Flexible lead-acid batteries based on the fuel cell concept and their uses.

Description

1 / 7 DESCRIPTIVE REPORT “Flexible Lead-Acid Batteries Based on the Fuel Cell Concept and their Uses” Field of invention

[001] The present invention relates to the development of new lead-acid battery architectures aimed at reducing the weight and increasing the flexibility of electrodes in conventional batteries. The technology consists of replacing metallic lead plates with lead / lead oxide metallic nanoparticles dispersed in high surface area carbon, which presents an innovative character and consequently results in a lower final battery weight and a larger electrode surface area, thus allowing its use in mobile, portable and stationary applications. A second contribution of the technology consists of the introduction of proton-conducting polymeric membranes that will provide greater flexibility to the battery electrodes, consequently greater versatility in terms of use and applications. The use of the wetted membrane allows for the non-use of acid electrolytes and additives. This new concept was inspired by fuel cell architecture. State of the art

[002] Commercially available lead-acid batteries use metallic lead and lead oxide electrodes in contact with a sulfuric acid solution, requiring the addition of additives for proper functioning. Although this architecture is effective, it is outdated compared to other modern batteries. Currently, studies on lead-acid batteries focus on the development of additives for both the electrode and the electrolyte, resulting in a stagnation in the development of Petition 870250052929, dated 06 / 24 / 2025, page 4 / 10 2 / 7 new architectures. This limits their use in electric vehicles due to the weight and space they occupy.

[003] Patent document TWI792610 discloses a method for making lead-carbon electrode sheets, lead-carbon electrode foils, and a lead-carbon battery. The method consists of oxidizing lead under a low-temperature atmosphere, using the oxidized lead as a lead-carbon coupling interface layer, and using a specialized venting method to coat the carbon onto the lead. The oxidized lead interface layer forms a stable interface between the carbon and the lead. Meanwhile, by controlling pressure and temperature, a multiporous metal compound is formed, and the porosity can provide penetration pathways for air and liquid when applied. The lead-carbon compound is applied as a lead-carbon electrode sheet and is subsequently soldered as a lead-carbon electrode foil of a lead-carbon battery.The lead-carbon battery carrying the lead-carbon electrode demonstrates 100% Coulomb efficiency without heat loss under an unsaturated charge-discharge condition of high-efficiency charging and high-efficiency discharging. The technology claimed for protection discloses a method for making lead-carbon electrode sheets, lead-carbon electrode sheets, and a lead-carbon battery. Although the document discloses a lead-carbon battery, it does not present the configuration of the search object containing a polymeric membrane.

[004] Prior patent US20230041652 discloses a method for making lead-carbon electrode sheets, lead-carbon electrode foils and lead-carbon batteries. The method consists of oxidizing lead under a low-temperature atmosphere, using the oxidized lead as a lead-carbon coupling interface layer, and using a specialized venting method to coat the carbon onto the lead. Petition 870250052929, dated 06 / 24 / 2025, page 5 / 10 A 3 / 7 layer of oxidized lead interface forms a stable interface between the carbon and lead. Meanwhile, through pressure and temperature control, a multiporous metal compound is formed, and the porosity can provide penetration pathways for air and liquid when the multiporous metal compound is applied. The lead-carbon compound is applied as a lead-carbon electrode sheet and is subsequently soldered as a lead-carbon electrode sheet of a lead-carbon battery. The lead-carbon battery carrying the lead-carbon electrode demonstrates 100% Coulomb efficiency without heat loss under an unsaturated charge-discharge condition of high-efficiency charging and high-efficiency discharging.

[005] Although the document presents a carbon / lead nanoparticle battery, it reveals the use of sulfuric acid and does not present the main configuration of the present search object, which is the electrode structure with a polymer electrolyte that allows the production of a flexible device.

[006] Document US11121356B2 describes a new type of method for preparing battery electrode plates. The method may include the following steps: a) a mixing process; b) a milling and polishing process; c) an extrusion, shearing, and extension process; d) cutting to obtain an electrode membrane; e) high-temperature and high-pressure pressing to obtain a battery electrode plate. The method may adopt the active material of different electrochemical batteries as the main body to prepare a thick-type battery electrode plate with high conductivity, high capacity, and high active material load, which has a viscoelastic body. The electrode plate may have a flexible organic network structure and excellent mechanical strength, and may still exist in a variety of electrolytes after hundreds or even thousands of deep charge and discharge cycles. The thick electrode plate prepared using the method Petition 870250052929, dated 06 / 24 / 2025, page 6 / 10 4 / 7 can be applied to a variety of batteries, such as lead-acid battery positive and negative electrode plates, lead-carbon battery electrode plates, lithium-ion battery electrode plates, supercapacitor electrode plates, NiMH battery electrode plates, and others.

[007] This document discloses a method for preparing a battery electrode plate, wherein said method can be applied to a variety of batteries, such as lead-acid (LAB) battery positive and negative electrode plates and lead-carbon battery electrode plates. The result of the method reveals an electrode plate with a flexible organic network structure and excellent mechanical strength. The document does not disclose the polymer electrode battery configuration as the object of the search.

[008] The invention presents a novel architecture that allows the use of advanced nanostructured materials, reducing the weight and increasing the surface area of ​​the electrodes without the need for additive electrolytes.

[009] For the preparation of battery electrodes, the technology claiming protection uses a developed method that allows the production of lead nanoparticles or lead oxides by electrical current discharge. These nanoparticles result in a significantly larger surface area than the lead plates normally used as electrodes in lead-acid batteries. The technology provides new applications and the development of new commercial and industrial products.

[010] Among the advantages of using lead nanoparticles is the larger surface area of ​​the electrodes, resulting in a lower final battery weight. The nanoparticles are produced by electrical discharge, which allows for savings in reagents and synthesis time, an advantage over conventional chemical methods. The use of the membrane allows for greater Petition 870250052929, dated 06 / 24 / 2025, page 7 / 10 5 / 7 electrode flexibility and a wider range of practical applications, eliminating the need for electrolytes and additives.

[011] Development of a flexible lead-acid battery using a polymeric membrane with lead or lead oxide particles dispersed in high surface area carbon. This innovation is based on the concept of fuel cells. Description of the drawings

[012] In order that the present invention may be fully understood and put into practice by any technician in this technological sector, it is described in a clear, precise and sufficient manner, based on the attached drawings, listed below, which illustrate preferred embodiments of the technology.

[013] Figure 1 shows a schematic of the Flexible Lead Battery constructed with technology applied in PEM type fuel cells. (1) carbon fabric, (2) anodic layer, (3) polymer electrolyte proton exchanger, (4) cathodic layer, (5) carbon fabric. Note that the carbon mesh with support for the nanoparticles was shown in the inset of the schematic. Detailed description of the invention

[014] The invention follows the scheme described in Figure 1, where two lead electrodes are prepared with lead nanoparticles dispersed in high surface area carbon. The nanoparticles are anchored in a carbon fabric or mesh and then pressed into a polymeric membrane, resulting in a battery unit to which terminals are subsequently added.

[015] Lead-carbon based nanoparticles are not commercially available and were synthesized by means of electron discharges in lead oxide and Petition 870250052929, dated 06 / 24 / 2025, page 8 / 10 6 / 7 carbon only and obtaining nanoparticles between 2 and 100 nm, in lead and carbon proportions of 1 to 80%. The nanoparticles are synthesized with 1 to 1000 current discharge pulses.

[016] Carbon-supported lead nanoparticles are dispersed in an ink and deposited onto a carbon fabric or mesh or a light metal. For the synthesis of nanoparticles, in addition to lead oxide, different other sources of the metal can be used, such as sulfates, chlorides, nitrates, among others.

[017] This synthesis process, using electrical discharge, provides the construction of 2D lead-based materials, with the synthesis carried out at ambient pressure and temperature.

[018] The materials obtained by this synthesis are usually only a few nanometers thick, characterizing a 2D material, although the length may have larger dimensions.

[019] These materials are transferred to carbon fabrics, originating the anode and cathode of the battery with a high surface area, whose properties are superior to those of a lead metal electrode. The advantage lies in the savings in material used, reduction in the final weight of the battery, savings in reagents and synthesis time compared to conventional chemical methods.

[020] To obtain a final battery unit, the produced electrodes are pressed into a proton-conducting polymer membrane. This membrane allows for greater electrode flexibility and does not require electrolytes in its compartment; moisture is sufficient for proton conductivity to occur without additives. This behavior allows for new applications for these batteries, not limiting their use to automotive applications. Petition 870250052929, dated 06 / 24 / 2025, page 9 / 10 7 / 7

[021] To build a higher-power battery module, several flexible battery units can be connected in series. These batteries withstand more than 600 charge and discharge cycles, making them viable for large-scale application and modular production.

[022] Flexible batteries are not limited by weight and can be applied to automobiles, boats, motorcycles, and airplanes. They are a more viable alternative to current technologies, considering the existing infrastructure, as they can be easily recycled. New mining operations are not necessary due to the abundance and availability of lead, thus preserving the environment. Petition 870250052929, dated 06 / 24 / 2025, page 10 / 10

Claims

1 / 1 CLAIMS 1 - FLEXIBLE LEAD-ACID BATTERY based on the concept of fuel cells characterized by being made up of anode and cathode manufactured with nanoparticles of metallic lead or lead oxide dispersed in carbon with a high surface area, which are anchored in carbon fabrics or meshes, or other metals, and subsequently pressed into a proton-conducting polymeric membrane. 2 - Flexible lead-acid battery, as claimed in claim 1, characterized by the lead-based flexible battery electrodes containing lead nanoparticles or lead oxides produced by electrical discharge, chemical or electrochemical methods. 3 - Flexible lead-acid battery, according to claim 1, characterized by proton-conducting polymer membranes for the construction of a flexible battery unit. 4 - Flexible lead-acid battery, as claimed in claim 1, characterized by the flexible lead-acid battery units being able to be connected in series and / or in parallel to produce small, medium and large battery modules depending on the required power density. 5 - USE OF FLEXIBLE LEAD-ACID BATTERIES, as defined in claims 1 to 4, characterized by the electrodes being used in mobile, portable and stationary applications. 6 - USE OF FLEXIBLE LEAD-ACID BATTERIES, as defined in claims 1 to 4, characterized by the battery modules being constituted of a flexible battery unit for applications in electric or hybrid vehicles or boats, mobile and / or portable devices, drones, airplanes, agricultural machinery, toys, bicycles, scooters. Petition 870240108658, dated 12 / 19 / 2024, page 12 / 19

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