Coated lead acid battery electrode plates; method for making coated electrode plates and lead acid batteries containing coated electrode plates

1. An electrode plate for a lead acid battery having a coating comprising:

an electrode plate for a lead acid battery comprising a lead or lead alloy grid coated with an active material and

a porous, non-woven mat comprised of polymer fibers arranged with the electrode plate.

2. The electrode plate of claim 1 wherein the lead alloy is a lead-antimony, a lead-calcium or a lead-tin grid.

3. The electrode plate of claim 2 wherein the alloy is a lead-antimony alloy.

4. The electrode plate of claim 2 wherein the active material is a lead oxide active material.

5. The electrode plate of claim 1 wherein the polymer fibers have a fiber diameter of from about 5 nm and about 30 μm.

6. The electrode plate of claim 1 wherein the polymer fibers have a fiber diameter of from 500 nm to about 1 μm.

7. The electrode plate of claim 1 wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g.

8. The electrode plate of claim 1 wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g.

9. The electrode plate of claim 1 wherein the polymer fiber coating has a porosity of from 30% to about 90%.

10. The electrode plate of claim 1 wherein the polymer fiber coating has a porosity of from about 50% to about 70%.

11. The electrode plate of claim 1 wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm.

12. The electrode plate of claim 1 wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm.

13. The electrode plate of claim 1 wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm.

14. The electrode plate of claim 1 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof.

15. The electrode plate of claim 14 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers.

16. The electrode plate of claim 1 wherein the polymer fiber coating further comprises an active agent.

17. The electrode plate of claim 16 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof.

18. The electrode plate of claim 1 wherein the electrode plate is a positive electrode plate for a lead acid battery.

19. The electrode plate of claim 1 wherein the electrode plate is a negative electrode plate for a lead acid battery.

20. The electrode plate of claim 1 wherein the electrode plate comprises a face, and the porous, non-woven mat is coated on the face of the electrode plate.

21. A method for coating an electrode plate for a lead acid battery comprising the step of:

electrospinning a polymer onto the surface of an electrode plate collector, the electrode plate collector comprising a lead or lead alloy grid coated with an active material, to form a porous, non-woven mat coating comprised of polymer fibers on the surface of the electrode plate collector.

22. The method of claim 21 wherein the lead alloy grid is a lead-antimony, a lead-calcium or a lead-tin alloy grid.

23. The electrode plate of claim 22 wherein the alloy is a lead-antimony alloy.

24. The electrode plate of claim 23 wherein the active material is a lead oxide active material.

25. The method of claim 21 wherein the polymer fibers comprising the porous, non-woven mat coating have a fiber diameter of from 5 nm and about 30 μm.

26. The method of claim 21 wherein the polymer fibers comprising the porous, non-woven mat coating have a fiber diameter of from 500 nm to about 1 μm.

27. The method of claim 21 wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g.

28. The method of claim 21 wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g.

29. The method of claim 21 wherein the polymer fiber coating has a porosity of from 30% to about 90%.

30. The method of claim 21 wherein the polymer fiber coating has a porosity of from about 50% to about 70%.

31. The method of claim 21 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof.

32. The method of claim 31 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers.

33. The method of claim 21 further comprising the step of formulating the polymer to be electrospun spun as a solution comprising the polymer and a solvent for the polymer.

34. The method of claim 33 wherein the polymer solution further comprises an active agent.

35. The method of claim 34 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof.

36. The method of claim 33 wherein the solvent is formic acid, dimethyl formamide, n-methylpyrrolidone, acetone, ethyl acetate, propyl acetate, water, dichloromethane, tetrahydrofuran, isopropyl alcohol, dicloromethane, ethanol, methanol, chloroform, acid acid, trifluoroacetic acid, trifluoroethanol, hexafluoro propanol, dimethylacetamide, carbon disulfide, cyclohexane, toluene, N-methylmorpholine, xylenes and dimethylsulfoxide or combinations thereof.

37. The method of claim 36 wherein the solvent is formic acid or dimethyl formamide.

38. The method of claim 31 further comprising the step of formulating the polymer to be electrospun spun as a polymer melt.

39. The method of claim 38 wherein the polymer melt further comprises an active agent.

40. The method of claim 39 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof.

41. The method of claim 31 wherein the electrode plate collector is a positive electrode plate for a lead acid battery.

42. The method of claim 31 wherein the electrode plate collector is a negative electrode plate for a lead acid battery.

43. The method of claim 21 wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm.

44. The method of claim 21 wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm.

45. The method of claim 21 wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm.

46. A lead acid battery comprising:

a housing containing

a negative electrode plate;

a positive electrode plate, where the electrode plates are comprised of a lead or lead alloy grid coated with an active material;

a separator disposed between the first and second electrode plates;

an electrolyte immersing the negative electrode plate, the positive electrode plate the separator;

a porous, non-woven mat comprised of polymer fiber arranged with one of the electrode plates.

47. The lead acid battery of claim 46 wherein the lead alloy grid is a lead-antimony, a lead-calcium or a lead-tin alloy grid.

48. The lead acid battery of claim 47 wherein the alloy is an antimony.

49. The lead acid battery of claim 46 wherein the active material is a lead oxide active material.

50. The lead acid battery of claim 46 wherein the polymer fibers have a fiber diameter of from 5 nm and about 30 μm.

51. The electrode of claim 46 wherein the polymer fibers have a fiber diameter of from 500 nm to about 1 μm.

52. The lead acid battery of claim 46 wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g.

53. The lead acid battery of claim 46 wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g.

54. The lead acid battery of claim 46 wherein the polymer fiber coating has a porosity of from 30% to about 90%.

55. The lead acid battery of claim 46 wherein the polymer fiber coating has a porosity of from about 50% to about 70%.

56. The lead acid battery of claim 46 wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm.

57. The lead acid battery of claim 46 wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm.

58. The lead acid battery of claim 46 wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm.

59. The lead acid battery of claim 46 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof.

60. The lead acid battery of claim 59 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers.

61. The lead acid battery of claim 46 wherein the polymer fiber coating further comprises an active agent.

62. The lead acid battery of claim 61 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof.

63. The lead acid battery of claim 46 wherein the lead acid battery is a flooded lead acid battery or a valve regulated lead acid battery.

64. The lead acid battery of claim 63 wherein the lead acid battery is a flooded lead acid battery.

65. The lead acid battery of claim 63 wherein the lead acid battery is a valve regulated lead acid battery.

66. The lead acid battery of claim 65 wherein the valve regulated lead acid battery is an AGS lead acid battery or a gel lead acid battery.

67. The lead acid battery of claim 49 wherein the negative electrode plate comprises a first face and the positive electrode plate comprises a second face opposing the first face, and wherein the porous, non-woven mat is coated on said one of the electrode plates.