Methods for separating and recycling battery and electrochemical cell materials are disclosed.

Apparatus and techniques described herein can be used to provide a bipolar battery plate with lower resistance as compared to other approaches. In an example, a bipolar plate comprises a conductive current collector substrate with lead-containing surfaces on both sides, onto which active materials are applied. Interfaces with low contact resistance can be created between the active materials and the current collector substrate by a combination of mechanical, thermochemical, and electrochemical techniques. Specifically, the present subject matter can include a bipolar plate fabricated by applying wet, (e.g., uncured) active materials to the current collector, and performing a curing procedure such that a corrosion layer with low contact resistance is formed between the active materials and the underlying surfaces of the current collector.

A surface coating for application to the surface of lead-grids for lead-acid batteries includes a resin and a carbon material of graphene, graphene nanoplatelets, or a combination thereof, wherein the surface coating is configured to be applied to either electrode of the lead-acid battery. The surface coating providing both a protective coating to prevent corrosion of either or both of the positive and/or negative lead grids and a flexible buffer coating to reduce delamination at the interface of either or both of the positive and/or negative lead grids and the active paste.

A surface coating for application to the surface of lead-grids for lead-acid batteries includes a resin and a carbon material of graphene, graphene nanoplatelets, or a combination thereof, wherein the surface coating is configured to be applied to either electrode of the lead-acid battery. The surface coating providing both a protective coating to prevent corrosion of either or both of the positive and/or negative lead grids and a flexible buffer coating to reduce delamination at the interface of either or both of the positive and/or negative lead grids and the active paste.

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.

A method of making an active layer for an activated carbon anode in a lead carbon battery includes forming a solvent mixture including poly(vinylidene fluoride) and a solvent; combining the solvent mixture with a non-solvent to form a precipitate comprising an activated carbon in a fibrillated poly(vinylidene fluoride) matrix; separating the precipitate from the solvent and the non-solvent; and forming the active layer from the precipitate. An active layer is formed by the method. A lead carbon battery includes an activated carbon anode comprising the active layer and a current collector, wherein the active layer is in electrical contact with the current collector; a lead oxide cathode that is in electrical contact with a cathode side current collector; an acid located in between the activated carbon anode and the cathode; and a casing encapsulating the activated carbon anode, the cathode, and the acid.

A method of making an active layer for an activated carbon anode in a lead carbon battery includes forming a solvent mixture including poly(vinylidene fluoride) and a solvent; combining the solvent mixture with a non-solvent to form a precipitate comprising an activated carbon in a fibrillated poly(vinylidene fluoride) matrix; separating the precipitate from the solvent and the non-solvent; and forming the active layer from the precipitate. An active layer is formed by the method. A lead carbon battery includes an activated carbon anode comprising the active layer and a current collector, wherein the active layer is in electrical contact with the current collector; a lead oxide cathode that is in electrical contact with a cathode side current collector; an acid located in between the activated carbon anode and the cathode; and a casing encapsulating the activated carbon anode, the cathode, and the acid.

The present invention deals with employing Heteroatoms namely Nitrogen, Sulphur intrinsic embedded carbon nanotubes (H-CNT) as multifunctional additive for preparing lead acid battery electrodes to substitute the expander chemicals namely, Vanisperse, Dinel Fibre, Barium sulphate and carbon black. Further the invention provides H-CNT in-situ produced from Crude oil or its products.

The present invention deals with employing Heteroatoms namely Nitrogen, Sulphur intrinsic embedded carbon nanotubes (H-CNT) as multifunctional additive for preparing lead acid battery electrodes to substitute the expander chemicals namely, Vanisperse, Dinel Fibre, Barium sulphate and carbon black. Further the invention provides H-CNT in-situ produced from Crude oil or its products.

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.