Lightweight, durable lead-acid batteries
A lightweight, durable lead-acid battery is disclosed. Alternative electrode materials and configurations are used to reduce weight, to increase material utilization and to extend service life. The electrode can include a current collector having a buffer layer in contact with the current collector and an electrochemically active material in contact with the buffer layer. In one form, the buffer layer includes a carbide, and the current collector includes carbon fibers having the buffer layer. The buffer layer can include a carbide and/or a noble metal selected from of gold, silver, tantalum, platinum, palladium and rhodium. When the electrode is to be used in a lead-acid battery, the electrochemically active material is selected from metallic lead (for a negative electrode) or lead peroxide (for a positive electrode).
1. An electrode for an electrochemical cell, the electrode comprising:
a current collector having a buffer layer in contact with the current collector, the buffer layer comprising a ternary carbide; and
an electrochemically active material in contact with the buffer layer.
2. The electrode of claim 1 wherein:
the current collector comprises carbon fibers having the buffer layer.
3. The electrode of claim 2 wherein:
the current collector has a layer of the electrochemically active material in contact with the buffer layer on one side of the current collector, and
the current collector has a layer of a second electrochemically active material in contact with the buffer layer on an opposite side of the current collector.
4. The electrode of claim 3 wherein:
the electrochemically active material is metallic lead, and
the second electrochemically active material is lead peroxide.
5. The electrode of claim 1 wherein:
the current collector consists essentially of carbon fibers having the buffer layer.
6. The electrode of claim 1 wherein:
the electrochemically active material is selected from metallic lead or lead peroxide.
7. The electrode of claim 1 wherein:
the carbide includes lead.
8. The electrode of claim 1 wherein:
the ternary carbide includes lead and a transition metal.
9. The electrode of claim 8 wherein:
the transition metal is selected from titanium, zirconium, hafnium, and mixtures thereof.
10. A lead acid battery comprising the electrode of claim 1 .
11. An electrode for an electrochemical cell, the electrode comprising:
a current collector having a buffer layer in contact with the current collector, the buffer layer comprising a carbide; and
an electrochemically active material in contact with the buffer layer,
wherein the carbide includes lead.
12. The electrode of claim 11 wherein:
the current collector comprises carbon fibers having the buffer layer.
13. The electrode of claim 12 wherein:
the current collector has a layer of the electrochemically active material in contact with the buffer layer on one side of the current collector, and
the current collector has a layer of a second electrochemically active material in contact with the buffer layer on an opposite side of the current collector.
14. The electrode of claim 13 wherein:
the electrochemically active material is metallic lead, and
the second electrochemically active material is lead peroxide.
15. The electrode of claim 11 wherein:
the electrochemically active material is selected from metallic lead or lead peroxide.
16. A lead acid battery comprising the electrode of claim 11 .
17. An electrode for an electrochemical cell, the electrode comprising:
a current collector having a buffer layer in contact with the current collector, the buffer layer comprising a carbide; and
an electrochemically active material in contact with the buffer layer,
wherein the carbide is a ternary carbide including lead and a transition metal.
18. The electrode of claim 17 wherein:
the transition metal is selected from titanium, zirconium, hafnium, and mixtures thereof.
19. The electrode of claim 17 wherein:
the current collector comprises carbon fibers having the buffer layer.
20. The electrode of claim 19 wherein:
the current collector has a layer of the electrochemically active material in contact with the buffer layer on one side of the current collector, and
the current collector has a layer of a second electrochemically active material in contact with the buffer layer on an opposite side of the current collector.
21. The electrode of claim 20 wherein:
the electrochemically active material is metallic lead, and
the second electrochemically active material is lead peroxide.
22. The electrode of claim 17 wherein:
the electrochemically active material is selected from metallic lead or lead peroxide.
23. A lead acid battery comprising the electrode of claim 17 .