Abstract: A method for producing a valve-regulated lead acid battery includes the steps of (i) providing a battery comprising a preformed positive electrode plate, a preformed negative electrode plate and a porous separator mat having pores and being compressibly disposed between the electrodes to define a cell assembly, and a container for securably and sealingly holding the cell assembly; (ii) forming a electrolyte mixture comprising an aqueous colloidal dispersion of silica and sulfuric acid that is a precursor to a flowable thixotropic gel; (iii) applying a vacuum to the container; and (iv) introducing a quantity of the gel-precursor electrolyte into the container under a vacuum so that the flowable electrolyte mixture penetrates into the pores of the compressed mat, whereby as the acid absorbs onto the plates, the flowable electrolyte solidifies and forms a thixotropic gel within the pores and around peripheral edges of the mat to surround and seal the cell assembly.

Abstract: A battery charging system includes a battery management module and a battery charger. The battery charging system provides controlled charging in accordance with an algorithm utilizing historical battery data. The historical battery data is data pertaining to the historical status of the battery, and is acquired while the battery is in service and during previous charge cycles. The historical battery data is stored in memory in the battery management module. In one embodiment of the battery charging system, the battery management module is physically and electrically coupled to the battery during service and during charging. The historical battery data is provided to the battery charger during charging. The historical battery data is used to provide parameters to a charging algorithm, wherein the battery charging system provides controlled charging of the battery in accordance with the algorithm.

Abstract: A lead-acid battery includes a compartmented case and a polarity of electrochemically lead-acid cells serially connected via respective positive and negative terminals. Each cell includes planar positive and negative plates and resides in one compartment of the case. The battery further includes an electrochemically inactive cell serially connected with the electrochemically active cells and being intermediately disposed respecting the electrochemically active cells. Plates of the inactive cell preferably have connecting lugs extending therefrom which align with corresponding connecting lugs of the positive and negative plates of the active cells. Rigid homogeneous foam separates the inactive cell plates from one another and fills the inactive cell compartment thereby providing support for the inactive cell plates.