An electrochemical cell includes solid-state, printable anode layer, cathode layer and non-aqueous gel electrolyte layer coupled to the anode layer and cathode layer. The electrolyte layer provides physical separation between the anode layer and the cathode layer, and comprises a composition configured to provide ionic communication between the anode layer and cathode layer by facilitating transmission of multivalent ions between the anode layer and the cathode layer.

A method for reusing components of a battery (used battery assembly), such as a bipolar battery, to form another battery (reused battery assembly). The method may find use in allowing for a battery to be used, disassembled, recycled or reprocessed, assembled, and reused all within a single facility. A method for preparing a reused battery assembly including: a) disassembling a used battery assembly; b) salvaging one or more used components from the used battery assembly to provide for one or more reused components; and c) assembling a reused battery assembly with the one or more reused components.

A method for reusing components of a battery (used battery assembly), such as a bipolar battery, to form another battery (reused battery assembly). The method may find use in allowing for a battery to be used, disassembled, recycled or reprocessed, assembled, and reused all within a single facility. A method for preparing a reused battery assembly including: a) disassembling a used battery assembly; b) salvaging one or more used components from the used battery assembly to provide for one or more reused components; and c) assembling a reused battery assembly with the one or more reused components.

Disclosed are electrode plates for a lead acid battery. The electrode plates are formed of an electrode plate having a face, the electrode plate comprising a lead or lead alloy grid coated with an active material and the electrode plates having a porous, non-woven mat comprised of polymer fibers coating on the face of the electrode plate, as well as a method for making the coated electrode plates and lead acid batteries containing the coated electrode plates.

Disclosed are electrode plates for a lead acid battery. The electrode plates are formed of an electrode plate having a face, the electrode plate comprising a lead or lead alloy grid coated with an active material and the electrode plates having a porous, non-woven mat comprised of polymer fibers coating on the face of the electrode plate, as well as a method for making the coated electrode plates and lead acid batteries containing the coated electrode plates.

Methods for making lead-carbon coupling, lead-carbon electrode sheets, and a lead-carbon battery are revealed. The coupling methods consist of steps of assembling the carbon material that contains oxygen functional groups or metal precursors and lead material in contact with each other and then heating the assembled lead-carbon pair to form lead oxides or metal carbides as a bridge to form coupled lead-carbon interface with high electrochemical and mechanical stability. This coupled lead-carbon structure is applied to form lead-carbon electrode sheets and is further used as electrode sheets of lead-carbon batteries by lead welding.

Methods for making lead-carbon coupling, lead-carbon electrode sheets, and a lead-carbon battery are revealed. The coupling methods consist of steps of assembling the carbon material that contains oxygen functional groups or metal precursors and lead material in contact with each other and then heating the assembled lead-carbon pair to form lead oxides or metal carbides as a bridge to form coupled lead-carbon interface with high electrochemical and mechanical stability. This coupled lead-carbon structure is applied to form lead-carbon electrode sheets and is further used as electrode sheets of lead-carbon batteries by lead welding.

According to one or more embodiments presently described, a mixture of lead oxide and lead metal particles may be formed by a method that includes forming a molten metal lead material from a solid lead metal supply material, introducing the molten metal lead material into a reaction zone of a reactor, and contacting the molten metal lead material with an oxidizing gas in the reaction zone to oxidize a portion of the molten metal lead material and form at least solid lead oxide particles and solid lead metal particles. The molten metal lead material may be introduced to the reaction zone in a laminar flow or as atomized molten particles. The weight ratio of formed solid lead oxide particles to solid lead metal particles may be less than 99:1.

According to one or more embodiments presently described, metal-containing particles may be formed by a method including forming a molten material from a solid supply material, introducing the molten material into a reaction zone of a Barton reactor, and contacting the molten material with a processing gas in the reaction zone to form solid metal-containing particles comprising solid metallic particles and solid metal oxide particles. The Barton reactor may include a reaction vessel which may include a top cover and sidewalls defining the reaction zone, an agitator, a processing gas inlet, and a product outlet. The molten material may be introduced to the reaction zone in a laminar flow or as atomized molten particles. Less than 99% of the particles may include metal oxide.

According to one or more embodiments presently described, metal-containing particles may be made by a method that includes introducing a molten material into a reaction zone of a reactor system, passing a process gas into the reaction zone in a direction substantially tangential to a sidewall of the reaction zone, and contacting the process gas with the molten material in the reaction zone to form metal-containing particles. The molten material may be introduced into an upper portion of the reaction zone The reaction zone may include a substantially circular cross-section, and the molten metal may be introduced into the reaction zone in a laminar flow or as atomized particles.