Bipolar electrode support structures

Claim 2

A bipolar electrode support structure for use in a lead-acid battery comprising a sheet-like member having a first side adapted to support positive active mass and a second side adapted to support negative active mass wherein: (i) at least a portion of said member adjacent said first side comprises a continuous matrix of a metal selected from the group consisting of titanium, tantalum, niobium and zirconium, or of an alloy of said metal which alloy exhibits valve metal-like electrical characteristics; (ii) said matrix has tortuous paths therethrough, the volume of which constitutes about 15 to 55% of the combined volume of said matrix and paths; (iii) said paths are filled adjacent said first side with essentially lead dioxide such that in use said dioxide blocks entry of battery electrolyte into said matrix; (iv) at least part of the remainder of said paths is filled with lead or a lead alloy in electronic conductive contact with said matrix and said dioxide; (v) the extent of penetration of said dioxide from said first side is such as to ensure that in operation the voltage drop between said first side and the lead dioxide-lead metal or alloy interface is sufficient to inhibit substantially anodic formation of any oxidic product of metal at said interface; and (vi) said first side includes a rim portion adjacent the whole perimeter of said member, said rim portion being characterized in that less than 10% of the outer surface thereof is constituted by lead-containing material.

Claim 3

A support structure as claimed in claim 1 wherein said outer surface of said rim portion is essentially lead-free.

Claim 4

A support structure as claimed in claim 1 wherein said rim portion constitutes a predetermined portion of said matrix.

Claim 5

A support structure as claimed in claim 3 wherein none of said tortuous paths of said matrix communicate with said outer surface of said rim portion.

Claim 6

A support structure as claimed in claim 3 wherein any tortuous paths of said matrix which communicate with said outer surface of said rim portion are void of lead-containing material at least adjacent said outer surface.

Claim 7

A support structure as claimed in claim 3 wherein any tortuous paths of said matrix which communicate with said outer surface of said rim portion are essentially filled, at least adjacent said outer surface, with a sealing material inert to battery electrolyte.

Claim 8

A support structure as claimed in claim 6 wherein said sealing material is a ceramic or plastic composition which is resistant to temperatures at least as high as the melting point of lead.

Claim 9

A support structure as claimed in claim 1 wherein said sheet-like member comprises a circular disc, and said outer surface of said rim-portion comprises an annular surface adjacent the edge of said disc.

Claim 10

A support structure as claimed in claim 1 wherein said rim-portion comprises a solid body of said metal or alloy which constitutes said matrix, said solid body being metallurgically bonded to said matrix.

Claim 11

A bipolar electrode support structure for use in a lead-acid battery comprising a sheet-like composite member which includes: a solid sheet of an electronically conductive material selected from the group consisting of titanium, tantalum, niobium, zirconium, and alloys thereof which exhibit valve metal-like electrical characteristics which is inert to battery electrolyte; a continuous matrix of metal or alloy selected from the group consisting of titanium, tantalum, niobium, zirconium, and alloys thereof which exhibit valve metal-like electrical characteristics, said matrix being metallurgically bonded to a surface of said solid sheet and having therein a plurality of tortuous paths, the volume of which constitutes about 15-55% of the combined volume of said matrix and said paths; any of said paths which communicate with the matrix surface remote from said solid sheet having lead dioxide therein such that in use said dioxide blocks entry of battery electrolyte into said matrix; at least part of the remainder of said paths being filled with lead or a lead alloy in electronic conductive contact with said matrix and said dioxide; the extent of penetration of said dioxide from said remote surface being such as to ensure that in operation the voltage drop between said remote surface and the lead dioxide-lead metal or alloy interface is sufficient to inhibit substantial anodic formation of any oxidic products of metal at said interface; and the relative dimensions of said solid sheet and said matrix being such that a rim-portion of said solid sheet adjacent the whole perimeter of said solid sheet is not covered by said matrix.

Claim 12

A bipolar electrode support structure for use in a lead-acid battery comprising a sheet-like composite member which includes: a solid sheet of an electronically conductive material selected from the group consisting of titanium, tantalum, niobium, zirconium, and alloys thereof which exhibit valve metal-like electrical characteristics which is inert to battery electrolyte; a continuous matrix of metal or alloy selected from the group consisting of titanium, tantalum, niobium, zirconium, and alloys thereof which exhibit valve metal-like electrical characteristics, said matrix being metallurgically bonded to a surface of said solid sheet and having therein a plurality of tortuous paths, the volume of which constitutes about 15-55% of the combined volume of said matrix and said paths; any of said paths which communicate with the matrix surface remote from said solid sheet having lead dioxide therein such that in use said dioxide blocks entry of battery electrolyte into said matrix; at least part of the remainder of said paths being filled with lead or a lead alloy in electronic conductive contact with said matrix and said dioxide; the extent of penetration of said dioxide from said remote surface being such as to ensure that in operation the voltage drop between said remote surface and the lead dioxide-lead metal or alloy interface is sufficient to inhibit substantial anodic formation of any oxidic products of metal at said interface; and the relative dimensions of said solid sheet and said matrix being such that a rim-portion of said solid sheet adjacent the whole perimeter of said solid sheet is not covered by said matrix.

Claim 13

A support structure as claimed in claim 10 wherein said solid sheet comprises a sheet of the same metal or alloy as said matrix.

Claim 14

A support structure as claimed in claim 11 wherein said solid sheet comprises a circular disc, and said rim-portion constitutes an annular portion adjacent the edge of said disc.

Claim 15

In a lead-acid battery which comprises a housing; a plurality of disc-shaped electrodes, stacked in parallel to one another within said housing and consisting of a pair of end electrodes, which support respectively positive and negative active mass, and a plurality of bipolar electrodes disposed between said end electrodes, each bipolar electrode having positive active mass on one side thereof and negative active mass on the other side thereof; a plurality of tubular cell wall members each of which is disposed between a respective pair of said electrodes and in sealing contact therewith so as to define therewith an individual cell compartment; and battery electrolyte within each said cell compartment; the improvement whereby each of said bipolar electrodes includes a support structure in accordance with claim 1, wherein said rim-portion comprises an annular surface adapted to co-operate with said respective cell wall member so as to provide said sealing contact.