Abstract: Embodiments of solid-state batteries, battery components, and related construction methods are described. The components include one or more embodiments of a low melt temperature electrolyte bonded solid-state rechargeable battery electrode and one or more embodiments of a composite separator having a low melt temperature electrolyte component. Embodiments of methods for fabrication of solid-state batteries and battery components are described. These methods include co-extrusion, hot pressing and roll casting.

Abstract: Embodiments of solid-state batteries, battery components, and related construction methods are described. The components include one or more embodiments of a low melt temperature electrolyte bonded solid-state rechargeable battery electrode and one or more embodiments of a composite separator having a low melt temperature electrolyte component. Embodiments of methods for fabrication of solid-state batteries and battery components are described. These methods include co-extrusion, hot pressing and roll casting.

Abstract: Rechargeable galvanic cells are disclosed which comprise a manganese dioxide cathode, a zinc anode and a potassium hydroxide electrolyte wherein the cathode includes additive compounds to increase the cumulative discharge capacity of the cell thereby increasing its cycle life. The additives consist of a) barium or strontium compounds, and mixtures thereof, and b) titanium, lanthanum, yttrium, cerium, zinc, calcium, tin or magnesium compounds, and mixtures thereof.

Abstract: A cylindrical electrochemical cell includes a cathode, an anode, a cylindrical separator, coaxial with the cell, for electrically separating the cathode and anode, and a cup seal at an end of the separator for electrically separating the anode and cathode and maintaining an ionic connection therebetween. The cup seal is comprised of one or more first layers of a micro-porous or a non-porous membrane, or a combination thereof, and one or more second layers of a porous membrane and wherein the seal overlaps at least a portion of the separator.

Abstract: A method for preparing a cylindrical separator from sheet material and for inserting the separator in the cylindrical anode space of a semi-finished cell, in which the separator is wound from a sheet material around a mandrel to have a diameter smaller than the diameter of the anode space so that the sheet is temporarily affixed to the outer surface of the mandrel by providing vacuum through the mandrel wall, and the so obtained winding is inserted axially in the cathode cylinder. When the insertion is ready, the vacuum is disrupted, and the wound structure expands and presses against the cathode wall.

Abstract: A method of assembling a bipolar battery, most preferably a lead-acid battery, includes assembling the electrochemical components necessary to provide the necessary voltage and capacity, maintaining the electrochemical components under the desired compression and then sealing such electrochemical components as a unit utilizing various assembly components. The resulting bipolar battery in the preferred embodiment includes an electrolyte fill/vent box that seals the top of the electrochemical component unit and a vacuum box that seals the bottom surface.

Abstract: A method and apparatus is disclosed for charging lead-acid batteries which includes periodic voltage sweeps to determine the charging voltage that should be used for the battery and then adjusting the charging voltage in accordance with that voltage sweep information so as to ensure that a highly efficient charging process is achieved which avoids undue gassing and inherently compensates for factors such as the temperature, type and service life history of the battery and resistance due to the interactive nature of the technique and apparatus.

Abstract: The zinc active powder for a mercury-free rechargeable electrochemical cell is coated with a surfactant, and separately with an aqueous solution of indium sulphate. Without any subsequent filtering, washing or drying, the powder is assembled into an electrochemical cell. The cell can include a hydrogen recombination catalyst in contact with the electrochemically active material of the cathode.

Abstract: Apparatus and method for charging a battery, wherein a charging voltage is applied to a battery. The charging voltage depends on a base charging voltage which is continually adjusted in the direction that provides a more optimal level of charge acceptance. The direction of a more optimal charge acceptance is determined by adjusting the charging voltage in steps of predetermined magnitudes such that the steps provide an upper pair and a lower pair of spaced-apart charging levels. The current at each stepped voltage is measured, and used to calculate first and second current differentials corresponding to the upper and lower pairs. The base charging level is incremented or decremented to adjust the base charging level in the direction that provided the smaller differential. As the process is repeated, the charging level continually moves closer to a charging voltage level that minimizes the differential thereby providing a more optimal charge acceptance.

Abstract: Apparatus and method for charging a battery, wherein a target voltage is applied to a battery. During charging, the applied voltage is periodically increased and decreased a predetermined amount to modify the applied voltage by a small step in either direction. The charging input is measured as the current flow to the battery at each of the applied levels, and the target charging voltage is adjusted in the direction of the improved charge acceptance as indicated by the differentials of the input current flow at the increased and decreased levels. By repeating the process, the charging voltage is continually moved in the direction of an optimized charge acceptance level. Alternatively, a target current is applied and increased and decreased by a small step and adjusted in the direction of the improved charge acceptance, which corresponds to the differentials of the resulting voltages at the increased and decreased levels.

Abstract: Temperature-sensitive thermal insulators for batteries are provided for. The thermal insulators are fabricated from barrier film and have one or more expandable chambers containing a fluid. The fluid has a vaporization temperature of from about 90.degree. F. to about 200.degree. F., preferably from about 100.degree. F. to about 130.degree. F. The insulator has a first volume above the fluid vaporization temperature which is greater than a second volume of the insulator below the fluid vaporization temperature.

Abstract: A method of fabricating a modular, recombinant lead-acid battery is provided for. The method includes providing a plurality of thermoplastic frames, including at least two frames which support electrochemically active plates. The frames are adapted to be stacked and welded together such that the plates are spaced apart from each other a predetermined distance. One or more separators also are provided. The separators have an uncompressed state in which their thickness is equal to or greater than the predetermined distance between plates and a compressed state. The frames and separators are stacked such that a separator is disposed between adjacent plates in its compressed state. The frames then are successively vibration welded together, again while the separator is in its compressed state. The separator has a predetermined thickness in its compressed state effective to reduce damage to the separator caused by abrasion of the separators by the plates during vibration welding.

Abstract: An apparatus for delivering molten lead or a lead alloy to the cast-on-strap molds used in the manufacture and assembly of lead-acid batteries is disclosed which comprises a lead delivery member having a lead reservoir of the molten lead or lead alloy, at least one nozzle communicating with the lead reservoir and having an outlet, a valve for each nozzle which controls the amount of lead delivered to the molds when the apparatus is in a lead delivery position, and a heater for maintaining the molten lead at a selected temperature, a frame structure for mounting the apparatus to allow the lead supply member to be rotated between the lead delivery position and a home or wait position about an axis of rotation, a stepper motor and a right angle gear reducer to rotate the lead supply member between the respective positions, the lead reservoir being positioned sufficiently close to the axis of rotation so as to allow movement of the lead delivery member at a selected rate between the lead delivery and wait positio

Abstract: A multi-functional spacer is provided for which comprises a body portion removably attachable to the bottom of the battery and one or more auxiliary spacer members removably attached to the body portion and, when detached from the body portion, the auxiliary spacer members being attachable to a side or end wall of the battery. The body portion defines a top surface adapted to receive the battery and a bottom surface adapted to be received by a battery mounting device. The distance between the top and bottom surfaces of the spacer body portion is coordinated such that when the body portion is attached to the battery, the combined height of the body portion and battery is generally equivalent to the height requirement of a battery mounting device for a first vehicle having a height requirement greater than the height of the battery itself.

Abstract: An electrochemical cell of cylindrical type, with a metal can, an anode, a separator and a cathode arranged concentrically in one another, an aqueous alkaline electrolyte solution, and a closure assembly. The closure assembly comprises a plastic top inserted in the open end of the can and has an outer cylindrical zone, a lower rim, a central portion defining a central bore, and an intermediate portion interconnecting the central portion with the lower rim. A current collector nail is inserted through the central bore and penetrates into the anode. A negative cap of a metal sheet material forms the negative terminal of the cell. The negative cap has a flange portion ending in an inwardly bent rim, the can has a bead at a specific distance from its open end, and the bead serves as an abutment member for the closure assembly when inserted in the can. The plastic top defines a conforming support surface for the inwardly bent rim substantially at the connection zone of the outer cylindrical zone and the lower rim.

Abstract: A method of assembling a bipolar lead-acid battery includes assembling the electrochemical components necessary to provide the necessary voltage and capacity, maintaining the electrochemical components under the desired compression and then sealing such electrochemical components as a unit utilizing various assembly components. The resulting bipolar battery in the preferred embodiment includes an electrolyte fill/vent box that seals the top of the electrochemical component unit and a vacuum box that seals the bottom surface.

Abstract: A method and apparatus is disclosed for charging lead-acid batteries which comprises periodic voltage sweeps to determine the charging voltage that should be used for the battery and then adjusting the charging voltage in accordance with that voltage sweep information so as to ensure that a highly efficient charging process is achieved which avoids undue gassing and inherently compensates for factors such as the temperature, type and service life history of the battery and resistance due to the interactive nature of the technique and apparatus. One suitable technique for analysis and adjustment of the voltage sweep data involves analyzing the slope of the current versus the voltage sweep curve so as to determine certain slope values or changes in values.

Abstract: A lead-acid storage battery for starting, lighting and ignition applications is disclosed which minimizes convection-induced, heat transfer from the vehicle underhood environment surrounding the battery to the battery itself and comprises an injection-molded, integral plastic container having a multi-wall configuration in which an inner container includes the cell elements of the battery and at least one outer container spaced from the inner container provides at least one fluid compartment for allowing fluid flow through the fluid compartment to achieve the desired thermal regulation, the fluid flow path being created by a series of spaced fluid baffles.

Abstract: A sealed, lead-acid cell tray assembly for powering a vehicle characterized by the ability to provide vastly superior cycle life under regimes requiring relatively deep depths of discharge comprises a tray base, upstanding tray side walls connected to the base, the base and the side walls being dimensionally configured to provide a cell enclosure area having the ability to accept at least six sealed lead-acid cells in a horizontal position, cell-receiving members positioned above the base and attached to the upstanding side walls which divide at least part of the cell enclosure area into cell compartments capable of accepting at least one sealed lead-acid cell in a horizontal position and tray covers which limit access to the cells.

Abstract: A continuous method for making starting, lighting and ignition lead-acid battery positive plates and the resulting battery is disclosed which utilizes a direct cast alloy strip wherein the alloy consists essentially of lead, from about 0.02 to 0.05% calcium, from about 0.3 to about 0.5% tin, and from about 0.02 to 0.05% silver, the percentages being based upon the weight of the alloy strip, as well as related alloys utilizing calcium and strontium or strontium in place of calcium.