An Advanced Graphite deep discharge lead acid battery is described including: a deep storage lead acid cell energy storage device comprises: an electrode comprising lead; an electrode comprising lead dioxide; a separator between the electrode comprising lead and the electrode comprising lead dioxide; an aqueous solution electrolyte containing sulfuric acid; and a carbon-based additive having a specific surface area of approximately 250 to 550 m.sup.2/g.

An Advanced Graphite deep discharge lead acid battery is described including: a deep storage lead acid cell energy storage device comprises: an electrode comprising lead; an electrode comprising lead dioxide; a separator between the electrode comprising lead and the electrode comprising lead dioxide; an aqueous solution electrolyte containing sulfuric acid; and a carbon-based additive having a specific surface area of approximately 250 to 550 m.sup.2/g.

The invention relates to a laminar textile material for covering a pasty active mass on a battery electrode. The invention further relates to a battery electrode having such a material, to a battery, and to a method for producing battery electrodes. Potential improvements of lead batteries are disclosed that are more practical than previously known solutions, and that stabilize the pasty active mass on the battery electrodes. A laminar textile material is disclosed to this end, comprising glass fibers and fibers made of a thermoplastic, e.g. polyester.

The invention relates to a laminar textile material for covering a pasty active mass on a battery electrode. The invention further relates to a battery electrode having such a material, to a battery, and to a method for producing battery electrodes. Potential improvements of lead batteries are disclosed that are more practical than previously known solutions, and that stabilize the pasty active mass on the battery electrodes. A laminar textile material is disclosed to this end, comprising glass fibers and fibers made of a thermoplastic, e.g. polyester.

Articles and methods involving pasting papers are generally provided. In certain embodiments, a pasting paper may comprise a plurality of cellulose fibers, a plurality of multicomponent fibers, and a plurality of glass fibers. In some embodiments, the average fiber diameter of each plurality of fibers is greater than or equal to 1 micron. In some embodiments, a pasting paper may have a thickness of less than 0.2 mm, an air permeability of less than or equal to 300 CFM, a 1.28 spg sulfuric acid wicking height of greater than 3 cm, and/or may be configured to have a dry tensile strength in a machine direction of greater than or equal to 1 lb/in after storage in 1.28 spg sulfuric acid at 75 C. for 168 hours. In some embodiments, a pasting paper may be disposed on a battery paste, such as a battery paste for use in a lead-acid battery. In certain cases, forming a battery plate may comprise disposing a pasting paper on a battery paste. In certain cases, a lead-acid battery may be assembled by assembling a first battery plate comprising a pasting paper with a separator and a second battery plate.

A system to create a cell for a monopole or bipole lead acid battery includes a paster to produce wet paste, a first carrier structure to receive the wet paste, and a second carrier structure to receive an electrode substrate. A combining station combines the first carrier structure and corresponding wet paste and the second carrier structure and corresponding electrode substrate into an assembly. An ultrasonic welding system receives the assembly and provides mechanical pressure and ultrasonic energy to the assembly. A removal station via which to remove at least one of the first and second carrier structures to create a modified assembly.

A system to create a cell for a monopole or bipole lead acid battery includes a paster to produce wet paste, a first carrier structure to receive the wet paste, and a second carrier structure to receive an electrode substrate. A combining station combines the first carrier structure and corresponding wet paste and the second carrier structure and corresponding electrode substrate into an assembly. An ultrasonic welding system receives the assembly and provides mechanical pressure and ultrasonic energy to the assembly. A removal station via which to remove at least one of the first and second carrier structures to create a modified assembly.

A battery paste application tooling assembly includes a hopper, a connector assembly, and a clamp assembly. The battery paste application tooling assembly can be equipped in a pasting machine. The hopper receives battery paste material. The hopper has an orifice plate with an orifice therein. The connector assembly is engageable with the orifice plate and disengageable therefrom. The clamp assembly is movable between a first position and a second position. In the first position, the clamp assembly releasable secures the orifice plate to the hopper. In the second position, the clamp assembly permits removal of the orifice plate from the hopper.

A battery paste application tooling assembly includes a hopper, a connector assembly, and a clamp assembly. The battery paste application tooling assembly can be equipped in a pasting machine. The hopper receives battery paste material. The hopper has an orifice plate with an orifice therein. The connector assembly is engageable with the orifice plate and disengageable therefrom. The clamp assembly is movable between a first position and a second position. In the first position, the clamp assembly releasable secures the orifice plate to the hopper. In the second position, the clamp assembly permits removal of the orifice plate from the hopper.

According to one embodiment, a nonwoven fiber mat includes between 10% and 50% by weight of a plurality of first glass fibers having an average diameter of less than 5 m and between 50% and 90% by weight of a plurality of second glass fibers having an average diameter of greater than 6 m. The nonwoven fiber mat also includes an acid resistant binder that binds the first and second glass fibers together. The nonwoven fiber mat has an average pore size of between 1 and 100 m and exhibits an air permeability of below 100 cubic feet per minute per square foot (cfm/ft.sup.2) as measured by the Frazier test at 125 Pa according to ASTM Standard Method D737.