Abstract: The invention provides a system and method for assembling an electrical module. The module comprises a circuit board, a substrate and an electrical component carried on the substrate. The substrate is formed by a stamping process an is mounted at a location on the circuit board. The substrate forms part of an electrical circuit with a circuit in the circuit board and dissipates heat from the circuit board. The substrate and the circuit board are both initially carried in respective frames. Alignment registered in the frames allow the frames to be aligned such that the substrate is positioned at the location on the circuit board.

Abstract: A terminal post seal arrangement for lead acid batteries is provided which may be used both as a moveable post seal or as a static post seal. In a first aspect of the subject invention, a battery is provided with an elastomeric sealing member rigidly fixed to both the cover of the battery and a bushing about a terminal post. Preferably, the sealing member includes a slack portion between its rigid connections which allows for relative movement between the bushing and the cover. In a second aspect of the subject invention, a collar is formed in the cover to bound the terminal post. The collar and/or the sealing member are formed at least partially tapered such that relative movement between the collar and the sealing member causes interferent engagement. It is preferred that interference between the collar and the sealing member become greater with increasing extent of relative movement.

Abstract: A battery system having lead-acid cells, vertically upstanding cell support frame for supporting the cells, vertically upstanding members with receptacle means for slidably receiving and retaining vertical cell supports, and manually assemble means for connectively maintaining and spacing the upstanding members for receipt of the cell supports. The cells have horizontal positive and negative sandwiched lead-metal plates contained within a cell case resting on the vertical supports. The case has an expandable region surrounding the terminal for relieving pressure on that terminal from grid expansion while simultaneously maintaining the integrity of the case seal to the terminal. The cell support frame includes an elongated strap external of the case for connecting together terminals of the cell and having an output terminal and a central portion on the strap for electric communication with another battery.

Abstract: A lead-acid cell includes a case, positive and negative plates within the case, microporous separator material between adjacent plates and electrolyte in a starved amount, with the case having jar and covers joined by a weldment along overlapping cover and jars. The positive plates include a grid frame with an intermediate member extending between spaced apart generally peripheral portions of the frame, with pasted active material on the grid frame separated substantially into two portions by the intermediate member. Compressive force is adjustably continuously applied to the positive and negative plates within the case. The plates are suspended within the case at positions removed from the wall of the case, while plate growth is permitted in a manner that plate shorting is avoided.

Abstract: A terminal post seal arrangement for lead acid batteries is provided which may be used both as a moveable post seal or as a static post seal. In a first aspect of the subject invention, a battery is provided with an elastomeric sealing member rigidly fixed to both the cover of the battery and a bushing about a terminal post. Preferably, the sealing member includes a slack portion between its rigid connections which allows for relative movement between the bushing and the cover. In a second aspect of the subject invention, a collar is formed in the cover to bound the terminal post. The collar and/or the sealing member are formed at least partially tapered such that relative movement between the collar and the sealing member causes interferent engagement. It is preferred that interference between the collar and the sealing member become greater with increasing extent of relative movement.

Abstract: A 6,000 to 10,800 ampere rated modular power system for converting alternating current to direct current is provided. The modular power system includes a modular power bay having a plurality of rectifiers for converting alternating current to direct current and a modular power distribution assembly having a plurality of fuses for distributing the direct current. The modular power bay and the modular power distribution assembly include front access doors for ease of maintenance. The modular power system is also low profile for ease of maintenance. The modular design allows for expansion in the converting and delivery portions of the system.

Abstract: A recombinant lead-acid battery, and method for operating thereof, are provided wherein the battery includes a case with a a plurality of lead-acid cells therewithin. The cells are in vapor communication one with another, and in vapor communication with discrete catalyst units. The catalyst units act to enhance recombination within the case of hydrogen and oxygen into vapor phase water. The number of discrete catalyst units is fewer than the cells.

Abstract: A 6,000 to 10,800 ampere rated modular power system for converting alternating current to direct current is provided. The modular power system includes a modular power bay having a plurality of rectifiers for converting alternating current to direct current and a modular power distribution assembly having a plurality of fuses for distributing the direct current. The modular power bay and the modular power distribution assembly include front access doors for ease of maintenance. The modular power system is also low profile for ease of maintenance. The modular design allows for expansion in the converting and delivery portions of the system.

Abstract: A system for monitoring performance of one or more batteries in a battery plant facility. A set of sensors for each battery are used to measure a plurality of battery operation parameters comprising the battery current, battery voltage, and internal battery temperature of each said battery. A processor generates, for each battery, a plurality of battery status parameters comprising a true age parameter and a float capacity parameter. During a float period, the true age parameter is updated based on elapsed time corrected for battery temperature history and the float capacity is updated based on the most recent true age parameter. During a discharge period, the float capacity parameter is updated based on the evolution of plant voltage during the discharge. After the discharge period, at the beginning of a subsequent float period, the true age parameter is updated based on the float capacity parameter determined during the immediately previous discharge period.

Abstract: A recombinant lead-acid battery comprising a plurality of lead-acid cells in a case including apertured partitions defining space for vapor migration among cells and comprising a catalyst unit communicating with said vapor migration space and enhancing recombination of hydrogen and oxygen.

Abstract: The subject invention provides a tray assembly for use in forming a sealed lead-acid battery system which houses multiple battery cells in horizontal positions for motive-power applications. In one aspect of the subject invention, the battery system includes a plurality of sealed lead-acid battery cells, and a housing having a plurality of walls which define an interior for accommodating the battery cells. At least one tray insert bears against a base of the housing which partitions the interior into at least two compartments for accommodating the battery cells. In a second aspect of the subject invention, a sealed lead-acid battery system for motive-power applications may be provided which utilizes at least one spacer partially disposed between two battery cells to cause separation thereof.

Abstract: A battery system having lead-acid cells, vertically upstanding cell support frame for supporting the cells, vertically upstanding members with receptacle means for slidably receiving and retaining vertical cell supports, and manually assemble means for connectively maintaining and spacing the upstanding members for receipt of the cell supports. The cells have horizontal positive and negative sandwiched lead-metal plates contained within a cell case resting on the vertical supports. The case has an expandable region surrounding the terminal for relieving pressure on that terminal from grid expansion while simultaneously maintaining the integrity of the case seal to the terminal. The cell support frame includes an elongated strap external of the case for connecting together terminals of the cell and having an output terminal and a central portion on the strap for electric communication with another battery.

Abstract: A lead-acid cell includes a case, positive and negative plates within the case, microporous separator material between adjacent plates and electrolyte in a starved amount, with the case having jar and covers joined by a weldment along overlapping cover and jars. The positive plates include a grid frame with an intermediate member extending between spaced apart generally peripheral portions of the frame, with pasted active material on the grid frame separated substantially into two portions by the intermediate member. Compressive force is adjustably continuously applied to the positive and negative plates within the case. The plates are suspended within the case at positions removed from the wall of the case, while plate growth is permitted in a manner that plate shorting is avoided.

Abstract: A battery system having lead-acid cells, vertically upstanding cell support frame for supporting the cells, vertically upstanding members with receptacle means for slidably receiving and retaining vertical cell supports, and manually assemble means for connectively maintaining and spacing the upstanding members for receipt of the cell supports. The cells have horizontal positive and negative sandwiched lead-metal plates contained within a cell case resting on the vertical supports. The case has an expandable region surrounding the terminal for relieving pressure on that terminal from grid expansion while simultaneously maintaining the integrity of the case seal to the terminal. The cell support frame includes an elongated strap external of the case for connecting together terminals of the cell and having an output terminal and a central portion on the strap for electric communication with another battery.

Abstract: A lead-acid cell includes a case, positive and negative plates within the case, microporous separator material between adjacent plates and electrolyte in a starved amount, with the case having jar and covers joined by a weldment along overlapping cover and jars. The positive plates include a grid frame with an intermediate member extending between spaced apart generally peripheral portions of the frame, with pasted active material on the grid frame separated substantially into two portions by the intermediate member. Compressive force is adjustably continuously applied to the positive and negative plates within the case. The plates are suspended within the case at positions removed from the wall of the case, while plate growth is permitted in a manner that plate shorting is-avoided.

Abstract: A recombinant lead-acid battery comprising a plurality of lead-acid cells in a case including apertured partitions defining space for vapor migration among cells and comprising a catalyst unit communicating with said vapor migration space and enhancing recombination of hydrogen and oxygen.

Abstract: A recombinant lead-acid battery comprising a plurality of lead-acid cells in a case including apertured partitions defining space for vapor migration among cells and comprising a catalyst unit communicating with said vapor migration space and enhancing recombination of hydrogen and oxygen.

Abstract: An expandable, flexible connection between a battery cell case cover and a terminal is provided which compensates for expansions of plates or grids of one polarity connected to that terminal. The expandable design encompasses a flexible battery case which facilitates movement of the battery terminal without compromising the scal between the case and the terminal. Preferably, a tubular thermoplastic sleeve is formed integrally with the case cover and extends into an opening between the cover and a terminal bushing which supports battery plates of one polarity. An annular flexible thermoplastic connector connects the sleeve to the case or to the bushing, with the connector being thinner than the case cover to afford more flexibility than the case cover.

Abstract: A vent valve is capable of mechanical attachment to a lead acid battery through vent hole structure provided in the case cover. The vent valve is a molded hollow tubular housing having a cup portion, the bottom of which rests atop the battery case, and a neck portion extending through an opening into the battery case. The neck carries cam members on its outer surface which are engaged by similar opposed surfaces or pins on a portion of the case so that, when the cup bottom is seated on a sealing gasket on the case cover and the vent valve is rotated, it is secured and sealed to the case cover. A barrier extends across the inside of the vent valve housing and blocks passage of gases. A pair of oppositely directed valve openings through the barrier establish vent passages which are defined by nozzles protruding through the barrier in opposite directions. Each nozzle is covered by a resilient cup valve member arranged to yield to a higher pressure within a cup at predetermined pressure differentials.

Abstract: A battery is delineated comprising, in combination, a battery cover having a Cast on Strap (COS) post extending into an aperture located in a top surface of the battery cover; and a battery terminal bushing, integrally coupled to the battery cover, having a first portion fitting about and coupled to the COS post, and having a second portion extending away from the first portion approximately orthogonally. The second portion of the battery terminal bushing extends through the battery cover and is accessible via an aperture located on a side surface of the battery cover, thereby providing frontal access to battery termination.