Abstract: A sealed, through partition terminal for an electrochemical cell featuring the use of gasketing material to prevent the spread of electrolyte past the terminal seal assembly is disclosed. An orifice formed in a lid of an electrochemical cell accepts a terminal member that is secured to the lid with a fastener threaded onto the terminal member. A shoulder molded on the bottom face of the lid and adjacent to the orifice prevents axial movement of the terminal member while torquing the fastener. A gap formed between the wall of the orifice and the terminal member is filled with gasketing material that is compressed by torquing the fastener. The compressed gasketing material seals any gaps between the terminal member and lid orifice preventing electrolyte leakage.

Abstract: A separator screen installation system for a shaker separator device, including an improved wedge block and vertical screen rail which provide rapid and secure screen installation and reduced accumulation of solids on the upstream end of the wedge blocks.

Abstract: A high performance double layer capacitor having an electric double layer formed in the interface between activated carbon and an electrolyte is disclosed. The high performance double layer capacitor includes a pair of aluminum impregnated carbon composite electrodes having an evenly distributed and continuous path of aluminum impregnated within an activated carbon fiber preform saturated with a high performance electrolytic solution. The high performance double layer capacitor is capable of delivering at least 5 Wh/kg of useful energy at power ratings of at least 600 W/kg.

Abstract: A novel apparatus and method for constructing a stress resistant battery which allows the use low modulus materials through end wall rib reinforcements and a cover having a plurality of integral bosses which vertically project and connect to cast on straps. A plurality of baffles adapted to snap fit into the inner bottom portion of the cover and augment stress resistance through rigid contact against the battery plates. A plurality of cast on straps welded back to back in pairs through each of said electrochemical cell walls each having a seating boss so as to connect with each of the cover bosses.The battery of the present invention also includes means of affixing terminal connectors in a scalloped configuration thereby preventing over-torquing and failure of the cover during electrical-mechanical connection.

Abstract: A sealed, through partition terminal for an electrochemical cell featuring the use of gasketing material to prevent the spread of electrolyte past the terminal seal assembly. An orifice formed in an inner lid of an electrochemical cell accepts a terminal member that is secured to the inner lid with a fastener threaded onto the terminal member. A shoulder molded on the bottom face of the inner lid and adjacent to the orifice prevents axial movement of the terminal member while torquing the fastener. A gap formed between the wall of the orifice and the terminal member is filled with gasketing material that is compressed by torquing the fastener. The compressed gasketing material seals any gaps between the terminal member and inner lid orifice preventing electrolyte leakage.

Abstract: An up-and-through battery intercell connection for electrochemical batteries or cells is disclosed featuring battery partition wall extensions formed on battery partition walls located within a battery container through which lead intercell connector nuggets are secured to provide electrical connection between battery intercells. A battery container top is formed with recesses to accept the battery partition wall extensions. The container top is further formed with adhesive channels to accept a paste adhesive that allows the battery container top to be secured to the battery container without having to invert the battery during manufacture.

Abstract: A recombinant lead acid battery is provided having positive and negative plates coated with active material and separated by a compressible separator material containing an electrolyte. A casing provides structural support for the plates and encases the battery's components. The battery is preferably a recombinant lead acid battery with its plates being formed of lead foil sheets. The casing is reinforced and arranged to i) maintain a substantially evenly distributed compressive force on the separator material and ii) maintain a constant spacing between the plates. The battery is arranged to maintain a compressive force of at least eight psi on the plates which has been found to significantly reduce the incidence of premature capacity loss (PCL). By way of example, compressive forces in the range of 8-14 psi work well for conventional separator materials.

Abstract: In one aspect the invention is a lead-acid cell of the type having a container. The container has a jar and a lid. The jar has an upper perimeter defining an opening matingly engaging and closed by the lid. The container houses at least one positive electrode plate, at least one negative electrode plate, a separator interposed between the electrode plates, acid electrolyte absorbed in the electrode plates and separator, and electrical connections from the electrode plate(s) through the container to an output terminal location. The lid is sealed to the jar. The cell is improved by the lid and the jar including a mechanical means for retaining the mating relationship of the lid and with the jar, when the lid is placed upon the upper perimeter, of the jar.

Abstract: A sealed, through partition terminal for an electrochemical cell is disclosed featuring a high conductivity terminal member embedded in a lead strap current collector, penetrating a through hole in the partition wall. A cup-like well is formed around the hole to receive the terminal which is located and immobilized by the combination of a fastening member which grips the outer surface of the terminal, and by an epoxy contained within the cup-like well which embeds the fastening member and surrounds the terminal. An elastomeric sealing member is preferably compressed between the strap and the underside of the cup-like well.

Abstract: A rechargeable battery module is disclosed that is particularly well adapted for use in multi-module battery packs. The module includes top and bottom cover plates. At least a portion of each cover plate is formed from electrically conductive materials so that when the battery module is integrated into a stack, the contacts between adjacent battery units are formed by the cover plates. A positive plate that has a positive surface is placed in electrical contact with a first cover plate. A negative plate having a negative surface is also provided. The negative plate is arranged in electrical contact with the second cover plate. The battery includes a plurality of active paste layers. Each active paste layer is applied to an associated surface. One or more separators are provided to isolate the paste layers. The first and second cover plates are electrically isolated by at least the paste layers and the separator means. The cover plates may be ribbed to provide structural support.

Abstract: A normally sealed multi-cell, lead-acid battery of the starved electrolyte type has each cell filled with a metered quantity of electrolyte by drawing down a vacuum on one or more of the cells; releasing the vacuum; and simultaneously drawing, through a filling port in the lid of each cell under vacuum, the metered quantity of electrolyte. Each cell houses a cell pack comprising at least one porous positive plate; at least one porous negative plate; and a porous, relatively fragile microfiber glass mat separator interleaved between the plates. A deflector platform, integral with the lid and having a deflecting surface, is positioned between the filling port and the cell pack of each cell of the battery. During filling, the electrolyte impinges upon the deflecting surface and is deflected laterally so that the electrolyte does not directly impinge upon and damage the cell pack.

Abstract: An electrical terminal connector is disclosed for use in an electrochemical cell. The terminal connector includes a first terminal member made from metal inert to the environment within said cell and adapted for interfacing internally within the cell. The first terminal member includes a socket portion communicating with the exterior of the cell. The terminal connector also includes a second terminal member made from low electrical resistance metal and is adapted for engagement within the socket portion from the exterior of the cell.

Abstract: A cadmium electrode for use in a rechargeable cell employing an alkaline electrolyte is disclosed. The electrode includes an electrically conductive substrate supporting an electrochemically active cadmium material. In addition, an effective amount of a nonionic, water soluble glycoside-based surfactant is added to retard cadmium agglomeration during operation of the electrode. Finally, a process for making such an electrode is also disclosed.

Abstract: A support assembly, including an end plate, for use in metal gas cells. The support assembly inhibits a plate stack which is positioned within a pressure vessel from impinging the walls of the pressure vessel. The support assembly comprises a first and a second weld ring and a first and a second end plate, each of the end plates being attached to a different end of the plate stack. The first and second weld rings mate with the first and second end plates, respectively, and cooperate to support the plate stack. The end plate comprises two plates secured together. A raised portion on one of the plates forming the end plate has a radially extending embossment formed therein to increase the rigidity thereof. The pressure vessel is constructed of generally cylindrical container defining two circumferentially extending lips, each of which is secured to an end portion.

Abstract: An electrode for a rechargeable electrochemical cell including an electrically conductive substrate, a layer of an electrochemically active material attached to the substrate, the active material comprising a reducible species of a metal, at least one conductive contact area formed of a metallic form of said metal attached to said substrate, said metallic contact area comprising said reducible species in a converted form. A positive electrode is further provided wherein said active material is nickel hydroxide and said metallic form of said metal is nickel metal. The invention further comprises the method for manufacturing electrodes as described above, featuring use of reducing gas to effect conversion.

Abstract: A metal hydride negative electrode plate for use in an alkaline electrochemical cell is disclosed including a conductive substrate carrier, a layer of electrochemically active hydrogen storage alloy material capable of reversibly storing hydrogen attached to the carrier, and the presence of a layer of carbon particles affixed to the outer surface of the active material layer. The carbon particle layer is present as a uniform distribution on the surface of the active material layer and prevents substantial oxidation of the active hydrogen storage alloy material during charge and overcharge of an alkaline cell incorporating the carbon coated metal hydride negative electrode of the invention.

Abstract: A lead-acid cell in which insert molded lead terminal connectors are provided with a surface layer of an elastic adhesive material bonded to the connector and making sealing contact with the enshrouding plastic molding. Electrolyte creepage and corrosion is suppressed.

Abstract: A battery powered energy-using device is disclosed which operably distinguishes between batteries having standard and non-standard terminal configurations. The battery compartment in the device is provided with a terminal having first and second insulated contacts, one contact configured to make contact with a battery of standard terminal configuration and the second contact adapted to make contact with a second terminal. In one embodiment the device is associated with charging circuitry which is adapted to recharge a rechargeable battery having the special non-standard terminal configuration, while permitting discharge but not recharge of a primary battery having a standard terminal configuration.

Abstract: A sealed rechargeable nickel electrode containing electrochemical cell has a pasted negative electrode having paste layers adhered to a nonforaminous conductive substrate, which retards growth (swelling) of the nickel electrode on cycling.