According to one embodiment, a plate or electrode for a lead-acid battery includes a grid of lead alloy material, a paste of active material applied to the grid of lead alloy material, and a nonwoven fiber mat disposed at least partially within the paste of active material. The nonwoven fiber mat includes a plurality of fibers, a binder material that couples the plurality of fibers together, and a conductive material disposed at least partially within the nonwoven fiber mat so as to contact the paste of active material. In some embodiments, the nonwoven fiber mat may have an electrical resistant of less than about 100,000 ohms per square to enable electron flow on a surface of the nonwoven fiber mat.

According to one embodiment, a plate or electrode for a lead-acid battery includes a grid of lead alloy material, a paste of active material applied to the grid of lead alloy material, and a nonwoven fiber mat disposed at least partially within the paste of active material. The nonwoven fiber mat includes a plurality of fibers, a binder material that couples the plurality of fibers together, and a conductive material disposed at least partially within the nonwoven fiber mat so as to contact the paste of active material. In some embodiments, the nonwoven fiber mat may have an electrical resistant of less than about 100,000 ohms per square to enable electron flow on a surface of the nonwoven fiber mat.

A machine for and method of making a paste of active material for application to a grid to make a plate for a lead acid battery. In the machine and method sulfuric acid, at least one dry additive and red lead or leady oxide are mixed together and the mixture is cooled by a plurality of cooling zones to maintain the mixture at a temperature not greater than a predetermined maximum temperature.

A machine for and method of making a paste of active material for application to a grid to make a plate for a lead acid battery. In the machine and method sulfuric acid, at least one dry additive and red lead or leady oxide are mixed together and the mixture is cooled by a plurality of cooling zones to maintain the mixture at a temperature not greater than a predetermined maximum temperature.

A battery grid is disclosed. The battery grid includes a pattern of grid wires. The pattern includes a grid wire having a first segment with a first corrosion resistance and a second segment with a second corrosion resistance which is less than the first corrosion resistance. The second segment corrodes at a rate which is faster than the corrosion rate of the first segment so as to dynamically release internal stress and control grid growth of the battery grid during its service life. A battery includes said grid and a method of forming said grid are also disclosed.

Disclosed is an electrode for a lead acid battery formed of an electrode plate having a first side and a second opposing the first side, an active material paste applied to at least one of the first and second sides and a fiber mat embedded in the active material paste.

Disclosed is an electrode for a lead acid battery formed of an electrode plate having a first side and a second opposing the first side, an active material paste applied to at least one of the first and second sides and a fiber mat embedded in the active material paste.

A lead-based alloy containing alloying additions of bismuth, antimony, arsenic, and tin is used for the production of doped leady oxides, lead-acid battery active materials, lead-acid battery electrodes, and lead-acid batteries.

A lead-based alloy containing alloying additions of bismuth, antimony, arsenic, and tin is used for the production of doped leady oxides, lead-acid battery active materials, lead-acid battery electrodes, and lead-acid batteries.

A method of manufacturing a lead-acid battery, including the steps of making paste from leady oxide, sulfuric acid, lead powder, Naples Yellow, and water, pasting a lead-containing alloy grid to define an uncured battery plate, curing the pasted battery plate, positioning the cured plate in a lead-acid battery cell, and charging the cell convert the basic lead sulfate crystal structures into lead dioxide containing one or more of the ancient pigments.