Lead acid battery including a two-layer carbon foam current collector

• US 8,399,134 B2
• Filed: 11/20/2007
• Issued: 03/19/2013
• Est. Priority Date: 11/20/2007
• Status: Expired due to Fees

• Current Assignee: Firefly International Energy Co.
• Original Assignee: Firefly Energy, Inc. (Firefly International Energy Co.)
• Inventors: Kelley, Kurtis C., Maroon, Matthew J.
• Primary Examiner(s): Ridley, Basia
• Assistant Examiner(s): Cullen, Sean P
• Application Number:
  US11/984,632
• Publication Number:
  US 20090130549A1
• Time in Patent Office: 1,946 Days
• Field of Search: 429/122, 429/245, 429/163, 429/233, 429/235, 429/238, 429/239, 429/241, 429/302
• US Class Current: 429/235
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/10 Immobilising of electrolyte
• CPC Class Codes: H01M 4/663 containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 4/668 Composites of electroconductive material and synthetic resins
• CPC Class Codes: H01M 4/73 for lead-acid accumulators, e.g. frame plates
• CPC Class Codes: H01M 4/808 Foamed, spongy materials
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A lead acid battery includes a housing and at least one cell disposed within the housing. Each cell includes at least one positive plate and at least one negative plate and an electrolyte disposed in a volume between the positive and negative plates. The at least one negative plate includes a current collector, consisting essentially of a layer of carbon foam disposed on a substrate, and a chemically active material disposed on the current collector.

Claims

1. A lead acid battery comprising:

a housing;

at least one cell disposed within the housing and including at least one positive plate and at least one negative plate; and

an electrolyte disposed in a volume between the positive and negative plates;

wherein the at least one negative plate includes a current collector, comprising of a layer of carbon foam physically attached to a structured substrate via a system of mechanical fasteners, and a chemically active material disposed on the current collector.

2. The lead acid battery of claim 1, wherein the substrate comprises an electrically conductive material.

3. The lead acid battery of claim 2, wherein the electrically conductive material includes a lead grid.

4. The lead acid battery of claim 1, wherein the substrate comprises glass or a polymer.

5. The lead acid battery of claim 4, where the substrate includes polycarbonate.

6. The lead acid battery of claim 1, wherein the at least one positive plate includes a lead grid current collector.

7. The lead acid battery of claim 6, wherein the lead grid current collector includes a radial or hexagonal grid pattern.

8. The lead acid battery of claim 1, wherein the at least one positive plate includes a carbon foam current collector.

9. The lead acid battery of claim 1, wherein the at least one positive plate includes a current collector consisting essentially of a layer of carbon foam disposed on a substrate.

10. The lead acid battery of claim 1, wherein the electrolyte includes aqueous sulfuric acid.

11. The lead acid battery of claim 1, wherein the electrolyte includes a silica gel.

12. The lead acid battery of claim 1, wherein the carbon foam has a total porosity value of at least 60% and an open porosity value of at least 70%.

13. The lead acid battery of claim 1, wherein the carbon foam has a resistivity value of less than about 1 ohm-cm.

14. The lead acid battery of claim 1, wherein said physical attachment is by a sewn thread.

15. A lead acid battery comprising:

a housing;

at least one cell disposed within the housing and including at least one positive plate and at least one negative plate; and

an electrolyte disposed in a volume between the positive and negative plates;

wherein the at least one negative plate includes a current collector, comprising of a layer of carbon foam physically attached to a structured substrate by a mechanical fastener, and a chemically active material disposed on the current collector.

16. The lead acid battery of claim 15 wherein said mechanical fastener is selected from the group consisting of a staple, a wire, a plastic loop fastener, a rivet, a swaged fastener and a screw.

17. The lead acid battery of claim 15, wherein said structured substrate is an open structure.

18. The lead acid battery of claim 15, wherein said structured substrate is a grid.

19. The lead acid battery of claim 18, wherein said grid has a cross member and a strut.

20. The lead acid battery of claim 15, further comprising a tab, said tab being disposed to establish an electrical connection to said current collector.

21. The lead acid battery of claim 15, further comprising a tab, said tab being in electrical contact with said current collector via an infusion of metal into said current collector.