Abstract: A device (111) for simulating a high battery temperature used in charging a rechargeable cell (101). The device takes advantage of a control signal generated by a voltage control circuit (103) used to disconnect a rechargeable cell (101) from a charging system (105) when a predetermined voltage is reached. The device (111) is generally used with cells having a lithium based chemistry and requiring a different charging regime then nickel chemistry cells. The device (111) is activated by the control signal from control circuit (103) which detects a predetermined voltage from rechargeable cell (101) enabling thermistor (113) to change its state. This change is detected by the charging system (105) which alters its mode of operation from a rapid charging rate to a slower charging rate. The device is retrofitable to existing rechargeable batteries allowing them to be charged using existing charging systems alien to the rechargeable battery.

Abstract: A battery recharge current source 12 provides a recharge current 14 to battery cells 16. Recharge current 14 is in excess of an optimum recharge current level for battery cells 16 and is divided into currents 26 and 28 by variable shunt load 24 as controlled by charge current control circuit 18. Charge current control circuit 18 is comprised of current sense circuit 20 and load control circuit 22. Current sense circuit 20 produces a current sense signal in response to current through battery cells 16. Load control circuit 22 is responsive to the current sense signal and controls variable shunt load 24 as needed to conduct excess current away from the battery cells.

Abstract: A process for joining at least two ultrathin plastic pieces by an ultrasonic welding method is disclosed. The process includes providing a plurality of energy directors for enhancing weld strength, and reducing unacceptable welds. The process also includes providing a groove in a flanged attachment member to assist in properly orienting the pieces to be joined.

Abstract: A battery comprises a battery cell (110) having positive (160) and negative (140) electrical terminals. The terminals are electrically coupled to the battery cell and situated on an external surface (120) of the battery cell. The exposed surface area of the positive terminal is greater than the exposed surface area of the negative terminal, thereby reducing the corrosion of the battery electrical terminals. A plurality of cells is also configured to form a cathodically protected multicell battery package for use in a corrosive environment. The multicell battery (200) comprises a battery housing (210) and a plurality of cells (250-300) within the housing. The cells are electrically coupled together so as to terminate in positive and negative electrical contacts (221 and 222) on the exterior (220) of the battery housing. The positive and negative terminals of the cells are connected to these contacts, and formed so that the ratio of the areas of the positive/negative contacts is greater than unity.

Abstract: A circuit assembly (400) includes a flexible circuit (402) having first (504) and second layers (502). A current-limiting device such as a nichrome strip (316) is coupled to the flexible circuit (402) for limiting the amount of current during a short circuit condition. A heat sink (404) is selectively placed between the first and second layers of the flexible circuit in thermal proximity to the nichrome wire (316) in order to dissipate some of the heat generated by the nichrome strip (316).

Abstract: An electrical energy source (5), comprises a power supply (14) located in a housing (16). The power supply has positive (22) and negative (24) terminals attached to it and to the exterior of the housing. Conductors (12) connect the power supply to the positive and negative terminals. The housing has one or more apertures (20) in it that correspond to the location of the power supply. A non-conductive film (36) having an adhesive portion (24) is adhesively bonded to both the power supply and the cover. The power supply can be one or more battery cells (10), and the housing typically consists of a top (18) and a bottom (20), each of which have openings that correspond to the battery cells. The cells are co-located with the openings so that the cylindrical wall (32) of the battery cell is tangent to the exterior (33) of the housing.

Abstract: A method of fabricating a battery package. The battery package (5) is made using a two-piece plastic housing (16, 18, 20), with one or both of the pieces having one or more apertures (30). Cylindrical-shaped batteries (10) are electrically connected to each other and situated in the housing so that the cylinder wall (32) of each battery is co-located with an aperture, and so that the cylinder wall is substantially tangent to the exterior surface (33) of the housing. The battery package has positive and negative terminals (22, 24) on the housing that are connected to the batteries. A cover, comprising a film (34) and an adhesive material (36), is placed on the exterior surface of the housing. The assembly is ultrasonically welded so that the two pieces of the housing are joined. The ultrasonic energy also forms an adhesive bond between the co-located battery cylinder walls, the cover, and the housing by heating the adhesive material to form a unitized battery package.

Abstract: An improved circuit protection device (30) comprises a PTC element (10), at least two electrodes (2 and 3) connectable to a source of electrical power (12) so that current passes between the electrodes (2 and 3) through the PTC element (10), and at least one nichrome electrical lead (122, 123) which electrically connects one of the electrodes (2, 3) to the source of electrical power (12).

Abstract: A cathodically protected battery comprising a battery cell (110) having positive (160) and negative (140) electrical terminals. A sacrificial anode (150) is electrically coupled to the battery cell and situated on an external surface (120) of the battery cell. The sacrificial anode is strategically located so as to be exposed to the corrosive environment, thereby negating the corrosion of the battery electrical terminals. A plurality of cells is also configured to form a cathodically protected multicell battery package for use in a corrosive environment. The multicell battery (200) comprises a battery housing (210) and a plurality of cells (250-300) within the housing. The cells are electrically coupled together so as to terminate in a positive and a negative terminal. Electrical contacts (221 and 222) are provided on the exterior (220) of the battery housing and the positive and negative terminals of the cells are connected to these contacts.