A current collector assembly, such as for a bipolar lead acid battery, can include an electrically-conductive silicon substrate and a frame bonded to the electrically-conductive silicon substrate. The substrate can be treated or modified, such as to include one or more thin films which render a surface substrate electrically conductive and electrochemically stable in the presence of a lead acid electrolyte chemistry. An interface between the frame and the electrically-conductive silicon substrate can be hermetically sealed. In an example, the frame can provide an edge-seal ring configuration. In an example, a casing assembly can include a spacer bonded to the substrate, along with a casing segment and a thermally-conductive rib, the spacer isolating the thermally-conductive rib from the electrically-conductive silicon substrate electrically.

The present disclosure is directed to bi-polar plates for use in lead-acid batteries, and methods of making the same. The bi-polar plates of the present disclosure comprise first and second conductive plates of lead joined by a plurality of connections through a plastic substrate. The connections may be formed by welding or in the process of casting the conductive plates, resulting in connections that are chemically homogenous with the conductive plates themselves. In addition, the welding and casting processes of the present disclosure offer significant time savings in the production of bi-polar plates.

A method for fabricating a reticulated lead electrode for a lead-acid battery, including: preparing a molten metal in a container; applying a DC voltage to the molten metal and the substrate; while the DC voltage is applied, placing a reticulated ceramic substrate in the molten metal; while the DC voltage is applied, withdrawing the substrate from the molten metal; and cooling the substrate. The method may be used to form reticulated electrodes for other types of batteries or capacitors. Also described is a method for making a reticulated ceramic substrate, including: adhering mineral fibers such as milled glass fibers on the surfaces of a reticulated PU substrate with an adhesive; coating the reticulated PU substrate with a ceramic slurry with the assistance ultrasonic waves; pre-baking the dried slurry at a low temperature to vaporizes the polymer substrate; and baking the substrate at sintering temperature of the ceramic slurry.

A method for fabricating a reticulated lead electrode for a lead-acid battery, including: preparing a molten metal in a container; applying a DC voltage to the molten metal and the substrate; while the DC voltage is applied, placing a reticulated ceramic substrate in the molten metal; while the DC voltage is applied, withdrawing the substrate from the molten metal; and cooling the substrate. The method may be used to form reticulated electrodes for other types of batteries or capacitors. Also described is a method for making a reticulated ceramic substrate, including: adhering mineral fibers such as milled glass fibers on the surfaces of a reticulated PU substrate with an adhesive; coating the reticulated PU substrate with a ceramic slurry with the assistance ultrasonic waves; pre-baking the dried slurry at a low temperature to vaporizes the polymer substrate; and baking the substrate at sintering temperature of the ceramic slurry.

A pasting carrier for a lead-acid battery. The pasting carrier includes a nonwoven fiber mat having a thickness between 5 and 50 mils, the nonwoven fiber mat being composed of a plurality of entangled glass microfibers.

A pasting carrier for a lead-acid battery. The pasting carrier includes a nonwoven fiber mat having a thickness between 5 and 50 mils, the nonwoven fiber mat being composed of a plurality of entangled glass microfibers.

A method of making a battery current collector foil includes heat treating a foil sheet and mechanically roughening the heat treated foil sheet to create a surface roughness of between 2-4 m. The heat treating and mechanical roughening of the foil sheet provides improved coating adhesion. One of an anode and cathode coating is then applied to the roughened, heat treated, foil sheet.

A method of making a battery current collector foil includes heat treating a foil sheet and mechanically roughening the heat treated foil sheet to create a surface roughness of between 2-4 m. The heat treating and mechanical roughening of the foil sheet provides improved coating adhesion. One of an anode and cathode coating is then applied to the roughened, heat treated, foil sheet.

A manufacturing method of a power storage device includes: an arrangement step of arranging a first resin member on a first surface of a metal foil and arranging a second resin member on a second surface of the metal foil; and a welding step of arranging a first pressurizing member and a second pressurizing member on a surface on an opposite side of the first resin member and the second resin member, respectively, from a surface on the metal foil side, and irradiating the end portion of the metal foil with an electromagnetic wave from the first pressurizing member side while pressurizing the end portion with the first pressurizing member and the second pressurizing member so as to weld the first resin member and the second resin member to the metal foil such that the end portion of the metal foil is covered.

A manufacturing method of a power storage device includes: an arrangement step of arranging a first resin member on a first surface of a metal foil and arranging a second resin member on a second surface of the metal foil; and a welding step of arranging a first pressurizing member and a second pressurizing member on a surface on an opposite side of the first resin member and the second resin member, respectively, from a surface on the metal foil side, and irradiating the end portion of the metal foil with an electromagnetic wave from the first pressurizing member side while pressurizing the end portion with the first pressurizing member and the second pressurizing member so as to weld the first resin member and the second resin member to the metal foil such that the end portion of the metal foil is covered.