Carbon coated battery electrodes

Abstract

A method for forming a corrosion resistant electrode for a battery includes supplying an electrode for use in the battery and exposing the electrode to an environment including vaporized carbon. At least some of the carbon from the environment may be transferred to the electrode.

1 . A method of forming a coated electrode plate for a battery, comprising: 
 supplying a current collector for use in the battery;    exposing the current collector to an environment including vaporized carbon, and    transferring at least some of the carbon from the environment to the electrode to form a carbon film on at least a portion of the current collector such that a substrate surface is formed that includes an outer surface of the carbon film and any exposed surfaces of the current collector; and    applying a chemically active paste to at least a portion of the substrate surface.    
   
   
       2 . The method of  claim 1 , wherein the current collector is configured to include a grid pattern.  
   
   
       3 . (canceled)  
   
   
       4 . The method of  claim 1 , wherein the carbon film has a thickness of less than about 1 μm.  
   
   
       5 . The method of  claim 1 , wherein the carbon film has a thickness of less than about 100 nm.  
   
   
       6 . The method of  claim 1 , wherein the carbon film covers substantially all surfaces of the current collector.  
   
   
       7 . The method of  claim 1 , wherein the vaporized carbon is generated as part of a chemical vapor deposition process.  
   
   
       8 . The method of  claim 1 , wherein the vaporized carbon is generated as part of a plasma deposition process.  
   
   
       9 . The method of  claim 1 , wherein the vaporized carbon is generated as part of a process including at least one of sputtering, evaporation, arc deposition, ion beam deposition, or laser ablation.  
   
   
       10 - 21 . (canceled)  
   
   
       22 . The method of  claim 1 , wherein the battery is a lead acid battery.  
   
   
       23 . The method of  claim 1 , wherein the chemically active paste includes an oxide of lead.  
   
   
       24 . The method of  claim 1 , wherein the carbon film includes at least some region having a graphitic structure.  
   
   
       25 . The method of  claim 1 , wherein the carbon film has at least some region having an amorphous structure.  
   
   
       26 . The method of  claim 1 , wherein the current collector includes lead.