Lightweight Electrode Grids for Lead Acid Aircraft Batteries

"There is need to reduce the weight of aircraft batteries, such as the V-22, without sacrificing capacity or performance. One weight savings strategy that has been attempted is to use lightweight electrode grids. Titanium grids with a protective coating(such as SnO2) have been investigated, due to their low density, high conductivity and good mechanical strength, but success has been limited due to the difficulty in creating a pinhole-free coating. US Nanocorp ("USN") has successfully applied theirthermal spray process to create thin, impervious oxide coatings on a wide range of surfaces, for use in electrochemical environments. The purpose of this program is to demonstrate the effectiveness of thermal sprayed protective coatings for lightweighttitanium grids for lead acid batteries. A weight savings of at least 10-15% for V-22 batteries will be achieved. During Phase I, titanium grids will be coated with SnO2 or TiOx, using US Nanocorp's patented thermal-spray process. The coating will becharacterized to determine the metal valence, as well as the evenness of the coating. Electrodes will be fashioned and evaluated in experimental lead-acid cells. Performance will be contrasted with that of cells where electrode grids are made fromlead-alloys. Lightweight lead acid battery grids would have a commercial potential of hundreds of millions of dollars. Automotive and other lead-acid batteries would be benefited, particularly when