A metering unit (14) for molten lead is paired with the molding cavity (13) of a molding block (6). The metering unit (14) includes a cylinder (1), to which molten lead is supplied via a blockable line (8), and a piston (2), which can be lifted in order to transfer molten lead into the molding cavity (13) in order to cast pole connectors onto battery plate lugs.

A metering unit (14) for molten lead is paired with the molding cavity (13) of a molding block (6). The metering unit (14) includes a cylinder (1), to which molten lead is supplied via a blockable line (8), and a piston (2), which can be lifted in order to transfer molten lead into the molding cavity (13) in order to cast pole connectors onto battery plate lugs.

A method of making a grid for a battery plate of a lead-acid battery. A substantially planar web is manufactured to include a plurality of spaced apart and interconnected wire segments, which at least partially define substantially planar surfaces, have a plurality of transverse lands, and interconnect at a plurality of nodes to define a plurality of open spaces between the wire segments. The web is reformed to change the cross-sectional shape of the wire segments. Other aspects may include simultaneously reducing the thickness of at least a portion of the web while reshaping the wire segments, and/or providing a controlled surface roughness on at least one of the surfaces of the web to increase surface area of the grid and thereby promote adhesion of an electrochemically active material to the grid.

A method of making a grid for a battery plate of a lead-acid battery. A substantially planar web is manufactured to include a plurality of spaced apart and interconnected wire segments, which at least partially define substantially planar surfaces, have a plurality of transverse lands, and interconnect at a plurality of nodes to define a plurality of open spaces between the wire segments. The web is reformed to change the cross-sectional shape of the wire segments. Other aspects may include simultaneously reducing the thickness of at least a portion of the web while reshaping the wire segments, and/or providing a controlled surface roughness on at least one of the surfaces of the web to increase surface area of the grid and thereby promote adhesion of an electrochemically active material to the grid.

Battery grid (1) comprising a grid structure (4) containing grid arms (2) and bordering arms (3), a supporting element (5) and lugs (6), as well as lead paste (7) spread on the surface of the supporting element (5). The invention also relates to a battery cell (35) comprising the battery grids (1) with separator plates (38) placed between them. The invention further relates to a storage battery (42) comprising battery cells (35) filled with acid. The supporting element (5) comprises fibreglass based material onto which the grid structure (4) is secured through chemical bond formed between the lead and the fibreglass. The lead paste (7) is secured to the supporting element (5) through chemical bond and the grid structure (4) has more than one lug (6). The battery cell (35) is composed of the battery grids (1). The lugs (41, 42) are connected to a jointing element (8). The storage battery (42) comprises the battery cells (35).

Apparatus and techniques are described herein for providing a battery plate assembly including a silicon current collector. The silicon current collector can include apertures. A lead layer or lead alloy layer can be formed on the silicon current collector. A monopolar battery assembly can be provided, such as including monopolar battery plate assemblies comprising silicon current collectors. The silicon can include a conductive metallurgical grade silicon, such as cast and cut to provide individual current collector substrates.

Apparatus and techniques are described herein for providing a battery plate assembly including a silicon current collector. The silicon current collector can include apertures. A lead layer or lead alloy layer can be formed on the silicon current collector. A monopolar battery assembly can be provided, such as including monopolar battery plate assemblies comprising silicon current collectors. The silicon can include a conductive metallurgical grade silicon, such as cast and cut to provide individual current collector substrates.

A battery grid comprising includes a first grid member having opposite first and second side frame elements and opposite first and second end frame elements extending between the first and second side frame elements. A second grid member having opposite first and second side frame elements and opposite first and second end frame elements extending between the first and second side frame elements is attached to the first grid member. A method of making a battery grid includes attaching a first grid member to a second grid member.

A method of forming an electrode includes casting a molten metal in a mold to form an electrode with a header portion and a blade portion. The blade portion of the electrode is then rolled after it has been cast. The blade portion may be rolled into at least two different thicknesses. In one embodiment the metal is lead or lead alloy and the method relates to the forming of a lead or lead alloy anode.

A method of forming an electrode includes casting a molten metal in a mold to form an electrode with a header portion and a blade portion. The blade portion of the electrode is then rolled after it has been cast. The blade portion may be rolled into at least two different thicknesses. In one embodiment the metal is lead or lead alloy and the method relates to the forming of a lead or lead alloy anode.