Coated lead acid battery electrode plates; method for making coated electrode plates and lead acid batteries containing coated electrode plates

Abstract

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.

1 . An electrode plate for a lead acid battery having a coating comprising:
 an electrode plate for a lead acid battery comprising a lead or lead alloy grid coated with an active material and   a porous, non-woven mat comprised of polymer fibers arranged with the electrode plate.   
     
     
         2 . The electrode plate of  claim 1  wherein the lead alloy is a lead-antimony, a lead-calcium or a lead-tin grid. 
     
     
         3 . The electrode plate of  claim 2  wherein the alloy is a lead-antimony alloy. 
     
     
         4 . The electrode plate of  claim 2  wherein the active material is a lead oxide active material. 
     
     
         5 . The electrode plate of  claim 1  wherein the polymer fibers have a fiber diameter of from about 5 nm and about 30 μm. 
     
     
         6 . The electrode plate of  claim 1  wherein the polymer fibers have a fiber diameter of from 500 nm to about 1 μm. 
     
     
         7 . The electrode plate of  claim 1  wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g. 
     
     
         8 . The electrode plate of  claim 1  wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g. 
     
     
         9 . The electrode plate of  claim 1  wherein the polymer fiber coating has a porosity of from 30% to about 90%. 
     
     
         10 . The electrode plate of  claim 1  wherein the polymer fiber coating has a porosity of from about 50% to about 70%. 
     
     
         11 . The electrode plate of  claim 1  wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm. 
     
     
         12 . The electrode plate of  claim 1  wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm 
     
     
         13 . The electrode plate of  claim 1  wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm. 
     
     
         14 . The electrode plate of  claim 1  wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof. 
     
     
         15 . The electrode plate of  claim 14  wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers. 
     
     
         16 . The electrode plate of  claim 1  wherein the polymer fiber coating further comprises an active agent. 
     
     
         17 . The electrode plate of  claim 16  wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof. 
     
     
         18 . The electrode plate of  claim 1  wherein the electrode plate is a positive electrode plate for a lead acid battery. 
     
     
         19 . The electrode plate of  claim 1  wherein the electrode plate is a negative electrode plate for a lead acid battery. 
     
     
         20 . A method for coating an electrode plate for a lead acid battery comprising the step of:
 electrospinning a polymer onto the surface of an electrode plate collector, the electrode plate collector comprising a lead or lead alloy grid coated with an active material, to form a porous, non-woven mat coating comprised of polymer fibers on the surface of the electrode plate collector.   
     
     
         21 - 68 . (canceled)