An electrochemical battery is disclosed. The electrochemical battery has an electrode plate comprising a frame and a generally flat grid connected to the frame, the frame comprising at least a top frame member having a contact lug, wherein the grid comprises a plurality of grid wires and a plurality of window-like open areas between the grid wires, further comprising an active mass within the open areas and/or on the grid wires, wherein the electrode plate comprises on one outer surface or on both opposing outer surfaces of the active mass a pattern of grooves, wherein the grooves extend diagonally from a position closer to the top frame member to a position further away from the top frame member. A method for producing an electrode plate is also disclosed.

A battery grid pasting system includes a battery grid pasting machine, a sensing station, and a controller. The battery grid pasting machine includes a conveying apparatus confronting a hopper's dispensing end across a space, and includes a motor actuatable to cause variance of the space and hence variance of the amount of battery paste received on carried battery grids through the space. The sensing station senses a value of a property of a pasted battery grid. And the controller receives the sensed value of the property and controls actuation of the motor based in part or more on the received value.

A battery grid pasting system includes a battery grid pasting machine, a sensing station, and a controller. The battery grid pasting machine includes a conveying apparatus confronting a hopper's dispensing end across a space, and includes a motor actuatable to cause variance of the space and hence variance of the amount of battery paste received on carried battery grids through the space. The sensing station senses a value of a property of a pasted battery grid. And the controller receives the sensed value of the property and controls actuation of the motor based in part or more on the received value.

A battery plate assembly for a lead-acid battery is disclosed. The assembly includes a plates of opposing polarity each formed by an electrically conductive grid body having opposed top and bottom frame elements and opposed first and second side frame elements, the top frame element having a lug and an opposing enlarged conductive section extending toward the bottom frame element; a plurality of interconnecting electrically conductive grid elements defining a grid pattern defining a plurality of open areas, the grid elements including a plurality of radially extending vertical grid wire elements connected to the top frame element, and a plurality of horizontally extending grid wire elements, the grid body having an active material provided thereon. A highly absorbent separator is wrapped around at least a portion of the plate of a first polarity and extends to opposing plate faces. An electrolye is provided, wherein substantially all of the electrolyte is absorbed by the separator or active material. A method for assembling a battery is also disclosed.

A battery plate assembly for a lead-acid battery is disclosed. The assembly includes a plates of opposing polarity each formed by an electrically conductive grid body having opposed top and bottom frame elements and opposed first and second side frame elements, the top frame element having a lug and an opposing enlarged conductive section extending toward the bottom frame element; a plurality of interconnecting electrically conductive grid elements defining a grid pattern defining a plurality of open areas, the grid elements including a plurality of radially extending vertical grid wire elements connected to the top frame element, and a plurality of horizontally extending grid wire elements, the grid body having an active material provided thereon. A highly absorbent separator is wrapped around at least a portion of the plate of a first polarity and extends to opposing plate faces. An electrolye is provided, wherein substantially all of the electrolyte is absorbed by the separator or active material. A method for assembling a battery is also disclosed.

A bipolar battery (1) comprising a stack of multiple bipolar plates (9) sandwiched between two monopolar plates (6, 8) is disclosed. The bipolar plates (9) each comprise a conductive polymer core (22) and an integrally formed non-conductive polymer surround (4), a layer of cathode material (16) on a first side of the bipolar plate (9), and a layer of anode material (28) on a second, opposite side of the bipolar plate (9). The integrally formed non-conductive polymer surround (4) extends from the conductive polymer core (22) further on one side than the other, such that on one side a first recess (19) is defined for accommodating electrolyte material of the battery (1). The layers of anode material (28) and cathode material (16) are contained within a casing formed at least in part by the integrally formed non-conductive polymer surrounds (4) of all of the bipolar plates (9).

A bipolar battery (1) comprising a stack of multiple bipolar plates (9) sandwiched between two monopolar plates (6, 8) is disclosed. The bipolar plates (9) each comprise a conductive polymer core (22) and an integrally formed non-conductive polymer surround (4), a layer of cathode material (16) on a first side of the bipolar plate (9), and a layer of anode material (28) on a second, opposite side of the bipolar plate (9). The integrally formed non-conductive polymer surround (4) extends from the conductive polymer core (22) further on one side than the other, such that on one side a first recess (19) is defined for accommodating electrolyte material of the battery (1). The layers of anode material (28) and cathode material (16) are contained within a casing formed at least in part by the integrally formed non-conductive polymer surrounds (4) of all of the bipolar plates (9).

Positive active material pastes for flooded deep discharge lead-acid batteries, methods of making the same and lead-acid batteries including the same are provided. The positive active material paste includes lead oxide, a sulfate additive, and an aqueous acid. The positive active material paste contains from about 0.1 to about 1.0 wt % of the sulfate additive. Batteries using such positive active material pastes exhibit greatly improved performance over batteries with conventional positive active material pastes.

Positive active material pastes for flooded deep discharge lead-acid batteries, methods of making the same and lead-acid batteries including the same are provided. The positive active material paste includes lead oxide, a sulfate additive, and an aqueous acid. The positive active material paste contains from about 0.1 to about 1.0 wt % of the sulfate additive. Batteries using such positive active material pastes exhibit greatly improved performance over batteries with conventional positive active material pastes.

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.