lugs and lying
against the top of the cover.
The lugs Fand the strips I and I', having been placed in this relative position, are
soldered together; whereby the plates A are firmly and solidly attached to the cover.
In order to prevent the insulation of the connections from being impaired by the
accumulation of dirt, and to thoroughly protect them. I make the cover G with an
upwardly projecting flange, K, about its edge; and after the various parts have been

page_text: put in place as described, I fill the basin formed by this flange with melted pitch, or
similar, insulating material, which, when it hardens, forms an effectual projecting
layer L. Circuit connections are made with the projecting points of the lugs Fin
any convenient manner.
For the purpose of separating the electrodes, instead of using the usual transverse
or vertical rods, which are objectionable, in that they rest against a considerable
portion of the active surface of the plates, to that extent diminishing their efficiency,
and also because they furnish supports and lodging places for the accumulation of
various kinds of sediment and dirt, which more or less interferes with the insulation
of the plates from each other, I have devised a round headed bolt, M, a suitable
number of which are set into each second plate, and effectually preventing the plates
from coming together. These bolts are made of hard rubber, or other insulating
material, and are each provided with a nut, N, shaped like their heads.
Heads and nuts of this shape are desirable because they impinge upon the least
possible amount of surface of the adjoining plate, and therefore offer the least possible
supporting area for the accumulation of sediment. It is obvious that the shaft of the
bolt may be made of metal, provided the heads and nuts are of insulating material.
Various modifications in the way of studs and bolts set perpendicularly into the plates,
for the purpose of separating them, might be readily suggested.
A pointed or wedge shape for the head and nut of the bolt would be an obvious
equivalent of the round shape, the important point being that the end of the bolt
should have a small surface for contact with the adjoining plate.
The usual plug, O, is provided in the cover, through which the supply of the
electrolytic fluid may be replenished, and having through its centro a ventilating
air passage.
While the lugs F are shown as being round, it is obvious that they may equally
well be of rectangular or other shape, and also that they may be attached in any
other way, as well as soldered to the strips I; or other means than attachment to
strips might easily be devised for holding the lugs in the cover.
I wish it understood that I claim the various details of construction described, for
making electrical connection with the plates, in their application to batteries of all
kinds as well as in connection with secondary batteries.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed I declare that what
I claim is
1. An electrode for secondary batteries made up of thin sheets of lead, platinum, or
other suitable material, placed face to face in close contact, and provided with
transverse channels or perforations for the passage of the electrolytic fluid.
2. An electrode for secondary batteries, made up of thin sheets of lead, platinum, or
other suitable material, riveted together face to face in close contact, and provided
with transverse channels or perforations for the electrolytic fluid.
3. An electrode for secondary batteries, made up of thin plates of lead, platinum, or
other suitable material, together with one or more supporting and conducting plates,
placed face to face in close contact, and provided with transverse channels or
perforations for the electrolytic fluid.
4. An electrode for secondary batteries, made up of thin plates of lead, platinum, or
other suitable material, together with one or more plates of thicker lead, placed face
to face in close contact, and provided with transverse channels or perforations for the
electrolytic fluid.
5. An electrode for secondary batteries, made up of superficially oxidized thin
sheets of lead, or other suitable material, placed in close contact, face to face, and
provided with transverse channels or perforations for the electrolytic fluid.
6. An electrode for secondary batteries, made up of punctured or roughened sheets
of thin lead, platinum, or other suitable material, placed face to face in close contact,
and connected together to form a compact mass; the entire mass being provided with
transverse channels for the electrolytic fluid,

page_text: 7. An electrode for secondary batteries, made up of punctured or perforated sheets
of thin lead, platinum, or other suitable material, together with one or more supporting
plates, all placed face to face in close contact, united by lead rivets, and provided with
transverse channels, at frequent intervals, for the electrolytic fluid.
8. An electrode for secondary batteries, made up of thin sheets of lead, or other
suitable material, the surfaces whereof have been artificially roughened, together with
one or more heavier supporting plates; such sheets and plates being placed face to face
in close contact, and provided with transverse channels or perforations for the passage
of the electrolytic fluid.
9. A top for a battery cell, provided with an upwardly projecting flange, in com-
bination with electrical connecting pieces, passing through the cover to the battery
plates, and a filling of insulating material in the cavity formed by the cover and said
flange.
16. The combination of the plates, A, the lugs, F, in electrical connection therewith,
and the strips, I and 1', and protecting layer, L, substantially as and for the purpose
set forth.
11. In a battery, the combination of a plate, lugs attached thereto, a cell cover
through which the lugs project, strips attached to the lugs, and a projecting layer of
plastic material, substantially as and for the purpose set forth.
T
ດາ
M. 1007
HASELTINE, LAKE & Co.,
45, Southampton Buildings, London,
Agents for the Applicant.