Montana Patent of the Month – January 2026

Patent Profile and Overview

In the rapidly evolving landscape of advanced energy storage, the interface between active electrochemical materials and external power loads represents a critical engineering bottleneck. Addressing this fundamental challenge, United States Patent No. 12,519,185, titled “Carbon adhered graphite tabs for battery terminal fastening,” was formally applied for on January 5, 2024, and subsequently granted on January 6, 2026. Assigned to Æsir Technologies, Inc., a company with significant research operations in Bozeman, Montana, and Joplin, Missouri, this intellectual property establishes a novel methodology for integrating graphite current collectors with metallic terminals—a solution that has historically eluded battery engineers. Recognizing the transformative potential of this technology to secure critical infrastructure and modernize national defense capabilities, Swanson Reed has distinguished this invention as the Montana Patent of the Month. This selection is not merely ceremonial; it underscores the immediate real-world impact of the technology in resolving the mechanical and electrical limitations that have previously prevented the widespread commercialization of high-performance, non-flammable Nickel-Zinc (NiZn) batteries.

The significance of Patent 12,519,185 lies in its ability to bridge the gap between the theoretical promise of carbon-based current collectors—lightweight, corrosion-resistant, and highly conductive—and the harsh realities of mechanical stress and electrical resistance. By utilizing a composite architecture of interleaved carbon layers and conductive adhesives, the invention enables the production of batteries that significantly outperform legacy lead-acid systems and offer a safer alternative to lithium-ion chemistries. As this report will demonstrate through detailed benchmarking, the technology facilitates specific energy improvements of over 2.7x compared to premium lead-acid incumbents while delivering the high-power discharge capabilities required for applications ranging from Intercontinental Ballistic Missile (ICBM) silos to hyperscale data centers. Furthermore, the development of this technology stands as a prime example of “Qualified Research” under the Internal Revenue Code, presenting substantial opportunities for R&D tax credit substantiation through the specialized services of Swanson Reed.

Technological Context: The Current Collector Dilemma

To fully appreciate the superiority of the invention described in Patent 12,519,185, one must first understand the severe limitations inherent in the prior art of battery manufacturing. The performance of any electrochemical cell is dictated not just by its chemistry (the interaction between anode, cathode, and electrolyte) but by the efficiency of its passive components—specifically, the current collector.

The Legacy of Lead and the Promise of Carbon

For over a century, the lead-acid battery has relied on lead grids to support the active material and conduct electricity. While chemically stable in sulfuric acid, lead is exceptionally heavy and mechanically soft. More detrimentally, lead grids are subject to corrosion, which gradually increases internal resistance and leads to catastrophic failure. This “lead penalty” is the primary reason legacy batteries suffer from low specific energy (typically 30-40 Wh/kg).

Carbon, specifically in the form of graphite or carbon foam, has long been identified as the ideal replacement for lead grids. Carbon is:

• Lightweight: Its density is approximately 2.2 g/cm³, compared to lead’s 11.3 g/cm³.
• Conductive: Graphite offers excellent in-plane electrical conductivity.
• Inert: Carbon is virtually immune to corrosion in many aggressive electrolytes, theoretically enabling infinite calendar life for the grid itself.

The Engineering Failure Mode

Despite these advantages, early attempts to commercialize carbon-based current collectors—such as those by Firefly Energy in the mid-2000s—failed to achieve mass market success. The primary failure mode was the terminal connection.

Graphite is brittle and anisotropic. Connecting a rigid, porous graphite plate to a metallic battery post (made of lead, copper, or brass) presents two fatal problems:

1. Mechanical Fracture: Traditional fastening methods like bolting, clamping, or riveting create stress concentrators. Under the vibration of a vehicle or the thermal expansion cycles of high-current discharge, the brittle graphite tabs would snap at the connection point, rendering the battery useless.
2. Contact Resistance: The interface between a carbon plate and a metal terminal is rough on a microscopic scale. “Dry” contact results in only a fraction of the surface area actually conducting current (the Holms radius effect). This high contact resistance generates significant heat during high-current draws, leading to terminal melting or casing failure.

Patent 12,519,185 specifically addresses this “Achilles’ heel” of advanced battery design.

Analysis of the Invention: US Patent 12,519,185

The invention disclosed by Æsir Technologies introduces a sophisticated composite structure that fundamentally alters the mechanics of the electrode-terminal interface.

The “Carbon Adhered” Architecture

The abstract of the patent describes an electrochemical cell comprising “a plurality of electrode graphite substrates each defining a current collector and a tab… and a plurality of carbon layers interleaved with the at least one stack such that each of the carbon layers is adhered between two of the graphite electrode tabs”.

This description reveals several key innovations:

• Interleaved Reinforcement: Rather than relying on a single, monolithic block of graphite to connect to the terminal, the invention utilizes a laminated structure. In materials engineering, lamination arrests crack propagation; if a micro-crack forms in one graphite layer, it is stopped by the interleaved carbon layer, preventing catastrophic failure of the tab.
• Conductive Adhesive Matrix: The term “adhered” implies the use of a specialized conductive resin. This adhesive serves a dual purpose:
  1. Mechanical: It distributes shear stresses evenly across the entire face of the tab, rather than concentrating them at a bolt hole.
  2. Electrical: The adhesive fills the microscopic voids and surface asperities of the porous graphite. This maximizes the effective contact area, lowering the contact resistance to negligible levels.

Solving the Vibration and Impedance Challenge

The resulting “Carbon Adhered Graphite Tab” acts as a unified, reinforced composite block. This structure is capable of withstanding the high G-forces associated with aerospace and defense applications (e.g., missile launches) without fracturing. Simultaneously, the low-resistance bond enables the battery to deliver massive surge currents—essential for starting heavy engines or powering directed energy weapons—without generating destructive waste heat at the terminals. This innovation effectively unblocks the path for high-power Nickel-Zinc chemistries to compete directly with high-performance lead-acid and lithium-ion batteries.

Comparative Analysis and Benchmarking

The commercial and technical superiority of the technology enabled by Patent 12,519,185 is best illustrated through a direct comparison with incumbent technologies. Æsir Technologies utilizes this patent to produce advanced Nickel-Zinc (NiZn) batteries that significantly outperform competitors in the critical power space.

Comparison with Premium Lead-Acid (AGM)

The most direct competitor for Æsir’s technology in the backup power and heavy-duty transportation sectors is the Absorbed Glass Mat (AGM) lead-acid battery, represented by industry leaders like EnerSys (Odyssey brand).

Analysis of Superiority:

The data unequivocally demonstrates that the patented technology enables a battery that is twice as energy-dense and nearly three times lighter than the equivalent lead-acid competitor.

• Weight Reduction: The elimination of the heavy lead grid (replaced by the patented graphite tabs) is the primary driver of the 2.7x improvement in specific energy. For mobile applications (military vehicles, aerospace), this weight reduction directly translates to increased payload capacity or range.
• Cycle Life: The corrosion resistance of the graphite current collectors allows the battery to endure 50% more deep discharge cycles and vastly more micro-cycles (grid frequency regulation), significantly reducing the Total Cost of Ownership (TCO) over the system’s life.

Comparison with Lithium-Ion

While Lithium-Ion (Li-ion) batteries generally offer higher specific energy (~150-250 Wh/kg), they suffer from critical safety flaws:

• Thermal Runaway: Li-ion electrolytes are organic solvents that are highly flammable. If a cell is punctured or overcharged, it can catch fire and propagate to adjacent cells.
• Supply Chain Risk: Li-ion relies heavily on Cobalt (mined in the DRC) and Nickel (refined largely in China/Russia), creating geopolitical vulnerabilities.

Æsir Superiority:

• Safety: The NiZn batteries enabled by Patent 12,519,185 use an aqueous (water-based) alkaline electrolyte that is inherently non-flammable. This allows them to be installed in safety-critical areas (e.g., inside submarines, data centers, or hospitals) without the complex fire suppression systems required for Li-ion.
• Power Density: The low-resistance connection provided by the patented carbon tabs allows for continuous discharge rates of up to 10C (ten times the rated capacity), surpassing many energy-optimized Li-ion cells.

Comparison with Other Zinc Competitors

• ViZn Energy: Also associated with the Montana innovation ecosystem, ViZn Energy specializes in Zinc-Iron Flow Batteries. While effective for grid-scale storage, flow batteries require massive tanks and pumps, making them wholly unsuitable for the compact, mobile, or drop-in replacement applications addressed by Æsir’s solid-state NiZn technology.
• ZincFive: A major competitor in the NiZn space. However, Æsir’s specific intellectual property regarding the carbon-adhered graphite tab provides a unique structural advantage in high-vibration environments, differentiating it from ZincFive’s electrode architecture which focuses more on commercial stationary UPS markets rather than hardened defense applications.

Real-World Impact and Future Potentials

The “Montana Patent of the Month” selection is driven by the immediate and strategic applicability of this invention in sectors vital to national security and economic stability.

Defense: Modernizing the Nuclear Triad

The most high-profile application of the technology described in Patent 12,519,185 is in the Minuteman III Intercontinental Ballistic Missile (ICBM) infrastructure. Æsir Technologies has been awarded a Phase II contract by the Department of Defense (Air Force) to develop and deliver emergency power batteries for these launch facilities.

• The Operational Challenge: ICBM silos are remote, unmanned, and subject to extreme environmental conditions. The legacy lead-acid batteries currently in use are heavy, require frequent maintenance sorties, and degrade quickly. More critically, in a launch scenario, the battery must survive massive shock and vibration loads.
• The Patent’s Impact: The reinforced graphite tab structure is specifically engineered to survive these kinetic events. The battery acts as a “drop-in” replacement that offers longer life (reducing dangerous and expensive maintenance trips) and higher reliability. This directly enhances the readiness of the US strategic deterrent.

Critical Infrastructure: Hyperscale Data Centers

Data centers are the backbone of the digital economy, consuming vast amounts of power. They require Uninterruptible Power Supplies (UPS) to bridge the gap between a grid failure and generator startup.

• The Problem: Lead-acid batteries are heavy (requiring reinforced floors) and unreliable. Li-ion batteries are lighter but pose a severe fire risk; a single cell fire can destroy a server hall worth millions of dollars.
• The Solution: The patented NiZn technology offers the perfect middle ground: the power density of Li-ion (thanks to the low-resistance tabs) with the fire safety of lead-acid. This allows data center operators to increase server density (revenue) while reducing insurance premiums and fire suppression costs.

Future Potential: The Metal-Free Battery

Looking further ahead, Patent 12,519,185 represents a foundational step toward the realization of fully non-metallic battery architectures. By perfecting the interface between carbon electrodes and external loads, Æsir is paving the way for batteries that eliminate heavy metals entirely from the current collection structure. This would lead to even lighter batteries with lower environmental footprints, utilizing abundant domestic materials like zinc and carbon rather than conflict minerals.

R&D Tax Credit Analysis: The Four-Part Test

The development of the technology described in Patent 12,519,185 involved significant technical risk and iterative engineering. As such, it represents a textbook case for eligibility under the Federal Research and Development (R&D) Tax Credit (IRC Section 41). For companies like Æsir Technologies, or other firms undertaking similar materials science innovation, substantiating these claims is a critical financial strategy.

Swanson Reed, a specialist R&D tax advisory firm, utilizes a rigorous methodology to ensure such projects meet the statutory Four-Part Test required by the IRS. Below is an analysis of how a project utilizing this technology satisfies each component.

Test 1: Permitted Purpose

Requirement: The research must relate to a new or improved business component (product, process, software, formula, or invention) with the specific intent of improving functionality, performance, reliability, or quality.

• Project Application: The development of the “carbon adhered graphite tab” was not for aesthetic purposes. The explicit engineering goal was to create a new battery terminal assembly that improved the reliability (mechanical strength under vibration) and performance (electrical conductivity) of the NiZn cell.
• Swanson Reed Strategy: Swanson Reed would isolate the specific “business component” (the electrode assembly) and document the functional specifications (e.g., target resistance < 1 milliohm, target tensile strength) established at the project’s outset to prove the “permitted purpose.”

Test 2: Elimination of Uncertainty

Requirement: Information available to the taxpayer at the start of the project must not establish the capability or method for developing or improving the business component, or the appropriate design of the component.

• Project Application: At the beginning of the research, it was not known if a graphite tab could be bonded to a metal terminal with sufficient strength to survive military-grade vibration testing. Furthermore, the optimal adhesive formulation and interleaving geometry to minimize contact resistance were unknown. The prior failures of competitors (like Firefly Energy) demonstrate that this knowledge was not standard in the industry.
• Swanson Reed Strategy: Swanson Reed assists in gathering contemporaneous documentation—such as email correspondence, technical meeting minutes, and literature reviews—that demonstrate the “knowledge gap” and the technical challenges the engineers faced (e.g., “We don’t know if this adhesive will survive the electrolyte acidity”).

Test 3: Process of Experimentation

Requirement: The taxpayer must engage in a systematic process designed to evaluate one or more alternatives to achieve a result where the capability or method is uncertain. This includes modeling, simulation, and trial-and-error testing.

• Project Application: The development of Patent 12,519,185 likely involved a rigorous iterative process:
  1. Hypothesis: Interleaving carbon layers will distribute stress.
  2. Prototyping: Fabricating tabs with 1, 2, and 3 interleaving layers; testing different conductive epoxies.
  3. Testing: Subjecting prototypes to destructive pull tests and thermal cycling.
  4. Analysis: analyzing fracture points and refining the design based on failure data.
• Swanson Reed Strategy: Swanson Reed focuses on capturing the “evidence of failure.” In the eyes of the IRS, a failed experiment is as valuable as a successful one because it proves a process of experimentation occurred. They would collate lab notebooks and test logs showing the progression from initial failure to the final patented design.

Test 4: Technological in Nature

Requirement: The process of experimentation must rely on principles of the “hard sciences”—physical or biological sciences, engineering, or computer science.

• Project Application: The research relied heavily on principles of Materials Science (anisotropy of graphite, rheology of adhesives), Electrical Engineering (current density distribution, Ohmic heating), and Chemistry (electrolyte compatibility).
• Swanson Reed Strategy: Swanson Reed’s technical consultants ensure that the claim narrative emphasizes the hard science principles utilized, distinguishing the eligible R&D from ineligible activities like market research or routine data collection.

How Swanson Reed Can Help Claim the Credit

Claiming the R&D credit involves complex calculations and strict documentation standards. Swanson Reed provides end-to-end support:

• Nexus Creation: Linking specific financial inputs (wages of inventors like Adam Weisenstein, supply costs for graphite/adhesives) directly to the qualified projects.
• Audit Defense: Providing representation and technical defense in the event of an IRS examination, utilizing their deep understanding of the 4-part test to justify the claim.
• Calculation: Optimizing the credit calculation (Regular vs. ASC methods) to maximize the benefit for the taxpayer.

Final Thoughts

United States Patent 12,519,185 is a landmark innovation in the field of energy storage. By solving the persistent mechanical and electrical challenges of connecting carbon electrodes to metal terminals, Æsir Technologies has unlocked the commercial viability of Nickel-Zinc batteries—a chemistry that offers a superior combination of energy density, power, and safety compared to incumbents.

The designation of this invention as the Montana Patent of the Month highlights its critical role in strengthening the US defense industrial base and modernizing critical infrastructure. As demonstrated by the performance benchmarks, this technology is not merely an incremental improvement but a generational leap in battery capability. Furthermore, the development of this patent serves as a definitive model for “Qualified Research,” offering a roadmap for how deep-tech companies can leverage the R&D Tax Credit—with the guidance of Swanson Reed—to fund the innovations that power the future.