US 201403 63 742A1

(19) United States

(12) Patent Application Publication (10) Pub. N0.2 US 2014/0363742 A1
(43) Pub. Date:

Wetzel et al.
(54)

FIBER SCRIM, BATTERY ELECTRODE AND

(60)

METHOD FOR MANUFACTURING SAME

(71) Applicant: Johnson Controls Technology

Company, Holland, MI (US)
(72) Inventors: Dennis A. Wetzel, Saline, MI (US);
Ramachandran Subbaraman, Fox

Point, WI (US); Christopher P. Kaniut,

Jacksonville, FL (US); William J. Ross,
Mukwonago, WI (US); Annette
Holbrook, Northville, MI (US); Jerome
R. Heiman, Campbellsport, WI (US);
Eric A. Sattler, Romulus, MI (US);
Derrick L. Jennings, Maumi, OH (US);

Donald Hennessey, JR., Lambertville,

MI (US)

Dec. 11,2014

Provisional application No. 61/155,763, ?led on Feb.

26, 2009.
Publication Classi?cation

(51)

Int. Cl.
H01M 4/74
H01M 4/20
H01M 10/06
(52) U.S. Cl.

(2006.01)
(2006.01)
(2006.01)

CPC .............. .. H01M4/74 (2020.01); H01M 10/06

(2020.01); H01M4/20 (2020.01); HOIM

2220/20 (2020.01)
USPC

(57)

........................................ .. 429/234; 29/6231

ABSTRACT

(21) Appl.No.: 14/466,651

A battery electrode with a pasting textile, fabric, or scrim

made with an electrode grid (e.g., a stamped grid or expanded
metal grid) coated in battery electrode and covered with past

(22) Filed:

is formed from one or more ?bers with an average length

ing textile formed of a bonded, non-woven ?ber web. The web

Aug. 22, 2014

Related U.S. Application Data

(63)

Continuation of application No. 13/202,530, ?led on

Oct. 28, 2011, now Pat. No. 8,846,252, ?led as appli
cation No. PCT/USO9/65108 on Nov. 19, 2009.

greater than 20 pm. In various embodiments, the web is

formed from one or more spun, continuous ?bers. The battery
electrode may be made in a continuous process where mul

tiple grids are formed in a single sheet, coated with electrode

active material and the scrim before being cut into individual
electrodes.

Patent Application Publication

Dec. 11, 2014 Sheet 1 0f 14

US 2014/0363742 A1

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Dec. 11, 2014

US 2014/0363742 A1

FIBER SCRIM, BATTERY ELECTRODE AND

METHOD FOR MANUFACTURING SAME

[0014] 10. A pasting textile that enhances the oxidative

reactions in the battery compared to conventional past

ing materials;
PRIORITY

[0015]

[0001] This application claims priority to Us. Provisional

Application 61/155,763 ?led Feb. 26, 2009, which is incor
porated herein by reference in its entirety.

[0016]

FIELD

[0017]

[0002] The present disclosure relates to the ?eld of batteries

(e. g., lead-acid batteries including batteries for vehicle start

ing, lighting and ignition applications; marine batteries; com

mercial batteries; industrial batteries; batteries for use with

hybrid-electric vehicles, microhybrid vehicles, etc.). The

present disclosure more speci?cally relates to electrodes or

plates including a pasting textile or scrim, or otherwise having

a pasting textile or scrim provided thereon.
BACKGROUND

11. A pasting textile that improves cyclability by

helping better retain active material and limiting active

material shedding;
12. A pasting textile that can allow for the elimi

nation of speci?c glass-mat separators in cyclic applica

tions;
13. A pasting textile that can allow for the reduc

tion of lead in electrodes and batteries (e.g., by allowing

use of thinner grids);
[0018] 14. Electrodes that generate or exhibit higher
reserve capacity (RC);
[0019] 15. Electrodes that generate or exhibit higher

cycling or 20-hour rate capacity (C20 capacity);

[0020] 16. A pasting textile that mitigates acid strati?ca
tion in a variety of applications, including stop/ start and

microhybrid applications;
[0021]

17. A pasting textile that extends the serviceable

life of a battery;

[0003]

To prevent the separation of active material from

grids and electrodes or plates and/ or to ensure easy handling

of the active material in the manufacture of electrodes or

plates for batteries, it is known to provide for a pasting mate

rial or paper that may be adhered as a support to the active

material after it is deposited on grid substrates. It is also

known to embed in active material a pasting material formed
of polyesters, polypropylenes, or viscous rayon, instead of

paper, to prevent or reduce separation and handling problems.

Such pasting papers and fabrics do not realize certain advan

tageous features (and/or combinations of features).

Outline of Basic and Other Advantageous Features
[0004]

It would be desirable to provide a battery, an elec

trode, and/or a pasting textile or scrim or the like of a type

disclosed in the present application that includes any one or
more of these or other advantageous features:

[0005] 1. A pasting textile that improves acid transport

over conventional pasting materials;
[0006] 2. A pasting textile that better adheres to the active
material of an electrode compared to conventional past

ing material;
[0007]

3. A pasting textile that allows for enhanced cap

illary action compared to conventional pasting material;

[0008] 4. A pasting textile that provides for enhanced
plate strength and/or integrity over conventional pasting

material;
[0009]

5. An electrode that allows for enhanced conduc

tivity and capacitance;

[0010]

6. A pasting textile that may be utilized during

high speed continuous manufacture of positive and

[0022] 18. A pasting textile that improves manufacturing

processes by, in part, reducing the generation of airborne
lead particles and other exposed lead, and/or lowering
lead-in-air emissions, and potential ?re hazards (e.g.,
baghouse ?res) more common to conventional pasting
Paper;
[0023] 19. A pasting textile that can improve formation

ef?ciency and active material conversion in battery elec

trodes;
[0024] 20. A pasting textile that reduces battery scrap
(e.g., by reducing number of batteries that may need to
be scrapped due to cast-on strap weld interference that
can result from use of conventional pasting materials)
and/or improves scrap recovery;
[0025] 21. A replacement or substitute for conventional
pasting material that leads to one or more of the above

described advantages, and may be used in connection

with conventional battery manufacturing systems and

processes;

[0026] 22. A pasting textile that replaces both the con

ventional pasting paper and glass mat separator;
[0027] 23. A pasting textile that improves reserve capac

1W;
[0028] 24. A pasting textile that reduces manufacturing
costs related to material costs, processing speed, and

cleanliness;
[0029] 25. A pasting textile that can be manufactured
with reduced stacker downtime and maintenance delays;
and
[0030] 26. A pasting textile that allows use of a lead-acid

battery in applications with higher cycling requirements

than conventional lead-acid batteries can achieve.

negative electrodes;
[0011] 7. A pasting textile with material properties that
require lower ?ash-drying and/ or oven drying tempera
tures (200 to 400 deg. F) compared to conventional

pasting material;
[0012]

8. A pasting textile that may be utilized under

higher plate manufacturing line speeds while reducing

line interruptions and breakage;
[0013] 9. A pasting textile with material properties that
require or allow for shortened plate curing and drying
processes, and/or a reduction in curing time;

SUMMARY OF THE INVENTION

[0031] An exemplary embodiment relates to a battery elec

trode comprising a grid, an active material provided on the
grid, and a pasting textile provided on or into the active
material wherein the pasting textile includes a ?ber web
including one or more ?bers with an average length greater
than 20 um and the ?bers are greater than about 2 denier per
?ber.

[0032] Another exemplary embodiment relates to a battery

electrode comprising a grid having a length and a width, an

Dec. 11, 2014

US 2014/0363742 A1

active material provided on the grid, and a pasting textile

provided on or into the active material wherein the pasting
textile includes a ?ber web including one or more ?bers with

[0051] FIG. 15 is a 10x magni?ed view of a pasting textile

or scrim according to a ?fth exemplary embodiment;
[0052] FIG. 16 is a detailed view of a portion of the pasting

an average length of approximately half of the sum of the

textile depicted in FIG. 15;

length and the width of the grid.

[0033] Another exemplary embodiment relates to a battery

[0053] FIG. 17 is a 10x magni?ed view of a pasting textile

or scrim according to a sixth exemplary embodiment;
[0054] FIG. 18 is a detailed view of a portion of the pasting

electrode comprising a grid having a perimeter, an active

material provided on the grid, and a pasting textile provided
on or into the active material wherein the pasting textile

textile depicted in FIG. 17;

end and a second end and wherein the ?rst end of each ?ber is

[0055] FIG. 19 is a 10x magni?ed view of a pasting textile

or scrim according to a seventh exemplary embodiment;
[0056] FIG. 20 is a detailed view of a portion of the pasting

positioned substantially near the perimeter of the grid.

textile depicted in FIG. 19;

[0034]

[0057] FIG. 21 is a 10x magni?ed view of a pasting textile

or scrim according to an eighth exemplary embodiment;
[0058] FIG. 22 is a detailed view of a portion of the pasting

includes a ?ber web including one or more ?bers with a ?rst

Another exemplary embodiment relates to a method

of manufacturing battery electrodes comprising providing a

lead sheet; stamping the lead sheet to form one or more grids;
providing the one or more grids with an active material;

forming a pasting textile from a spun, continuous ?ber; pro

viding the pasting textile on a surface of the sheet of one or
more grids; and cutting the sheet of one or more grids with

active material and pasting textile provided thereon.

[0035] These and other features and advantages of various
embodiments of systems and methods according to this

textile depicted in FIG. 21;

[0059] FIG. 23 is a graph comparing the stop start cycling
capacity of a battery utiliZing electrodes including a pasting
textile or scrim according to an exemplary embodiment com

pared to an electrode including conventional pasting paper;

[0060] FIG. 24 is a graph comparing the repetitive reserve

capacity cycling of a battery including positive electrodes

invention are described in, or are apparent from, the following

(including a pasting textile or scrim according to an exem

detailed description of various exemplary embodiments of

various devices, structures, and/or methods according to this

plary embodiment) and a conventional polyethylene separa

tor to a battery including positive electrodes (including con
ventional pasting paper) and a conventional glass mat

invention.

separator;
BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Various exemplary embodiments of the systems and

methods according to the present disclosure will be described
in detail, with reference to the following ?gures, wherein:
[0037]

FIG. 1 is an isometric view of a vehicle including a

battery according to an exemplary embodiment;

[0038]

FIG. 2 is an isometric exploded cut-away view of a

portion of a battery according to an exemplary embodiment;

[0039] FIG. 3 is a front plan cut-away view ofa portion of
a battery plate or electrode (e.g., positive battery plate) com
prising a stamped grid and active material according to an

exemplary embodiment;
[0040] FIG. 4 is a front plan view ofa stamped grid (e.g.,
positive grid) according to an exemplary embodiment;
[0041]

FIG. 5 is an isometric exploded cut-away view of a

battery plate or electrode (e.g., negative battery plate) and

separator according to an exemplary embodiment;
[0042]

FIG. 6 is a front plan cut-away view of a battery

plate or electrode (e. g., positive battery plate) including a

grid, active material and a pasting textile or scrim according
to an exemplary embodiment;
[0043] FIG. 7 is a detailed view of the pasting textile rep

resented in FIG. 6, magni?ed about 107;

[0044]

FIG. 8 is a detailed view ofa portion ofthe pasting

textile depicted in FIG. 7;

[0045]

FIG. 9 is a 10x magni?ed view of a pasting textile or

scrim according to a second exemplary embodiment;

[0046] FIG. 10 is a detailed view ofa portion ofthe pasting
textile depicted in FIG. 9;
[0047] FIG. 11 is a 10x magni?ed view ofa pasting textile
or scrim according to a third exemplary embodiment;
[0048] FIG. 12 is a detailed view ofa portion ofthe pasting
textile depicted in FIG. 11;
[0049] FIG. 13 is a 10x magni?ed view ofa pasting textile
or scrim according to a fourth exemplary embodiment;
[0050] FIG. 14 is a detailed view ofa portion ofthe pasting
textile depicted in FIG. 13;

[0061]

FIG. 25 is a graph comparing the reserve capacity of

a battery including positive electrodes (including a pasting

textile or scrim according to an exemplary embodiment) and
a conventional polyethylene separator to a battery including

positive electrodes (including conventional pasting paper)

and a conventional glass mat separator;
[0062] FIG. 26 is a graph comparing the C20 capacity of a

battery including positive electrodes (including a pasting tex

tile or scrim according to an exemplary embodiment) and a

conventional polyethylene separator, and a battery including

positive electrodes (including conventional pasting paper)

and a conventional glass mat separator; and

[0063] FIG. 27 is a graph comparing the life-cycle test

sequences of a battery including positive electrodes (includ
ing a pasting textile or scrim according to an exemplary
embodiment) and a conventional polyethylene separator to a

high cycle design battery including positive electrodes (in

cluding conventional pasting paper).
[0064] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary to the understanding of the invention or render
other details dif?cult to perceive may have been omitted. It
should be understood, of course, that the invention is not

necessarily limited to the particular embodiments illustrated

herein.
DETAILED DESCRIPTION OF THE PREFERRED
EMBODIMENTS

[0065] Referring to FIG. 1, a vehicle 140 is shown that

includes a battery 100 according to an exemplary embodi
ment. While vehicle 140 is shown as an automobile, accord

ing to various alternative embodiments, the vehicle may

include any variety of types of vehicles including, among

others, motorcycles, buses, recreational vehicles, boats, and

the like. According to an exemplary embodiment, vehicle 140
uses an internal combustion engine (not shown) for locomo
tive purposes.

Dec. 11, 2014

US 2014/0363742 A1

[0066]

Battery 100 shown in FIG. 1 is con?gured to provide

108 and 109 also extend through a terminal post seal assem

at least a portion of the power required to start or operate

bly (not shown) to help prevent leakage of acid. It will be

vehicle 140 and/or various vehicle systems (e.g., starting,

lighting, and ignition systems (SLI)). Further, it should be

recognized that a variety of terminal arrangements are pos

understood that battery 100 may be utilized in a variety of

the art.

sible, including top, side, or corner con?gurations known in

applications not involving a vehicle, and all such applications

[0073]

are intended to be within the scope of the present disclosure.

secondary battery (e.g., rechargeable battery). According to

which includes a rectangular, elongated body portion of a

length suf?cient to electrically couple each lug in a plate set
and an upwardly extending member having a rounded top.

an exemplary embodiment, battery 100 includes a lead-acid

FIG. 2 also illustrates a cast-on strap coupling lugs to be

storage battery. Various embodiments of lead-acid storage

unsealed (e. g., wet).

[0068] Battery 100, according to an exemplary embodi

coupled to negative terminal post. As shown in FIG. 2,

according to various embodiments, the cast-on strap includes
a body portion coupling the respective lugs in the end com
partments and a post formed therewith to protrude through a

ment, is illustrated in FIG. 2. In various embodiments, battery

cover.

[0067]

Battery 100 shown in FIG. 1 may include any type of

batteries may be either sealed (e.g., non-maintenance) or

100 includes several cell elements which are provided in

separate compartments of a container or housing 110 contain

ing electrolyte. The illustrations provided herein relate to

automotive applications, wherein groups of 12-16 plates 104
and 105 are used in each of six stacks 107 for producing a

standard automotive 12-volt battery. It will be apparent to

those skilled in the art after reading this speci?cation that the
size and number of the individual plates 104 and 105, the size
and number of plates 104 and 105 in any particular stack 107,
and the number of stacks 107 used to construct battery 100
may vary widely depending upon the desired end use.

[0069] In various embodiments, battery housing 110

includes a box-like base or container and is made at least in

part of a moldable resin. A plurality of stacks 107 or plate

blocks are connected in series according to the capacity of the
lead storage battery and are accommodated in the battery
container or housing 110 together with the electrolyte, which
is commonly aqueous sulfuric acid.
[0070] In various embodiments, battery 100 includes a
compartment having a front wall, end walls, a rear wall, and
a bottom wall. In various embodiments, ?ve cell partitions or

dividers are provided between the end walls, resulting in the

formation of six compartments, as typically would be present
in a twelve volt automotive battery. In other embodiments, the
number of partitions and compartments may be varied to
create batteries with different voltages. In various embodi

[0074]

FIG. 2 also shows a conventional cast-on strap 112

Each cell element or chapter includes at least one

positive plate 104, at least one negative plate 105, and a

separator 106 positioned between each positive plate 104 and
negative plate 105. Separators 106 are provided between the
plates to prevent shorting and undesirable electron ?ow pro
duced during the reaction occurring in battery 100.
[0075] Positive and negative electrode plates 104 and 105
can be classi?ed into various types according to the method of
manufacturing the same. As one example, a paste type elec
trode is shown in FIGS. 3-5. In various embodiments, the
paste type electrode includes a grid substrate and an electro
chemically active material or paste 116 provided on the
substrate. The grid may be formed of a soft alloy containing a

trace of calcium for enhancing the mechanical strength of the

substrate.

[0076]

Referring to FIGS. 3-5, positive plates 104 and

negative plates 105 each include a lead and/ or lead alloy grid
113 and/or 115 that supports an electrochemically active
material 116. The grids 113 and/or 115 provide an electrical
contact between the positive or negative active materials or
paste 116 which serves to conduct current. The grids 113
and/or 115 also serve as a substrate for helping support elec

trochemically active material 116 (e.g., paste) deposited or

otherwise provided thereon during manufacture to form bat
tery plates 104 and/or 105.
[0077]

As set forth in greater detail below, known arts of

ments, a plate block or stack 107 is located in each compart

lead acid battery grid making include: (1) batch processes

ment, each plate block or stack 107 including one or more

such as book mold gravity casting; and (2) continuous pro

cesses such as strip expansion, strip stamping, continuous

positive plates 104 and negative plates 105, each having at

least one lug 103, and a separator 106 placed or provided

casting, and continuous casting followed by rolling. Grids

between each positive plate 104 and negative plate 105. In

various exemplary embodiments, the positive plates 104 and

made from these processes tend to have unique features char

negative plates 105 include a grid 101 and 102 with an

attached lug 103 that are coated with positive or negative
electrode active material or paste, respectively.

acteristic of the particular process and behave differently in

lead acid batteries, especially with respect to the pasting
process. It should be appreciated that grids formed from any
conventional or later-developed grid manufacturing process

[0071]

may be utilized, and it is not the intent to limit the invention to

Cover 111 is provided for housing 110, and in vari

ous embodiments, cover 111 includes terminal bushings and

?ll tubes to allow electrolyte to be added to the cells and to

permit servicing. To prevent undesirable spillage of electro

lyte from the ?ll tubes, and to permit exhausting of gases
generated during the electrochemical reaction, the battery
may also include one or more ?ller hole caps and/or vent cap

assemblies.

[0072]

At least one positive terminal post 108 and negative

terminal post 109 may be found on or about the top or front

compartments of the battery. Such terminal posts 108 and 109

typically include portions which may extend through cover
111 and/or the front of battery housing 110, depending upon
the battery design. In various embodiments, terminal posts

the grid design disclosed herein.

[0078] In various embodiments, at least some of the grids
are stamped grids 113. FIG. 3 illustrates an exemplary

embodiment of stamped grid 113 (e.g., a grid for a positive

plate) with active material or paste 116 provided thereon.
FIG. 4 illustrates stamped grid 113 shown in FIG. 3, but
without active material. In various embodiments, stamped
grid 113 includes a frame that includes a top frame element,
?rst side frame element, second side frame element, and a

bottom frame element. In various embodiments, stamped grid

113 includes grid wires 114 that de?ne open areas that help
hold the active material or paste 11 6 that helps provide current
generation. In various embodiments, a current collection lug

Dec. 11, 2014

US 2014/0363742 A1

103 is integral with the top frame element. While FIGS. 3-4
depict lug 103 as offset from the center of the top frame

element, lug 103 may alternatively be centered or positioned

closer to either the ?rst or second side frame elements. The
top frame element may include an enlarged conductive sec

ited, or otherwise provided onto the grids. The paste compo

sition may be determined by power requirements, cost, and
battery environment, as it is known in the art. In various
embodiments, active material 116 of a lead-acid battery is

prepared by mixing lead oxide, sulfuric acid, and water. The

tion at least a portion of which is directly beneath the lug to

lead oxide reacts with the sulfuric acid to form mono-, tri-,

help optimize current conduction to the lug.

and/or tetrabasic lead sulfate(s). Dry additives, such as ?ber

and expander, may also be added to the active material. For
example, in various embodiments, expanders such as ?nely
divided carbons (e.g., lampblack or carbon black), barium
sulfate, and various lignins may be included in the active
material. In various embodiments, the mixture is then dried

[0079]

The bottom frame element may be formed with one

or more downwardly extending feet (not shown) for spacing

the remainder of the stamped grid away from the bottom of
the battery container. In various embodiments, at least some
of the grid wires 114 increase in cross-sectional area along
their length from bottom to top or have a tapered shape so as

and water is re-added to form a paste of the desired consis

to help optimize the current carrying capacity of wires 114 to

help carry away increasing current being generated from the
bottom to the top. The width and spacing of wires 114
between the ?rst and second side elements may be predeter
mined so that there are substantially equal potential points
across the width of stamped grid 113. To assist in supporting
the electrochemical paste and/or permit the formation of

tency.

paste pellets, in various embodiments, the stamped grid 113

also includes horizontal wires which are equally spaced apart
and are parallel to the top and/ or bottom frame elements. As
shown in FIG. 3-4, however, at least some of the horizontal

[0084]

The active material provided on the positive grid

(e.g., lead dioxide [PbOZ]), is typically in micro-particle

form, so that the electrolyte is allowed to diffuse andpermeate
through the lead dioxide microparticles on the positive elec
trode plate. The spongy lead, the active material of the nega
tive electrode plate, is typically porous and reactive, so that
the electrolyte is allowed to diffuse and permeate through the
sponge lead on the negative electrode plate.
[0085]

Referring now to FIG. 6, which is a cut-away view

and/ or bottom frame elements.

of a battery plate or electrode including grid 101, active

material 116, and a pasting textile, fabric or scrim 120, in
various embodiments, pasting textile, fabric, or scrim 120

[0080] Various stamped grid designs may be utilized. See,

may be provided into or onto the surface of active material

e.g., US Pat. Nos. 5,582,936; 5,989,749; 6,203,948; 6,274,

116 provided on grids 101. Pasting textiles or scrims 120,

according to various embodiments, are magni?ed and shown

wires may not be equally spread apart or parallel to the top

274; 6,921,611; and 6,953,641 and Us. patent application

Ser. Nos. 10/996,l68; ll/086,525; 10/819,489; and 60/904,
404, each of which are incorporated herein by reference in

in FIGS. 7 to 22. In various embodiments, pasting textile or

scrim 120 may include bonded, non-woven ?ber webs. More

grid designs may be utilized and therefore, it is not the intent

of the following description to limit the invention to the grid
design shown in FIGS. 3-5, which are presented for the pur

particularly, pasting textile or scrim 120 may include point

bonded, non-woven webs of ?bers. Point bonding helps
improve the adhesiveness of the pasting scrim material to the
active material. It should be appreciated, however, that the

poses of illustration.

pasting textile need not be non-woven and may be woven,

[0081] An exemplary embodiment of an expanded metal

grid 115 (e.g., a grid for the negative plate) is illustrated in
FIG. 5. In various embodiments, the expanded metal grid has

loosely woven, knit, etc. Also, the pasting textile may not be
bonded. In various embodiments, pasting textile or scrim 120
may be manufactured using a wet-laid process.
[0086] In various embodiments, pasting textile or scrim

their entireties. It should be noted that an in?nite number of

a pattern (e.g., a diamond pattern such as that shown in FIG.

5), which is well known in the art, with a bottom frame
element and a top frame element that is integral with a lug.

120 is 0.06 to 5 mm in thickness, preferably 0.06 to 0.5 mm in

thickness, and more preferably 0.06 to 0.25 mm in thickness.

[0082] Referring to FIGS. 3-5, the cross-section of the grid

wires may vary depending upon the grid making process. To

As one of ordinary skill in the art will appreciate, however, the

thickness of the pasting textile depends in part upon the

help improve adhesion of the battery paste, however, in vari

intended application and the desired properties of the battery,

ous embodiments, the grid wires may be mechanically

such as cold cranking ampere, the cycling or 20-hour rate

capacity, or reserve capacity.

reshaped or re?nished. It should be appreciated that any num

ber of grid wire shapes may be utilized as long as the shape

provides suitable paste adhesion characteristics. For
example, the cross-section of wires may be of any cross

section design including substantially oval shaped, substan

tially rectangular, substantially diamond shape, substantially

rhomboid shape, substantially hexagon shape, and/or sub
stantially octagon shape. In the battery grid, each grid wire
section may have a different cross-sectional con?guration, or
each grid wire section may have the same or a similar cross

sectional con?guration. However, it is preferred that each grid

wire section have the same cross-sectional con?guration.
Depending on the needs, a grid can be deformed at the vertical
wire elements only, the horizontal wire elements only, or at
both the vertical and horizontal wire elements.
[0083] Active material or paste 116 is typically a lead

based material (e.g., PbO, PbOZ, Pb or PbSO4 at different

charge/discharge stages of the battery) that is pasted, depos

[0087] In various embodiments, pasting textile, fabric or

scrim 120 may be used in place of conventional pasting paper.
In other embodiments, the pasting textile (e.g., non-woven
material or scrim) may be laminated to or otherwise provided
on conventional pasting paper to improve the characteristics
and properties of an electrode utilizing such pasting paper or

a battery utilizing an electrode utilizing such pasting paper.

As one will appreciate, a thinner pasting textile or scrim than

that described above may be utilized where it is laminated,

coupled to, or otherwise provided on a pasting paper.

[0088]

In various embodiments, the pasting textile may be

used in conjunction with or in addition to traditional pasting

paper or material. For example, in various embodiments, the
pasting textile or scrim may be used in place of conventional

pasting material in connection with the positive electrodes

only. In various other embodiments, the pasting textile or
scrim may be used in place of conventional pasting paper in

Dec. 11, 2014

US 2014/0363742 A1

only the negative electrodes. In those embodiments where the

pasting textile or scrim 120 is used in place of conventional
pasting paper in connection with one type of electrode (e. g. in
positive electrodes or negative electrodes), and where con
ventional pasting paper or material is used in connection with
the other type of electrode, visual distinctions between the
pasting textile or scrim 120 and conventional pasting paper or
material may make it easier during manufacturing to differ

entiate the between positive plates and the negative plates,

and can reduce confusion and inadvertent misidenti?cation of

about 2, but not greater than 10. In other embodiments, the

?bers have a denier greater than about 2, but not greater than
4. In various embodiments, the surface of the ?bers is sub
stantially smooth, having little or no texture. In various other
embodiments, the ?bers may have other cross-sectional

shapes.
[0095]

The ?ber may also include a blend or multiple com

ponents. For example, the ?ber may be made of various

copolymer blends. In various embodiments, the ?ber is made
of bi-component sheath/core ?bers. In other embodiments,

plates (e.g., negative plates for positive plates or vice versa).

the ?ber is a homopolymer or a monopolymer. In some

[0089] In various embodiments where the pasting textile or

scrim is used in place of conventional pasting paper in con

embodiments, the ?ber or micro?ber is carbon-based (i.e.,

includes pure carbon or other types of carbon including,

nection with multiple types of electrodes (e.g., positive elec

trodes and negative electrodes), the pasting textile used in

without limitation, carbon black, graphite, expanded graph

ite, nanotubes, nano?bers, acetylene black, and derivatives

connection with one type of electrode (e.g., positive elec

trodes) may be visually distinct (e.g., colored or pigmented
differently) from that used with the other types of electrodes
(e.g., negative electrodes) to improve ease of differentiation
between positive electrodes and the negative electrodes,
thereby reducing confusion and inadvertent misidenti?cation
of such electrodes.
[0090] In various embodiments, pasting textile or scrim
120 has a weight range or density range of about 0.15 ounces
per square yard to about 2.0 ounces per square yard. Again, as

with thickness, the preferred weight or density range of the

pasting textile depends in part upon the intended application
or desired performance characteristics, such as cold cranking
ampere, cycling or 20-hour rate capacity, or reserve capacity.
In various embodiments, the choice of weight range or den

sity may also modify the nature of bonding between the

pasting textile and the active material in its native form. In

various embodiments, the weight or density range depends

upon conventional manufacturing processes and limitations
such that the electrode may be easily and economically manu

factured utiliZing conventional battery manufacturing pro

cesses, systems, and equipment.
[0091] In various embodiments, pasting textile 120 is con
structed primarily of ?ber or micro?ber. In various embodi
ments, the ?ber or micro?ber is made of one or more thermo

plastic resins, such as polyesters, polypropylene, viscous

rayon, polyamides (e.g., nylons), etc.
[0092] In various embodiments, pasting textile 120 is made
from a spun, continuous ?ber. Use of a spun, continuous ?ber

helps improve acid transport and adhesion of pasting textile

120 to active material 116. In addition, by using a continuous

?ber ?lament, pasting textile 120 formed by such ?ber exhib

its improved mechanical properties because the ?ber is gen
erally in plane or parallel to the plane of pasting textile or
scrim 120.
[0093] As one of ordinary skill in the art will appreciate,

however, the pasting textile may be made from multiple

?bers, including staple ?bers or cut ?bers. In various embodi
ments, the staple or cut ?bers vary in length, and have lengths
generally ranging from 1.5 to 15 mm. It should be appreci
ated, however, that the ?bers may be of any suitable length or

lengths. However, in various embodiments, the average

length of the staple or cut ?bers exceeds 20 pm.
[0094] In various embodiments, the ?bers or micro?bers
have a generally rounded cross-sectional shape. In various
embodiments, the ?ber diameter ranges from 10 to 25 pm. In
various embodiments, the ?bers have a denier per ?ber rang
ing from 1 to 10 and preferably from 2 to 4. In various
exemplary embodiments, the ?bers have a denier greater than

thereof). The ?ber or micro?ber may be made of pure carbon

and/or other carbon types, or various percentages of pure
carbon and/ or other carbon types.

[0096]

In various embodiments, the pasting textile or scrim

may be loaded with one or more additives including titanium

dioxide (TiOZ), graphite, carbon black, etc. to help in the

conversion of active material during formation. In various
embodiments, the pasting textile, material, or scrim and/or
the ?ber is chemically treated. In various embodiments, the
pasting textile or ?ber may be carbon treated or impregnated.
In various embodiments, the pasting textile or ?ber may be
treated with a delustering agent such as titanium dioxide

(TiOZ), silica, clays, talcs, oxides, etc. By treating it with a

delustering agent, the pasting textile or ?ber may have a
surface roughness or texture that improves adherence to the

active material and/or improves the wetability of the pasting

textile or ?ber. In addition, the pasting textile or ?ber may
include surfactants or wetting agents such as water-soluble

silicon to enhance wetability.

[0097] In various embodiments, the pasting scrim or textile
is formed by creating a web from a single continuous ?ber and
cutting the web to the desired shape and size. In such embodi
ments, the average length of the ?bers after the pasting textile
is cut out of the web is substantially equal to the average of the
length and width of the pasting textile. In various embodi
ments, the pasting scrim or textile may be formed in one step
on the battery electrodes or may be formed in a separate

process and applied onto the electrode plates in a subsequent

step. In embodiments where the pasting textile or scrim is
formed on the electrode plates, a pasting textile or scrim sheet

is provided on a sheet of pasted grids or plates prior to the

sheet being cut into individual pasted grids or plates.

[0098] Referring again to FIG. 5, in various embodiments,
one or more battery separators 106 are used to conductively

separate the positive and negative electrodes. The separator

material is typically microporous to allow the through pas
sage of ions from the positive and negative electrodes. Sepa
rators for automotive batteries are typically made in continu
ous lengths and rolled, subsequently folded as shown in FIG.
5, and sealed along one or more of their edges to formpouches

that receive a battery plate (e. g., a negative plate as shown in

FIG. 5 or a positive plate as shown in FIG. 2).

[0099]

In various embodiments, separator material gener

ally has a substantially uniform thickness and a substantially

uniform pore distribution. The pore distribution helps ensure

an overall uniform current density during operation, thereby

helping achieving a uniform charging and discharging of the
electrodes and maximum battery ef?ciency. A separator 106