Abstract: Thermal management of flat pack rechargeable batteries is accomplished by providing extensions on individual cell housing components, which extensions are connected to provide open air channels between individual cells. In an alternate embodiment of the invention, cells within the stack are filled with a thermally conductive liquid, such as a silica gel, to assist in heat dissipation from adjacent cells.

Abstract: A battery system for a vehicle includes a main battery for energizing the vehicle SLI circuits and an auxiliary battery for energizing the vehicle EHC system, the battery system providing back-up of the auxiliary battery by the main battery under certain conditions and back-up of the main battery by the auxiliary battery under certain other conditions, and the battery system providing opportunity charging of the auxiliary battery once the vehicle engine is running whereby the auxiliary battery shares the charging current with the main battery with the auxiliary battery being gradually connected to the source of charging current for the main battery by increasing the duty cycle of the drive circuit that connects the auxiliary battery to the source of charging current while monitoring the state of charge of the main battery and decreasing the duty cycle of the drive circuit to protect the main battery state of charge.

Abstract: A vacuum turret apparatus for moving objects from a first location to a second location is disclosed. The turret is specifically designed to move individual plate-like objects from a stack of such objects located at the first location to the second location. Flexible bellows in combination with vacuum are used to lift, hold, and move the objects. An air knife ejecting a stream of high pressure air towards the selected object helps separate that object from the rest of the stack.

Abstract: An arrangement for mounting a battery monitoring circuit on the cover of the battery and for connecting the terminal ends of first and second lead wires of a battery monitoring circuit to the positive and negative terminals of the battery, the arrangement including a cavity formed in the battery cover for mounting the battery monitoring circuit, first and second battery terminal bushings which are molded integrally with the cover and are adapted to be mounted on and connected to the positive and negative battery terminals when the battery cover is installed on the battery, each of the battery terminal bushings including a pad having an upwardly directed mounting post that is adapted to receive and secure the terminal end of one of the lead wires of the battery monitoring circuit, the battery cover having first and second lead wire slots in its surface which extend from the cavity in which the battery monitoring circuit is mounted, to the locations of the battery terminal bushings for directing the lead wires

Abstract: A battery cell includes at a plurality of composite separator/electrode structures, each composite structure including a support member having a plurality of parallel, closely spaced ribs defining a plurality of grooves which extend longitudinally of the support member, alternating ones of the grooves having a positive paste of an active material therein, and the remaining grooves having a negative paste of an active material therein, and a current collector lead wire in each groove embedded in the paste and centrally located in the groove with the terminal ends of the lead wires of the positive electrodes extending out of one end of the composite structure and being interconnected to form a positive termination, and the terminal ends of the lead wires of the negative electrodes extending out of the opposite end of the composite structure and being interconnected to form a negative termination, a plurality of the battery cells being stacked together to form a battery having a desired amp hour capacity.

Abstract: A cast-on strap for use in connecting current collecting lugs in battery systems is disclosed. In the most preferred embodiment, the invention includes a caston strap formed of electrically conductive material, such as lead, having a first elongate portion in electrical contact with a line of spaced apart battery plate lugs. The connector strap includes a second portion lying in a plane which is perpendicular to that of the elongate portion so that the latter is laterally displaced. The preferred cast-on strap also includes an angularly extending portion between the elongate portion and the second portion. Increased current transfer efficiency is achieved using the strap of the present invention.

Abstract: A state of charge indicator monitors a voltage produced by a depletable energy source and provides an indication when the state of charge of the depletable energy source falls below a predetermined threshold. The state of charge indicator includes an input circuit for sensing the voltage and producing a plurality of tap voltages. The state of charge indicator further includes a monitor circuit for comparing each tap voltage with a corresponding threshold voltage and producing a result for each tap voltage falling below its corresponding threshold. The state of charge indicator still further includes a storage device for storing each result and producing an accumulated status and an output circuit for producing the indication when the accumulated status exceeds an accumulated status threshold.

Abstract: An anti-theft battery system for vehicles includes a control circuit which is connected in the starting circuit and responds to a starting current which exceeds a set point value to interrupt the starting circuit, thereby disconnecting the starter motor from the battery preventing starting of the vehicle, a reset circuit responsive to the control circuit which resets the control circuit after a delay interval to permit the starter motor to be connected to the vehicle battery, and an override circuit for generating an override signal for overriding the control circuit for a preselected interval of time to permit an authorized operator to start the vehicle, the override circuit including a small portable transmitter adapted to be carried by the vehicle operator and a receiver connected to the control circuit.

Abstract: An architecture, arrangement, or construction for battery systems such as monopolar and bipolar batteries is disclosed. The battery system includes a stack of bipolar or monopolar modules having current collectors extending from opposite sides of the battery system. The current collectors are located in cooling channels. The cooling channel is surrounded by an insulating material. The cooling channel contains a fluid which may be air, water, forced air, Freon.RTM. or any other media useful in heating and cooling applications. The battery may be vented or a heat exchanger may be provided in communication with the cooling channels. The thermal management system is particularly useful in applications such as electric vehicles. Heat may be provided through the cooling channels in order to raise the temperature inside the battery system.

Abstract: A process for cutting a moving strip to form a series of plates, such as battery plates, includes the initial step of transporting the strip past a rotary divider including a cutter having radial blades configured to cut the strip into the plates. The cutter further has a set of blades for cutting individual pieces from the strip, which pieces are not part of the plates. As the cutter blades cut the strip to form the plates and pieces, a vacuum system applies suction to draw the pieces cut from the strip inwardly into the cutter through holes in the cutter, and then out of the cutter. The holes are each located adjacent each one of the corresponding blades and are shaped and positioned to permit the cut-away piece to pass through. In a preferred embodiment, the vacuum system includes a pair of vacuum manifolds that apply suction at opposite ends of the cylindrical cutter. An apparatus for carrying out the foregoing process accordingly includes a rotary divider as described above provided with a vacuum system.

Abstract: A flexible rib plaque is provided for insertion between battery cell elements and the end and/or an interior wall of the battery container. The plaque improves performance by limiting the harmful effects caused by flexing of the container walls due to hydraulic pressure changes of the electrolyte contained within the battery. The ribs of the plaques may be located on one or both sides of the plaque. If ribs extend from only one side, they may contact the cell element or the container wall.

Abstract: Absorption mat lead-acid batteries poorly dissipate heat from the internal components of the battery due to the air gap which exists between the plates and the inner wall of the container. Improved thermal management of the battery is achieved by filling the air gap, an insulating gap, with a thermally conductive gel, such as a gel formed of fumed silica and sulfuric acid electrolyte.

Abstract: A thermocell includes a negative electrode, such as a lead-acid electrode, and a porous oxygen (air) electrode disposed in a housing and separated by a separator. During discharge, oxygen is allowed to permeate through the oxygen electrode and separator to reach the negative electrode. Chemical oxidation of the negative electrode by oxygen in the presence of sulfuric acid yields water, lead sulfate, and heat. The heat can be used in many ways, such as warming up an adjoining automotive battery in winter, or as a personal heating pad. The heating rate is controlled by the rate of oxygen ingress. When not in use, the oxygen electrode is sealed by taping or by other means to stop ingress of oxygen. The used thermocell can be recharged by charging the negative electrode while evolving oxygen at the oxygen electrode.

Abstract: The present invention relates to rechargeable batteries which include cell casing components enclosing positive and negative plates, separator material and acid electrolyte. The battery includes a plurality of support members extending from one or the other of the casing components, or from both casing components, the support members passing through the plates to permit uniform compression of the internal components. In its preferred embodiment, the battery includes one or more intermediate cell partitions which permit stacking of individual cells to increase voltage. The partition continues the utilization of the support members. In another disclosed embodiment, the electrode plates contained within any particular cell are punched to permit the support members to pass therethrough, with hole sizing selected so that a small hole will remain at each support location, while also insuring that for each support member, only one of the positive and negative plates will touch it, but not both.

Abstract: Thermal management of flat pack rechargeable batteries is accomplished by providing extensions on individual cell housing components, which extensions are connected to provide open air channels between individual cells. In an alternate embodiment of the invention, cells within the stack are filled with a thermally conductive liquid, such as a silica gel, to assist in heat dissipation from adjacent cells.

Abstract: A battery monitor which monitors the operating parameters of a battery to provide an indication of, for example, the absolute state of charge, the relative state of charge, and the capacity of the battery under battery discharge, rest, and recharge conditions. The battery monitor includes a current sensor for sensing battery current, a voltage sensor for sensing battery voltage, and a temperature sensor for sensing battery temperature. A processor approximates to a high level of accuracy the battery parameters utilizing an iterative process based upon predetermined relationships, employing empirically determined constants and parameters determined in the immediately proceeding iteration stored in memory. Output signals indicative of the determined parameters are provided and may be utilized for many different battery applications.

Abstract: A dual-battery switch circuit associated with a load is provided. The switch circuit includes a primary battery, a secondary battery, a circuit disposed to apply energy from the primary battery to the load, and a controller which disposed to sense attempts to apply energy to the load. The controller is configured to couple the secondary battery to the primary battery with respect to the load when a predetermined number of attempts to apply energy to the load occur within a predetermined time period after a first attempt. Alternatively, a controller is provided which couples the secondary battery to the primary battery with respect to the load when an attempt is made to apply energy to the load and the temperature is below a predetermined level.

Abstract: Improvements in the end block design for zinc/bromine batteries include modification of the end block configuration which previously has included rigid resin covers and end block plates with a honeycomb structure sandwiched therebetween. Such prior structures were used adjacent to terminal electrode frames. In the present invention, the terminal electrodes are preferably contained within the end plate, thereby eliminating two components used in prior zinc/bromine battery design and the end block itself is formed from two components by building a rib structure into the plate and cover and welding the two components together to join the ribs and form an integral and structurally sound unit. The end block configuration could be used for bipolar lead-acid batteries or other types of flowing or non-flowing batteries or capacitors.