FREESTANDING LAMINATE, METHOD FOR THE MANUFACTURE THEREOF, AND METHOD OF MAKING A LEAD CARBON BATTERY

1 . A freestanding laminate, comprising

a separator; and

an anode layer comprising an electrically conductive carbon active material comprising greater than or equal to 60 weight percent of an activated carbon;

1 to 40 weight percent of a binder; and

0 to 10 weight percent of an electrically conductive filler;

wherein weight percent of each component is based on the total weight of the anode layer; and

wherein the anode layer is in direct physical contact with a first side of the separator.

2 . The freestanding laminate of claim 1 , wherein the separator comprises an acid-resistant, porous sheet having a thickness of 3 millimeters or less and a porosity of greater than 30%.

3 . The freestanding laminate of claim 1 , wherein the separator comprises an absorbent glass mat, a polyvinyl chloride, a polyolefin, a non-woven fiber glass mat, an activated carbon cloth, a carbon nanofiber cloth, or a carbon nanotube cloth.

4 . The freestanding laminate of claim 1 , wherein the electrically conductive filler is present, and comprises at least one of carbon black, graphite, carbon nanotubes, carbon fibers, or graphene.

5 . The freestanding laminate of claim 1 , wherein the binder comprises poly(vinylidene fluoride).

6 . The freestanding laminate of claim 1 , wherein the anode layer comprises 85 to 99 weight percent of the activated carbon based on the total weight of the active layer, and 1 to 15 weight percent of the binder based on the total weight of the active layer.

7 . The freestanding laminate of claim 1 , wherein the anode layer has a thickness of 0.5 to 10 millimeters.

8 . The freestanding laminate of claim 1 , wherein the anode layer has a density of 0.5 to 1.0 grams per cubic centimeter.

9 . The freestanding laminate of claim 1 , wherein the anode layer has a porosity of 30 to 75 volume percent.

10 . The freestanding laminate of claim 1 , wherein the anode layer further comprises a reinforcing filler.

11 . The freestanding laminate of claim 10 , wherein the reinforcing filler comprises glass fibers, carbon fibers, polymeric fibers, or a combination thereof.

12 . A method of making a freestanding laminate comprising

a separator; and

an anode layer comprising an electrically conductive carbon active material comprising greater than or equal to 60 weight percent of an activated carbon;

1 to 40 weight percent of a binder; and

0 to 10 weight percent of an electrically conductive filler;

wherein weight percent of each component is based on the total weight of the anode layer; and

wherein the anode layer is in direct physical contact with a first side of the separator;

the method comprising

applying the anode layer to the first side of the separator.

13 . The method of claim 12 , wherein the applying comprises

forming a powder comprising the electrically conductive carbon active material;

applying the powder to the separator; and

calendering to provide the freestanding laminate.

14 . The method of claim 12 , wherein the applying comprises

applying a flocculated material comprising the electrically conductive carbon active material to the separator; and

calendering to provide the freestanding laminate.

15 . The method of claim 12 , wherein the applying comprises

forming a powder comprising the electrically conductive carbon active material;

applying the powder to the separator; and

compression molding the powder to the separator to provide the freestanding laminate.

16 . The method of any of claim 12 , further comprising cutting the freestanding laminate into a preselected shape.

17 . An energy storage device comprising the freestanding laminate of claim 1 .

18 . A method of making a lead carbon battery, the method comprising:

attaching a lead oxide cathode to the separator of the freestanding laminate of claim 1 ;

enclosing the lead oxide cathode adhered to the freestanding laminate in a case; and introducing an acid into the case such that the cathode and the anode are at least partially immersed in the acid.