A shoe for dispensing a molten metal such as lead into a mold cavity of a rotating drum to continuously cast a web of a plurality of serially connected grids or battery composite electrodes of a carbon fiber material with a cast metal conductor. The shoe may have at least one elongate orifice slot in a face confronting the drum, a molten metal supply passage communicating with the orifice slot and an excess molten metal return slot opening into the confronting face downstream of the supply slot relative generally to the direction of rotation of the drum.

A shoe for dispensing a molten metal such as lead into a mold cavity of a rotating drum to continuously cast a web of a plurality of serially connected grids or battery composite electrodes of a carbon fiber material with a cast metal conductor. The shoe may have at least one elongate orifice slot in a face confronting the drum, a molten metal supply passage communicating with the orifice slot and an excess molten metal return slot opening into the confronting face downstream of the supply slot relative generally to the direction of rotation of the drum.

A paste coating system comprises a dispensing head assembly operatively connected to a coating frame, the dispensing head assembly including one or more dispensing heads configured to dispense paste (thixotropic and/or non-Newtonian) onto a grid with respect to the coating frame, and a ultrasonic transducer adjacent to the one or more dispensing heads configured to regulate viscosity of the paste such that the paste is coated onto the grid uniformly without risking material properties. The paste coating system also comprises a controller configured to automatically control operation of the dispensing head assembly and ultrasonic transducer during coating according to one or more coating profile.

A paste coating system comprises a dispensing head assembly operatively connected to a coating frame, the dispensing head assembly including one or more dispensing heads configured to dispense paste (thixotropic and/or non-Newtonian) onto a grid with respect to the coating frame, and a ultrasonic transducer adjacent to the one or more dispensing heads configured to regulate viscosity of the paste such that the paste is coated onto the grid uniformly without risking material properties. The paste coating system also comprises a controller configured to automatically control operation of the dispensing head assembly and ultrasonic transducer during coating according to one or more coating profile.

A shoe for dispensing a molten metal such as lead into a mold cavity of a rotating drum to continuously cast a web of a plurality of serially connected grids or battery composite electrodes of a substrate material with a cast metal conductor. The shoe may have at least one elongate orifice slot in a face confronting the drum, a molten metal supply passage communicating with the orifice slot and an excess molten metal return slot opening into the confronting face downstream of the supply slot relative generally to the direction of rotation of the drum.

A shoe for dispensing a molten metal such as lead into a mold cavity of a rotating drum to continuously cast a web of a plurality of serially connected grids or battery composite electrodes of a substrate material with a cast metal conductor. The shoe may have at least one elongate orifice slot in a face confronting the drum, a molten metal supply passage communicating with the orifice slot and an excess molten metal return slot opening into the confronting face downstream of the supply slot relative generally to the direction of rotation of the drum.

A method of making metal battery grids for lead-acid battery manufacture, as well as a metal battery grid manufacture assembly for lead-acid batteries, are set forth. A cleaning operation is performed to a continuous strip of metal battery grids that is continuously produced. The cleaning operation involves emittance of one or more laser beams via one or more laser assemblies to one or more exterior surfaces of the continuous strip of metal battery grids. Residual lubricants, oils, corrosion, and/or other additives or unwanted contaminants residing at the exterior surface(s) can be partially or wholly removed via the emittance of the laser beam(s). Enhanced surface adherence of a subsequently-applied battery paste material at the exterior surface(s) can result.

A method of making metal battery grids for lead-acid battery manufacture, as well as a metal battery grid manufacture assembly for lead-acid batteries, are set forth. A cleaning operation is performed to a continuous strip of metal battery grids that is continuously produced. The cleaning operation involves emittance of one or more laser beams via one or more laser assemblies to one or more exterior surfaces of the continuous strip of metal battery grids. Residual lubricants, oils, corrosion, and/or other additives or unwanted contaminants residing at the exterior surface(s) can be partially or wholly removed via the emittance of the laser beam(s). Enhanced surface adherence of a subsequently-applied battery paste material at the exterior surface(s) can result.

In an aspect, a method of making a composition, comprising forming a solvent mixture comprising a polymer and a solvent; precipitating the solvent mixture with a non-solvent to form the composition comprising the filler in a fibrillated polymer matrix, wherein the composition is in the form of a particulate and at least one of the solvent and the non-solvent comprises a filler; and separating the composition from the solvent and the non-solvent to isolate the composition. In another aspect, a porous material wherein the filler particles are mechanically bonded together by the polymer and wherein the polymer is present as filaments adhering to and connecting the filler particles across interstitial spaces between the filler particles. In another aspect, a precipitated polymer solution produced by a phase inversion where the majority of the liquids can be mechanically removed.

In an aspect, a method of making a composition, comprising forming a solvent mixture comprising a polymer and a solvent; precipitating the solvent mixture with a non-solvent to form the composition comprising the filler in a fibrillated polymer matrix, wherein the composition is in the form of a particulate and at least one of the solvent and the non-solvent comprises a filler; and separating the composition from the solvent and the non-solvent to isolate the composition. In another aspect, a porous material wherein the filler particles are mechanically bonded together by the polymer and wherein the polymer is present as filaments adhering to and connecting the filler particles across interstitial spaces between the filler particles. In another aspect, a precipitated polymer solution produced by a phase inversion where the majority of the liquids can be mechanically removed.