LEAD-ACID BATTERY FORMULATIONS CONTAINING DISCRETE CARBON NANOTUBES

1 . A composition for lead-acid battery construction comprising:

a plurality of discrete carbon nanotube fibers, the nanotubes having an aspect ratio of about 10 to about 500, and an oxidation level from about 1 weight percent to about 15 weight percents;

wherein the discrete carbon nanotubes are open ended.

2 . (canceled)

3 . The composition of claim 1 , further comprising at least one surfactant or dispersing aid, wherein the surfactant or dispersing aid contains a sulfate moiety.

4 . The composition of claim 1 , further comprising water, wherein the nanotube fibers are dispersed in the water to form an expander material or battery paste.

5 . The composition of claim 3 , wherein the surfactant or dispersing aid is a sulfonated polymer selected from the group consisting of: ligno-sulfonate, sulfonated polystyrene, and combinations thereof.

6 . A material for a battery paste for a lead-acid battery, comprising:

a plurality of discrete carbon nanotube fibers having an aspect ratio of about 10 to about 500, and an oxidation level from about 1 weight percent to about 15 weight percents;

an organic material;

an inorganic salt; and

a non-fiber carbon moiety.

7 . The composition of claim 6 , wherein the inorganic salt is selected from the group consisting of: barium sulfate, lead sulfate, calcium sulfate, and tin oxide.

8 . The composition of claim 6 , wherein the non-fiber carbon moiety is selected from the group consisting of: carbon black, graphite, and graphene.

9 . A process for producing a lead-acid battery material, comprising the steps of:

(a) selecting discrete carbon nanotube fibers having an aspect ratio from 10 to 500;

(b) selecting discrete carbon nanotube fibers having an oxidation level from 1-15% by weight;

(c) selecting discrete carbon nanotubes having at least a portion of open-ended tubes;

(d) blending the fibers with a liquid to form a liquid/fiber mixture;

(e) combining the liquid/fiber mixture with a sulfonated polymer;

(f) adjusting the pH to a desired level;

(g) combining the liquid/fiber mixture with at least one surfactant;

(h) agitating the liquid/fiber mixture to a degree sufficient to disperse the fibers to form a liquid/dispersed fiber mixture;

(i) combining the liquid/dispersed fiber mixture with at least one inorganic salt to form a fiber/salt mixture;

(j) combining a non-fiber carbon moiety with the fiber/salt mixture to form a fiber/non-fiber carbon mixture;

(k) drying the fiber/non-fiber carbon mixture; and

(l) combining the fiber/non-fiber carbon mixture with lead containing components to form a battery paste mix.

10 . A battery, comprising:

the material of claim 1 .

11 . The composition of claim 1 , further comprising conducting polymers selected from the group consisting of: polyaniline, polyphenylene vinylene, polyvinylpyrollidone, polyacetylene polythiophene, polyphenylene sulfide, and blends, copolymers, or derivatives thereof.

12 . A battery paste, comprising:

the material of claim 1 ;

wherein the battery paste exhibits at least 10% improved adhesion to carbon/lead electrodes, lead electrodes, or carbon electrodes, than pastes without carbon nanotubes.

13 . A battery, comprising:

the material of claim 1 ;

wherein the battery paste exhibits a 10% or greater increase in ion transport at any temperature for a given electrolyte concentration compared to a battery without carbon nanotubes at the same electrolyte concentration and temperature.

14 . A negative electrode for an energy storage device, comprising:

a current collector;

a corrosion-resistant conductive coating secured to at least one face of the current collector;

a sheet comprising carbon particles and discrete carbon nanotube fibers comprising 1-15 percent by weight of oxidized species with aspect ratio of from about 10 to about 500, said sheet adhered to the corrosion-resistant conductive coating;

a tab portion extending from a side of the negative electrode;

a lug comprising a lead or lead alloy that encapsulates the tab portion; and

a cast-on strap comprising lead or lead alloy above the lug and encapsulating at least part of the lug.

15 . A lead-acid battery, comprising:

the composition of claim 1 ;

wherein at least one electrode comprises a battery paste having a concentration gradient of the composition of claim 1 through the thickness of the battery paste.

16 . The lead-acid battery of claim 15 , wherein the highest concentration of the composition of claim 1 is at the surface of the current collector or at the surface of the separator.

17 . The use of the lead-acid battery composition of claim 1 in vehicles equipped with energy regenerative braking systems or start-stop technology for improved fuel efficiency.

18 . The use of the lead-acid battery composition of claim 1 in uninterrupted power supplies and power smoothing.