Lightweight laminated grid for lead-acid storage batteries

• US 4,221,854 A
• Filed: 02/09/1979
• Issued: 09/09/1980
• Est. Priority Date: 02/09/1979
• Status: Expired due to Term

• Current Assignee: General Motors Corporation (Motors Liquidation Co. GUC Trust)
• Original Assignee: General Motors Corporation (Motors Liquidation Co. GUC Trust)
• Inventors: Hammar, Richard H., Harvey, Douglas J.
• Primary Examiner(s): LeFevour, Charles F.
• Application Number:
  US06/010,898
• Time in Patent Office: 578 Days
• Field of Search: 429/234, 429/241, 429/243, 429/244
• US Class Current: 429/234
• CPC Class Codes: H01M 4/68 for use in lead-acid accumulators
• CPC Class Codes: H01M 4/745 Expanded metal
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Lightweight grids for lead-sulfuric acid type storage batteries are characterized by their laminated reticulated open meshed portions for retaining chemically active, lead-based paste materials. The laminated portions comprise a support layer of a rigid or semi-rigid plastic, an electrically conductive lead foil layer coextensive with the plastic layer, and a sulfuric acid resistant adhesive bonding layer between the plastic support and foil layers. In a preferred embodiment, the grid wires and nodes are twisted relative to the principal plane of the grid so that the lead foil layer is oriented to face the grid header portion and act as a ledge for retaining a desired battery paste. Such laminated grids may be rapidly and inexpensively formed by expanded metal processes of the type used to make battery grids made entirely of lead.

Claims

1. A lightweight grid for a lead-sulfuric acid type storage battery, said grid having a laminated reticulated open mesh portion for retaining chemically active lead-based paste material, said laminated portion comprising:

a support layer of a plastic material chemically compatible with the battery environment;

an electrically conductive foil layer coextensive with a face of said support layer, said foil being formed of a composition selected from the group consisting of lead and lead alloys and said foil layer being adapted for contact with a said paste material; and

a sulfuric acid resistant adhesive bonding layer between said support and foil layers.

2. A lightweight laminated grid for a lead-sulfuric acid type storage battery wherein said grid has a header portion for collecting grid current and a depending reticulated open mesh portion for retaining chemically active lead-based paste material, at least said open mesh portion comprising:

a support layer of a plastic material chemically compatible with the battery environment;

an electrically conductive foil layer coextensive with a face of said support layer, said foil being formed of a composition selected from the group consisting of lead or lead alloys and said foil layer being adapted for contact with a said paste material; and

a sulfuric acid resistant adhesive bonding layer between said support and foil layers.

3. A lightweight substantially flat grid for a lead-sulfuric acid type storage battery, said grid having a header portion and a pendant expanded open mesh portion for supporting a battery paste, said mesh portion comprising a network of grid wires interconnected at nodes, at least said open mesh portion being formed of a trilaminate comprising a support layer of a synthetic polymeric plastic material chemically compatible with the battery environment;

a foil layer of lead or lead alloy coextensive with a face of said support layer; and

an intermediate flexible, sulfuric acid resistant adhesive layer bonding together said support and foil layers,

said grid wires and nodes being twisted relative to the principal plane of the grid to provide foil-surfaced ledge-like portions for carrying said paste material.

4. An expanded open mesh lightweight laminate grid for a lead-sulfuric acid type storage battery formed of a trilaminate sheet having a supporting layer of a thermoplastic material chemically compatible with the battery environment, said layer having a thickness of about 0.25 to 2.5 millimeters;

a foil layer consisting essentially of lead or a lead alloy, said foil having a thickness of about 0.05 to 0.5 millimeters; and

a hot melt adhesive bonding layer between said supporting and foil layers.

5. A lightweight grid for a lead-sulfuric acid type storage battery, said grid having a header portion for collecting grid current and a pendant open mesh portion for retaining chemically active lead-based paste material comprising a reticulated open mesh network of grid wires interconnected by nodes, at least said open mesh grid portion comprising:

a support layer of a plastic material chemically compatible with the battery environment;

an electrically conductive foil layer coextensive with a face of said support layer, said foil being formed of a composition selected from the group consisting of lead and lead alloys; and

an intermediate sulfuric acid resistant adhesive layer bonding together said support and foil layers;

wherein said open mesh portion of said grid, the grid wires and nodes are twisted relative to the principal plane of the grid such that the coextensive foil layer thereof is oriented at an angle to face said pendant header portion and form ledges for retaining a said paste material in contact with said foil layer and within the mesh openings defined by said network.