Abstract: A double layer structure for use as a capacitor or battery electrode, for use in other electrochemical systems, includes in one embodiment a first layer containing conductive transition metal oxides and a second layer which includes conductive carbon embedded in a suitable binder. For capacitor and lead-acid battery applications the transition metal containing material is used as the negative terminal substrate. Another embodiment includes a carbon layer on an electrode surface, the electrode being made from the transition metal oxide in a binder. The last mentioned carbon layer is thin, inexpensive and more conductive than a laminate layer in which the carbon is imbedded in a self-supporting binder.

Abstract: A battery cover for a battery casing has a plurality of electrolyte containing cells, a primary cover and a secondary cover. The primary cover has a plurality of barrels arranged along a longitudinal axis and the secondary cover has a plurality of tubular elements extending downwardly and insertable in the barrels of the primary cover. Each of the tubular elements has an inner tubular member and an outer tubular member. The outer tubular member has an axially extending cutout portion which runs from its tip to the surface of the secondary cover. The battery cover also has a plurality of baffles defining a circuitous passageway for gases which are evolved in the cells of the battery to be released to an external port located on the secondary cover.

Abstract: A battery cover and vent cap interface seal for electrical storage batteries is disposed between the vent opening in the battery cover and the vent cap to establish a fluid-fight seal. In a first embodiment an annular sealing member is provided in each vent opening in the battery cover. The sealing members extend slightly beyond the inner periphery of the vent opening in the cover and are compressed by the vent cap plugs as the vent cap is installed. In a second embodiment annular sealing members are provided around each plug on the vent cap. The sealing members extend slightly beyond the outer periphery of the plugs and are compressed as the vent cap is installed on the battery cover. The sealing members are made of a resilient material that deforms more easily than the materials used for the battery cover and vent cap.

Abstract: A self-latching handle for storage batteries includes a cam mechanism formed integrally with the ends of the battery handle, the cam mechanism cooperating with the battery housing as the battery handle is rotated downwardly from a vertical attachment position to a horizontal storage position to lift the ends of the battery handle to move pivot post portions of the battery handle into pivot apertures formed in the cover of the battery housing and to lock the battery handle to the battery housing while permitting the battery handle to be pivoted between the horizontal storage position and a vertical use position without becoming detached from the battery housing.

Abstract: A dual battery or back-up battery system includes a control and indicator circuit for driving the battery switch. The battery switch is coupled between the positive terminals of the primary battery and auxiliary battery. The control and indicator circuit includes an indicator such as an LED, an indicator switch such as a single pole, single throw switch, and a driver circuit. The driver circuit includes a voltage tripler for appropriately driving a MOSFET battery switch. The indicator requires only a single signal conductor between the driver circuit and the indicator switch or indicator light. The indicator switch may also be utilized to provide a signal to a computer or other control circuit. The indicator switch and indicator are advantageously located within the interior of an automobile so that the operator may easily monitor and control the battery switch.

Abstract: A battery shield for a storage battery includes first and second members which are dimensioned to fit around the battery, forming a shield structure, that is open at its top and encloses the battery on all four sides and on the bottom, forming a heat shield for protecting the battery from hot temperatures, the first and second members being hinged to a common base and are adapted to be pivoted about respective hinges outwardly away from another to an open position to facilitate installation of a battery in the shield and to then be moved upwardly and toward one another, in the manner of a "clamshell", to a closed position for enclosing the battery within the battery shield.

Abstract: A split-shell enclosure for a storage battery for motor vehicle includes identical first and second enclosure members which are dimensioned to fit around the battery, forming a shell structure, that is open at its top and bottom and partially encloses the battery on two sides and completely encloses the battery on the other two sides, forming a heat shield for protecting the battery from hot underhood temperatures, the enclosure members being adapted to snap together upon installation and to be held together by interlocking tongue and groove portions of mating sides of the enclosure members, upper portions of the enclosure members being disposed in juxtaposed relation with the handle brackets of the battery so that if the battery is lifted by the enclosure, the enclosure members will engage the handle brackets of the battery and the battery will effectively be lifted by its handle brackets and no load will be placed on the latches that hold the two sections of the enclosure together, and lower portions of the

Abstract: A cast strap for a lead-acid battery is made of a lead-based alloy consisting essentially of from about 2.5 to 3.5 wt. % antimony, about 0.01 to 0.5 wt. % arsenic, about 0.01 to 0.5 wt. % tin, about 0.008 to 0.1 wt. % selenium, and the balance lead. The content of at least one of arsenic, tin and selenium is within the following ranges: about 0.075 to 0.5 wt. % tin, about 0.1 to 0.5 wt. % arsenic, and 0.021 to 0.03 wt. % selenium. For lead-based alloys containing antimony, arsenic, tin and selenium, increased additions of antimony, arsenic, and selenium generally have a favorable effect on long term corrosion resistance of battery straps in a lead-acid battery environment, whereas tin has an unfavorable effect such that increased amounts of tin dramatically lower high temperature corrosion resistance.

Abstract: An injection molded containment for bipolar batteries of the type which include terminal electrodes and one or more bipolar battery cells is disclosed. In the most preferred embodiment of the present invention, a novel spacer is employed, including beveled edges to facilitate sealing of the injection molding material and the individual cells. Furthermore, the preferred spacer includes a crush ridge to assist in sealing. The present invention facilitates assembly of bipolar batteries in a way which improves sealing when compared to other techniques, such as vibration welding.

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: 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: 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 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: 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: 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 a unique battery arrangement including battery plates having a pair of spaced apart battery lugs for both the positive and negative plates. While being spaced apart, the lugs are located generally adjacent one top edge of the plates; on opposite sides for the positive and negative plate constructions. The straps used to electrically connect the lugs are lower in height than those used on current battery designs, providing excellent current collection, efficient fusion with smaller lugs and resistance to vibration caused by separation of the lugs from the straps. The present invention also features plates having greater plate surface area, improved current carrying capability and reduced voltage drop. A weld element couples straps of like polarity, and in the preferred embodiment, at least a portion of the weld element is located intermediate the ends of the straps.