Abstract: A method of making battery plates for lead-acid batteries includes providing a strip of material comprising lead; and punching material out of the strip to form a grid comprising wires having a non-rectangular cross-sectional shape by utilizing a die set comprising a plurality of male die components and female die components, wherein each of the male die components comprises a first portion having a first cross-sectional shape and a second portion having a second-cross sectional shape. A single punch of the material creates a hole in the material and also forms the periphery of the hole.

Abstract: A flooded lead-acid battery include a pasting substrate embedded into an active material of at least one surface of either the positive plates or the negative plates of each respective plurality, wherein the pasting substrate has an initial thickness. The pasting substrate thickness has a compressed thickness within the container that is at least 10 to 20% less than the initial thickness.

Abstract: An Advanced Graphite deep discharge lead acid battery is described including: a deep storage lead acid cell energy storage device comprises: an electrode comprising lead; an electrode comprising lead dioxide; a separator between the electrode comprising lead and the electrode comprising lead dioxide; an aqueous solution electrolyte containing sulfuric acid; and a carbon-based additive having a specific surface area of approximately 250 to 550 m2/g.

Abstract: An Advanced Graphite, with a lower degree of ordered carbon domains and a surface area greater than ten times that of typical battery grade graphites, is used in negative active material (NAM) of valve-regulated lead-acid (VRLA) type Spiral wound 6V/25 Ah lead-acid batteries. A significant and unexpected cycle life was achieved for the Advanced Graphite mix, where the battery was able to cycle beyond 145,000 cycles above the failure voltage of 9V, in a non-stop, power-assist, cycle-life test. Batteries with Advanced Graphite also showed increased charge acceptance power and discharge power compared to control groups.

Abstract: A lead-acid battery grid made from a lead-based alloy containing tin, calcium, bismuth and copper and characterized by enhanced mechanical properties, corrosion resistance, less battery gassing, lower sulfation and water loss, and no post-casting treatment requirements for age hardening. In one embodiment, the battery grids are formed from a lead-based alloy including about 2.0% tin, about 0.0125% copper, about 0.065% calcium, and about 0.032% bismuth. Preferably, the battery grid is free of silver beyond trace levels in the alloy.

Abstract: Determining a state of charge (SOC) of a rechargeable battery includes using a first process to determine a first value for the SOC of the battery and using a second process to determine a second value for the SOC of the battery and deriving the SOC as a weighted average of the first value for the SOC and the second value for the SOC. During a charging cycle of the battery an input charge of the battery is determined from an input current flowing into the battery and a charging time. During a discharging cycle an output charge of the battery is determined from an output current flowing out of the battery, a discharging time and an actual capacity of the battery is the sum of the input charge over charging cycles minus the sum of the output charge over discharging cycles.

Abstract: Disclosed herein is a composition for use in a negative active material in a valve regulated lead-acid battery, including a carbon material having a BET surface area from 150 m2/g to 2000 m2/g and having a D90-value greater than 5 ?m with the amount of carbon material ranging from 0.1 wt % to 1.5 wt % based on the total weight of the composition. Also disclosed herein is a valve regulated lead-acid battery, including a positive plate, a negative plate, a separator, and an electrolyte disposed in a container with a valve, the negative plate including a substrate of lead or a lead alloy and a negative active material of a composition including a carbon material having a BET surface area from 150 m2/g to 2000 m2/g and having a D90-value greater than 5 ?m, the amount of carbon material ranging from 0.1 wt % to 1.5 wt % based on the total weight of the composition.

Abstract: A lead-acid battery grid made from a lead-based alloy containing tin, calcium, bismuth and copper and characterized by enhanced mechanical properties, corrosion resistance, less battery gassing, lower sulfation and water loss, and no post-casting treatment requirements for age hardening. In one embodiment, the battery grids are formed from a lead-based alloy including about 2.0% tin, about 0.0125% copper, about 0.065% calcium, and about 0.032% bismuth. Preferably, the battery grid is free of silver beyond trace levels in the alloy.

Abstract: A separator (1) for electrode plates (2) in gel storage batteries having two substantially rectangular layers (3, 3?) of a flat separator material, which layers come to lie in mutually superposed relationship. In order to provide less expensive separators for the separation of plate electrodes in gel storage batteries, which have a low electrical resistance and which afford additional protection for the edges and side surfaces and at the same time permit homogenous gel filling of the storage battery, the invention proposes that the two layers of separator material are connected together at least portion-wise in the region of their edges, forming a casing or pocket for the introduction of an electrode plate and a method and battery employing the separator.

Abstract: An Advanced Graphite, with a lower degree of ordered carbon domains and a surface area greater than ten times that of typical battery grade graphites, is used in negative active material (NAM) of valve-regulated lead-acid (VRLA) type Spiral wound 6V/25 Ah lead-acid batteries. A significant and unexpected cycle life was achieved for the Advanced Graphite mix, where the battery was able to cycle beyond 145,000 cycles above the failure voltage of 9V, in a non-stop, power-assist, cycle-life test. Batteries with Advanced Graphite also showed increased charge acceptance power and discharge power compared to control groups.

Abstract: An Advanced Graphite, with a lower degree of ordered carbon domains and a surface area greater than ten times that of typical battery grade graphites, is used in negative active material (NAM) of valve-regulated lead-acid (VRLA) type Spiral wound 6V/25 Ah lead-acid batteries. A significant and unexpected cycle life was achieved for the Advanced Graphite mix where the battery was able to cycle beyond 145,000 cycles above the failure voltage of 9V in a non-stop, power-assist cycle-life test. Batteries with Advanced Graphite also showed increased charge acceptance power and discharge power compared to control groups.

Abstract: Disclosed herein is a absorbed glass matt (AGM) valve regulated lead-acid (VRLA) battery, comprising: a positive plate comprising a positive active material; a negative plate comprising a negative active material; wherein the negative active material comprises a composition comprising a carbon additive; an AGM separator; and an electrolyte; wherein the positive plate, the negative plate, the separator, and the electrolyte are disposed in a container comprising a valve; and wherein the electrolyte is present in an amount that ranges from 100 to 150% by volume based on the total pore volume of the separator.

Abstract: Disclosed herein is a composition for use in a negative active material in a valve regulated lead-acid battery, comprising: a carbon material having a BET surface area from 150 m2/g to 2000 m2/g and having a D90-value greater than 5 ?m; wherein the amount of carbon material ranges from 0.1 wt % to 1.5 wt % based on the total weight of the composition. Also disclosed herein is valve regulated lead-acid battery, comprising: a positive plate, a negative plate, a separator, and an electrolyte disposed in a container comprising a valve, wherein the negative plate comprises a substrate comprising lead or a lead alloy and a negative active material comprised of a composition comprising a carbon material having a BET surface area from 150 m2/g to 2000 m2/g and having a D90-value greater than 5 ?m; wherein the amount of carbon material ranges from 0.1 wt % to 1.5 wt % based on the total weight of the composition.

Abstract: A battery system including a battery pack having a plurality of battery cells and a charger control circuit configured to receive unregulated power from a source and to provide regulated power to the battery pack. The battery system also includes a battery management system configured to individually monitor and control the plurality of battery cells and the charger control circuit.

Abstract: A method of making battery plates for lead-acid batteries includes providing a strip of material comprising lead; and punching material out of the strip to form a grid comprising wires having a non-rectangular cross-sectional shape by utilizing a die set comprising a plurality of male die components and female die components, wherein each of the male die components comprises a first portion having a first cross-sectional shape and a second portion having a second-cross sectional shape. A single punch of the material creates a hole in the material and also forms the periphery of the hole.

Abstract: A method of rating a battery includes providing a plurality of numerical values by removing units from standardized ratings or tests for the battery; assigning a pre-calculated unit scaling factor to each numerical value of the plurality of numerical values; and calculating a total rating by multiplying each pre-calculated unit scaling factor by each corresponding numerical value of the plurality of numerical values to obtain a normalized value for each numerical value of the plurality of numerical values, and adding each normalized value.

Abstract: A winding assembly including positive and negative electrodes and a separator sheet wound in an overlying relationship such that the separator sheet is positioned between the positive and negative electrodes, and such that an exposed edge of the positive electrode is spaced longitudinally from an unexposed edge of the negative electrode at one end, and such that an exposed edge region of the negative electrode is spaced longitudinally from an unexposed edge of the positive electrode at an opposite end, and wherein a portion of the positive electrode proximate to the exposed edge of the positive electrode comprises a first plurality of apertures and a portion of the negative electrode proximate to the exposed edge of the negative electrode comprises a second plurality apertures.

Abstract: The present invention is directed to energy storage devices, such as lead-acid batteries, and methods of improving the performance thereof, through the incorporation of one or more carbon-based additives.