Electrode

Abstract

An electrode comprising a noble-metal free grid comprising lead, wherein the grid has an essentially PbO free PbO 2 coating covering all, or essentially all of the surface of the grid. Also described is a method of forming an electrode, comprising applying an essentially PbO free PbO 2 coating to a noble-metal free grid comprising lead, wherein the coating covers all, or essentially all of the surface of the grid.

1 . An electrode comprising: 
 a noble-metal free grid comprising lead, calcium, tin, or a combination comprising at least one of the foregoing; wherein said grid has an essentially PbO free PbO 2  coating essentially covering the surface of said grid; wherein the surface area of said essentially PbO free PbO 2  coating exceeds the geometric surface area of said grid by more than about 60 area percent; and wherein said essentially PbO free PbO 2  coating has an effective surface area greater than the geometric surface area of said grid.    
     
     
         2 . The electrode of  claim 1 , wherein said noble metal free grid further comprises calcium, tin, or a combination comprising at least one of the foregoing.  
     
     
         3 . The electrode of  claim 1 , wherein said essentially PbO free PbO 2  coating has an effective surface area greater than the geometric surface area of said grid.  
     
     
         4 . A method of forming an electrode, comprising: 
 applying an essentially PbO free PbO 2  coating to the surface of a noble-metal free grid comprising lead, calcium, tin, or a combination comprising at least one of the foregoing; wherein said coating essentially covers the surface of said grid; wherein the surface area of said essentially PbO free PbO 2  coating exceeds the geometric surface area of said grid by more than about 60 area percent; and wherein said essentially PbO free PbO 2  coating has a density greater than about 8.5 grams per cubic centimeter.    
     
     
         5 . The method of  claim 4 , wherein said noble metal free grid further comprises calcium, tin, or a combination comprising at least one of the foregoing.  
     
     
         6 . The method of  claim 4 , wherein said essentially PbO free PbO 2  coating has a density greater than about 8.5 grams per cubic centimeter.  
     
     
         7 . A method of forming an electrode, comprising: 
 applying an essentially PbO free PbO 2  coating onto the surface of a noble-metal free grid comprising lead, tin and calcium, wherein said coating has a thickness not less than 5 microns and not more than 500 microns, and wherein said coating covers all, or essentially all of the surface of said grid to produce a coated grid;    applying a paste comprising lead and lead oxide to the surface of said coated grid to produce a pasted grid;    contacting said pasted grid with steam for at least one hour to produce a steamed grid;    curing said steamed grid at about 50 percent humidity and about 55° C. for at least about 24 hours to produce a cured grid; followed by    contacting said grid with aqueous sulfuric acid prior to passing an external electric current of sufficient voltage and amperage through said cured grid for a sufficient period of time to convert at least a portion of said applied paste into lead dioxide.