US4861689A
Expired / Lapsed
US
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Battery element and method for making same
Assignee: Ensci Inc
•
Filing: 1987-11-23
•
Granted: 1989-08-29
•
Expires: 2007-11-23
Abstract
Abstract In a method for producing a battery element useful as at least a positive plate in a lead-acid battery, the element comprising a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces and positive active electrode material associated with the first surface of the matrix, the improvement which comprises: conditioning the first surface to enhance the association of the positive active electrode material and the first surface; and applying and associating the positive active electrode material to the first surface.
Inventors
- 👤 Thomas J. Clough
- 👤 Naum Pinsky
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 16:05
CPC Classifications
H; H01; H01M; H01M10/00; H01M10/06; H01M10/18; H01M4/00; H01M4/02; H01M4/14; H01M4/64; H01M4/66; H01M4/661; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49108; Y10T29/49115
Claims Analysis
Total Claims: 91
Claim 1
Independent Claim
100 words
In a method for producing a battery element useful as at least a positive plate in a lead-acid battery, said element comprising a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces and positive active electrode material associated with said first surface of said matrix, the improvement which comprises: conditioning said first surface to render said first surface more wettable by said positive active electrode material or a precursor thereof to enhance the association of said positive active electrode material and said first surface; and applying and associating said positive active electrode material to said first surface.
Claim 2
Dependent Claim
100 words
In a method for producing a battery element useful as at least a positive plate in a lead-acid battery, said element comprising a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces and positive active electrode material associated with said first surface of said matrix, the improvement which comprises: conditioning said first surface to render said first surface more wettable by said positive active electrode material or a precursor thereof to enhance the association of said positive active electrode material and said first surface; and applying and associating said positive active electrode material to said first surface.
Claim 3
Dependent Claim
17 words
The method of claim 1 wherein said conditioning comprises contacting said first surface with a wetting agent.
Claim 4
Dependent Claim
16 words
The method of claim 1 wherein said conditioning increases the hydrophilic nature of said first surface.
Claim 5
Dependent Claim
22 words
The method of claim 1 wherein said conditioning acts to attache hydrophilic groups to said matrix at or near said first surface.
Claim 6
Dependent Claim
19 words
The method of claim 1 wherein said conditioning comprises subjecting said first surface to the action of a plasma.
Claim 7
Dependent Claim
23 words
The method of claim 1 wherein said conditioning comprises subjecting said first surface to the action of a plasma in an oxidizing medium.
Claim 8
Dependent Claim
11 words
The method of claim 1 wherein said oxidizing medium contains ozone.
Claim 9
Dependent Claim
17 words
The method of claim 1 wherein said conditioning comprises applying a coupling material to said first surface.
Claim 10
Dependent Claim
30 words
The method of claim 8 wherein said coupling material comprises a mixture containing a polymer effective to wet said first surface, and said positive active electrode material or precursor thereof.
Claim 11
Dependent Claim
11 words
The method of claim 1 wherein said matrix includes polymeric material.
Claim 12
Dependent Claim
11 words
The method of claim 10 wherein said polymeric material is hydrophobic.
Claim 13
Dependent Claim
15 words
The method of claim 10 wherein said polymeric material has increased polarity relative to polypropylene.
Claim 14
Dependent Claim
14 words
The method of claim 10 wherein said polymeric material is a thermoset polymeric material.
Claim 15
Dependent Claim
33 words
The method of claim 1 wherein said element further comprises an acid resistant substrate at least partially coated with an electrically conductive coating, said substrate being at least partially embedded in said matrix.
Claim 16
Dependent Claim
28 words
The method of claim 14 wherein a portion of said coated substrate extends outwardly from said first surface of said matrix and into said positive active electrode material.
Claim 17
Dependent Claim
19 words
The method of claim 14 wherein said acid resistant substrate is glass and said coating is doped tin oxide.
Claim 18
Dependent Claim
17 words
The method of claim 1 wherein said positive active electrode material contains electrochemically active lead oxide material.
Claim 19
Dependent Claim
31 words
The method of claim 1 wherein said positive active e material is applied to said first surface as an aqueous mixture containing said positive active electrode material or a precursor thereof.
Claim 20
Dependent Claim
43 words
The method of claim 1 wherein said positive active electrode material is associated with said first surface by curing said positive active electrode material or a precursor thereof after said positive active electrode material or precursor thereof is applied to said first surface.
Claim 21
Dependent Claim
41 words
The method of claim 1 wherein said battery element is useful as a bipolar plate in a lead-acid battery, and further comprises a fluid impervious conductive layer that is resistant to reduction adjacent to said second surface of said matrix material.
Claim 22
Dependent Claim
26 words
The method of claim 20 wherein said conductive layer is selected from the group consisting of metals substantially non-conductive polymers containing conductive materials, and mixtures thereof.
Claim 23
Dependent Claim
29 words
The method of claim 21 wherein said conductive layer is a non-conductive polymer containing particles of a material selected from the group consisting of graphite, lead and mixtures thereof.
Claim 24
Dependent Claim
24 words
The method of claim 20 wherein said battery element further comprises a negative active electrode layer located adjacent to said fluid impervious conductive layer.
Claim 25
Dependent Claim
16 words
The method of claim 23 wherein said negative active electrode layer comprises a paste containing lead.
Claim 26
Dependent Claim
68 words
A battery element useful as at least a positive plate in a lead-acid battery comprising: a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces, said first surface being conditioned to render said first surface more wettable by said positive active electrode material or a precursor thereof; and positive active electrode material associated with said first surface and being situated in a plurality of segments.
Claim 27
Dependent Claim
68 words
A battery element useful as at least a positive plate in a lead-acid battery comprising: a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces, said first surface being conditioned to render said first surface more wettable by said positive active electrode material or a precursor thereof; and positive active electrode material associated with said first surface and being situated in a plurality of segments.
Claim 28
Dependent Claim
34 words
The battery element of claim 25 which further comprises segmenting means associated with said first surface and acting to partially define said plurality of segments in which said positive active electrode material is located.
Claim 29
Dependent Claim
27 words
The battery element of claim 25 wherein each of said segments is in the range of about 0.1 square inch to about 2.5 square inches in area.
Claim 30
Dependent Claim
24 words
The battery element of claim 26 wherein said segmenting means is made of a material selected from the group consisting of lead and polymers.
Claim 31
Dependent Claim
22 words
The battery element of claim 26 wherein said segmenting means is made of a material selected from the group consisting of polymers.
Claim 32
Dependent Claim
13 words
The battery element of claim 36 wherein said matrix includes a polymeric material.
Claim 33
Dependent Claim
26 words
The battery element of claim 30 wherein said segmenting means includes polymer material having substantially the same composition as said polymeric material included in said matrix.
Claim 34
Dependent Claim
16 words
The battery element of claim 30 wherein said polymeric material has increased polarity relative to polypropylene.
Claim 35
Dependent Claim
12 words
The battery element of claim 30 wherein said polymeric material is hydrophobic.
Claim 36
Dependent Claim
15 words
The battery element of claim 30 wherein said polymeric material is a thermoset polymeric material.
Claim 37
Dependent Claim
32 words
The battery element of claim 25 which further comprises an acid resistant substrate at least partially coated with an electrically conductive coating, said substrate being at least partially embedded in said matrix.
Claim 38
Dependent Claim
21 words
The battery element of claim 35 wherein said acid resistant substrate is glass and said coating is fluorine doped tin oxide.
Claim 39
Dependent Claim
20 words
The battery element of claim 35 wherein said acid resistant substrate is glass and said coating is doped tin oxide.
Claim 40
Dependent Claim
18 words
The battery element of claim 25 wherein said positive active electrode material contains electrochemically active lead oxide material.
Claim 41
Dependent Claim
42 words
The battery element of claim 25 wherein said battery element is useful as a bipolar plate in a lead-acid battery, and further comprises a fluid impervious conductive layer that is resistant to reduction adjacent to said second surface of said matrix material.
Claim 42
Dependent Claim
27 words
The battery element of claim 39 wherein said conductive layer is selected from the group consisting of metals, substantially non-conductive polymers containing conductive materials, and mixtures thereof.
Claim 43
Dependent Claim
30 words
The battery element of claim 40 wherein said conductive layer is a non-conductive polymer containing particles of a material selected from the group consisting of graphite, lead and mixtures thereof.
Claim 44
Dependent Claim
25 words
The battery element of claim 39 wherein said battery element further comprises a negative active electrode layer located adjacent to said fluid impervious conductive layer.
Claim 45
Dependent Claim
17 words
The battery element of claim 42 wherein said negative active electrode layer comprises a paste containing lead.
Claim 46
Dependent Claim
69 words
A battery element useful as at least a positive plate in a lead-acid battery comprising a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces, and positive active electrode material associated with said first surface of said matrix, provided that said first surface is conditioned to render said first surface more wettable by said positive active electrode material or a precursor thereof to enhance said association.
Claim 47
Dependent Claim
69 words
A battery element useful as at least a positive plate in a lead-acid battery comprising a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces, and positive active electrode material associated with said first surface of said matrix, provided that said first surface is conditioned to render said first surface more wettable by said positive active electrode material or a precursor thereof to enhance said association.
Claim 48
Dependent Claim
22 words
The battery element of claim 44 wherein said first surface is conditioned prior to said positive active electrode material being associated therewith.
Claim 49
Dependent Claim
41 words
The battery element of claim 44 wherein said positive active electrode material is adhered to said first surface of said matrix and said first surface is conditioned prior to said positive active electrode material being adhered thereto to enhance said adhesion.
Claim 50
Dependent Claim
13 words
The battery element of claim 44 wherein said matrix includes a polymeric material.
Claim 51
Dependent Claim
16 words
The battery element of claim 47 wherein said polymeric material has increased polarity relative to polypropylene.
Claim 52
Dependent Claim
12 words
The battery element of claim 47 wherein said polymeric material is hydrophobic.
Claim 53
Dependent Claim
15 words
The battery element of claim 47 wherein said polymeric material is a thermoset polymeric material.
Claim 54
Dependent Claim
32 words
The battery element of claim 44 which further comprises an acid resistant substrate at least partially coated with an electrically conductive coating, said substrate being at least partially embedded in said matrix.
Claim 55
Dependent Claim
29 words
The battery element of claim 51 wherein said portion of said coated substrate extends outwardly from said first surface of said matrix and into said positive active electrode material.
Claim 56
Dependent Claim
20 words
The battery element of claim 51 wherein said acid resistant substrate is glass and said coating is doped tin oxide.
Claim 57
Dependent Claim
18 words
The battery element of claim 44 wherein said positive active electrode material contains electrochemically active lead oxide material.
Claim 58
Dependent Claim
42 words
The battery element of claim 44 wherein said battery element is useful as a bipolar plate in a lead-acid battery, and further comprises a fluid impervious conductive layer that is resistant to reduction adjacent to said second surface of said matrix material.
Claim 59
Dependent Claim
27 words
The battery element of claim 55 wherein said conductive layer is selected from the group consisting of metals, substantially non-conductive polymers containing conductive materials, and mixtures thereof.
Claim 60
Dependent Claim
30 words
The battery element of claim 56 wherein said conductive layer is a non-conductive polymer containing particles of a material selected from the group consisting of graphite, lead and mixtures thereof.
Claim 61
Dependent Claim
25 words
The battery element of claim 55 wherein said battery element further comprises a negative active electrode layer located adjacent to said fluid impervious conductive layer.
Claim 62
Dependent Claim
17 words
The battery element of claim 58 wherein said negative active electrode layer comprises a paste containing lead.
Claim 63
Dependent Claim
25 words
The battery element of claim 25 wherein said first surface is conditioned by a method which comprises contacting said first surface with a wetting agent.
Claim 64
Dependent Claim
21 words
The battery element of claim 25 wherein said first surface is conditioned to increase the hydrophilic nature of said first surface.
Claim 65
Dependent Claim
27 words
The battery element of claim 25 wherein said first surface is conditioned by a method which comprises subjecting said first surface to the action of a plasma.
Claim 66
Dependent Claim
21 words
The battery element of claim 28 wherein said matrix includes a polymeric material selected from the group consisting of phenol-formaldehyde polymers.
Claim 67
Dependent Claim
25 words
The battery element of claim 44 wherein said first surface is conditioned by a method which comprises contacting said first surface with a wetting agent.
Claim 68
Dependent Claim
21 words
The battery element of claim 44 wherein said first surface is conditioned to increase the hydrophilic nature of said first surface.
Claim 69
Dependent Claim
27 words
The battery element of claim 44 wherein said first surface is conditioned by a method which comprises subjecting said first surface to the action of a plasma.
Claim 70
Dependent Claim
21 words
The battery element of claim 44 wherein said matrix includes a polymeric material selected from the group consisting of phenol-formaldehyde polymers.
Claim 71
Dependent Claim
21 words
The battery element of claim 51 wherein said acid resistant substrate is glass and said coating is fluorine doped tine oxide.
Claim 72
Dependent Claim
67 words
A battery element useful as at least a positive plate in a lead-acid battery comprising: a fluid impervious, matrix having mutually opposing first and second surfaces; an acid resistant substrate at least partially coated with an electrically conductive coating, said substrate being at least partially embedded in said matrix; and positive active electrode material associated with said first surface and being situated in a plurality of segments.
Claim 73
Dependent Claim
67 words
A battery element useful as at least a positive plate in a lead-acid battery comprising: a fluid impervious, matrix having mutually opposing first and second surfaces; an acid resistant substrate at least partially coated with an electrically conductive coating, said substrate being at least partially embedded in said matrix; and positive active electrode material associated with said first surface and being situated in a plurality of segments.
Claim 74
Dependent Claim
28 words
The battery element of claim 69 which further comprises segmenting means acting to partially define said plurality of segments in which said positive active electrode material is located.
Claim 75
Dependent Claim
24 words
The battery element of claim 70 wherein said segmenting means is made of a material selected from the group consisting of lead and polymers.
Claim 76
Dependent Claim
22 words
The battery element of claim 70 wherein said segmenting means is made of a material selected from the group consisting of polymers.
Claim 77
Dependent Claim
19 words
The battery element of claim 69 wherein said acid substrate is glass and said coating is doped tin oxide.
Claim 78
Dependent Claim
21 words
The battery element of claim 70 wherein said acid resistant substrate is glass and said coating is fluorine doped tin oxide.
Claim 79
Dependent Claim
65 words
A battery element useful as a bipolar plate in a lead-acid battery comprising: a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces; positive active electrode material associated with said first surface and being situated in a plurality of segments; and a fluid impervious conductive layer that is resistant to reduction and is located adjacent to said second surface of said matrix.
Claim 80
Dependent Claim
65 words
A battery element useful as a bipolar plate in a lead-acid battery comprising: a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces; positive active electrode material associated with said first surface and being situated in a plurality of segments; and a fluid impervious conductive layer that is resistant to reduction and is located adjacent to said second surface of said matrix.
Claim 81
Dependent Claim
27 words
The battery element of claim 75 wherein said conductive layer is selected from the group consisting of metals, substantially non-conductive polymers containing conductive materials and mixtures thereof.
Claim 82
Dependent Claim
37 words
The battery element of claim 75 wherein said conductive layer is selected from the group consisting of lead and non-conductive polymers containing particles of a material selected from the group consisting of graphite, lead and mixtures thereof.
Claim 83
Dependent Claim
21 words
The battery element of claim 75 which further comprises a negative active electrode located adjacent to said fluid impervious conductive layer.
Claim 84
Dependent Claim
17 words
The battery element of claim 78 wherein said negative active electrode layer comprises a paste containing lead.
Claim 85
Dependent Claim
28 words
The battery element of claim 75 which further comprises segmenting means acting to partially define said plurality of segments in which said positive active electrode material is located.
Claim 86
Dependent Claim
24 words
The battery element of claim 80 wherein said segmenting means is made of a material selected from the group consisting of lead and polymers.
Claim 87
Dependent Claim
22 words
The battery element of claim 80 wherein said segmenting means is made of a material selected from the group consisting of polymers.
Claim 88
Dependent Claim
21 words
The battery element of claim 75 wherein said matrix includes a polymeric material selected from the group consisting of phenol-formaldehyde polymers.
Claim 89
Dependent Claim
32 words
The battery element of claim 75 which further comprises an acid resistant substrate at least partially coated with an electrically conductive coating, said substrate being at least partially embedded in said matrix.
Claim 90
Dependent Claim
20 words
The battery element of claim 84 wherein said acid resistant substrate is glass and said coating is doped tin oxide.
Claim 91
Dependent Claim
21 words
The battery element of claim 84 wherein said acid resistant substrate is glass and said coating is fluorine doped tin oxide.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1992-08-28 | 1993-02-27 | 1993-08-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-08-28 | 1997-02-27 | 1997-08-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-08-28 | 2001-02-27 | 2001-08-29 | $7700.00 | Window Closed / Lapsed |