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Abstract

The Lightweight Battery Plates disclosed and claimed in this patent application solve the problems encountered by previous attempts to construct practical bipolar plates for lead-acid batteries. One of the preferred embodiments of the present invention comprises a novel combination of a self-repairing substrate (12) surrounded by a lead coating (16a & 16b) resulting in a bipolar plate (10A) which is nearly three times lighter than its pure lead counterpart. Since this innovative plate incorporates a core or substrate (12) that is self-passivating under the electrical potential and highly acidic conditions found in the lead-acid battery, any pinholes, gaps, or flaws in the lead coatings (16a & 16b) are naturally resealed. Another preferred embodiment utilizes a coating of a semi-conducting metal oxide (18), such as fluorine-doped stannic oxide, on the positive side of the bipolar plate (10B) instead of lead, which further reduces the weight. Alternative embodiments may utilize aluminum or aluminum alloy substrates, which can further lighten the plate but will forfeit its self-repairing quality.

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First Claim