High Energy, Lightweight, Sealed Lead Acid Battery for V-22 Applications

The objective of this proposal is to develop and demonstrate lightweight grids for a lead acid aircraft battery with a goal of achieving a 10 to 15% weight saving. Lead acid batteries are reliable, safe, and cost effective for most applications. These batteries have demonstrated remarkable reliability at most operating temperatures and conditions. However, they are heavy and bulky. A significant weight saving can be achieved by replacing the core of the present cast lead (Pb) alloy grid with a lightweight substrate of an aluminum (Al) alloy that has been treated and coated with a thin layer of lead. Additional weight savings can be realized by replacing the current intercell posts and cell top straps of lead with Pb coated lightweight materials. The lead layer being necessary to protect the lightweight materials from chemical and electrochemical corrosion and provide a bond to the active materials for the electrodes.