Lead acid battery including a two-layer carbon foam current collector
View Patent ↗A lead acid battery includes a housing and at least one cell disposed within the housing. Each cell includes at least one positive plate and at least one negative plate and an electrolyte disposed in a volume between the positive and negative plates. The at least one negative plate includes a current collector, consisting essentially of a layer of carbon foam disposed on a substrate, and a chemically active material disposed on the current collector.
1. A lead acid battery comprising:
a housing;
at least one cell disposed within the housing and including at least one positive plate and at least one negative plate; and
an electrolyte disposed in a volume between the positive and negative plates;
wherein the at least one negative plate includes a current collector, comprising of a layer of carbon foam physically attached to a structured substrate via a system of mechanical fasteners, and a chemically active material disposed on the current collector.
2. The lead acid battery of claim 1 , wherein the substrate comprises an electrically conductive material.
3. The lead acid battery of claim 2 , wherein the electrically conductive material includes a lead grid.
4. The lead acid battery of claim 1 , wherein the substrate comprises glass or a polymer.
5. The lead acid battery of claim 4 , where the substrate includes polycarbonate.
6. The lead acid battery of claim 1 , wherein the at least one positive plate includes a lead grid current collector.
7. The lead acid battery of claim 6 , wherein the lead grid current collector includes a radial or hexagonal grid pattern.
8. The lead acid battery of claim 1 , wherein the at least one positive plate includes a carbon foam current collector.
9. The lead acid battery of claim 1 , wherein the at least one positive plate includes a current collector consisting essentially of a layer of carbon foam disposed on a substrate.
10. The lead acid battery of claim 1 , wherein the electrolyte includes aqueous sulfuric acid.
11. The lead acid battery of claim 1 , wherein the electrolyte includes a silica gel.
12. The lead acid battery of claim 1 , wherein the carbon foam has a total porosity value of at least 60% and an open porosity value of at least 70%.
13. The lead acid battery of claim 1 , wherein the carbon foam has a resistivity value of less than about 1 ohm-cm.
14. The lead acid battery of claim 1 , wherein said physical attachment is by a sewn thread.
15. A lead acid battery comprising:
a housing;
at least one cell disposed within the housing and including at least one positive plate and at least one negative plate; and
an electrolyte disposed in a volume between the positive and negative plates;
wherein the at least one negative plate includes a current collector, comprising of a layer of carbon foam physically attached to a structured substrate by a mechanical fastener, and a chemically active material disposed on the current collector.
16. The lead acid battery of claim 15 wherein said mechanical fastener is selected from the group consisting of a staple, a wire, a plastic loop fastener, a rivet, a swaged fastener and a screw.
17. The lead acid battery of claim 15 , wherein said structured substrate is an open structure.
18. The lead acid battery of claim 15 , wherein said structured substrate is a grid.
19. The lead acid battery of claim 18 , wherein said grid has a cross member and a strut.
20. The lead acid battery of claim 15 , further comprising a tab, said tab being disposed to establish an electrical connection to said current collector.
21. The lead acid battery of claim 15 , further comprising a tab, said tab being in electrical contact with said current collector via an infusion of metal into said current collector.