Abstract: Terminal straps are positioned within a battery container via multiple formations formed integral to the battery container. The unique formations provide for positive location of the terminal straps relative to the battery container and the battery container lid simplifying the manufacturing process and improving product quality.

Abstract: A vehicle control unit estimates a temperature of the vehicle's battery including the temperature of each of the battery's plurality of cells. The control unit includes a memory unit having stored therein heat transfer coefficients of three types. The first type is representative of heat transfer between the cells of the battery; the second type is representative of heat transfer between the surrounding air and the middle cells of the battery; and the third type is representative of heat transfer between the surrounding air and the end cells of the battery. A microprocessor retrieves the heat transfer coefficients from the memory unit and determines individual cell temperatures of the battery based on the heat transfer coefficients, temperature of the ambient air, and the drive state of the vehicle.

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 bipolar plate assembly includes a frame member having a center opening therethrough between parallel opposed surfaces, the opening being countersunk on one side of frame the member defining a mounting shoulder, and a bipolar element including a thin lead foil substrate having positive and negative active electrode material disposed on opposite surfaces, the bipolar element being mounted in the opening of the frame member with the marginal edge of the substrate located on the mounting shoulder and secured thereto by an adhesive resin, securing the bipolar element to said frame member, one or more such bipolar plate assemblies being stacked together between first and second terminal electrode assemblies to form a single or multi-element bipolar module having positive and negative terminals, and a plurality of the bipolar modules can be stacked together with their terminals electrically interconnected to form a multi-cell bipolar battery structure.

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, the bottom of the storage battery having a plurality of transverse channels therein extending between opposing sides for permitting air flow around the bottom of the storage battery when the battery is enclosed within the battery shield.

Abstract: An improved housing system for a multi-cell battery including a container and a cover. The container has a bottom and a plurality of external walls cooperating to define a well and a plurality of internal walls which cooperate with the external walls and the bottom to define a plurality of cell reservoirs for receiving cells of a multi-cell battery. The external walls and the internal walls terminate in an array of edges oriented in a pattern substantially in a plane. The container and the cover are of material amenable to heat bonding. The improvement comprises the cover having an underside with a plurality of zones. Each zone has a respective thickness; one zone is oriented substantially in a plane and generally in register with the pattern of the array of edges presented by the container when the cover is positioned for attachment with the container. The one zone has a thickness which is greater than the thickness of adjacent zones.

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 grid for a lead acid battery plate with a conductive frame having a top element and a bottom frame element, with conductive wires extending from the bottom element to the top element which includes an enlarged section beneath a current collection lug and being of a size and shape so as to optimize the current flow to the lug. Other features disclosed are the conductive wire shape and spacing so that the amount of conductive material such as lead is reduced where it has been predetermined that the current flow is minimal. In addition, the grid is designed to have equidistant potential points relative to the lug to optimize current flow. The advantage of such a grid is that it maximizes performance of the battery while keeping its weight at a minimum.

Abstract: A flexible spacer for positioning a cell element in a cell compartment of a container of a storage battery includes a sheet member folded over on itself to a U-shaped configuration with the space between opposing surfaces of the sheet member defining a compartment for receiving the cell element, enabling the cell element and the spacer to be inserted as a unit into the cell compartment, the opposing surfaces of the sheet member each including a ribbed section that flexes upon insertion of the spacer and element into the cell, automatically adjusting for differences in cell element thickness.

Abstract: A protection system for motor vehicles includes a control circuit including a switching device which is connected between cells of the battery and operable between a first condition in which the voltage provided at the battery terminals insufficient to start the vehicle and a second condition in which the voltage provided at the battery terminals sufficient to start the vehicle, the switching device being operated between the first and second conditions by a control signal that is generated by a portable signal transmitting device which is remotely actuatable.

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 combined dual ganged manifold and cover arrangement for batteries features channeling of gas flow to an explosion attenuation device located between the manifolds and a cover designed for maximizing return to the battery of any electrolyte which may contact the cover from vibration, tilting, overheating, overcharge and the like. Splash barrels within the cover include a unique acid level indicator, and feet are provided on the manifold to prevent the manifolds from inadvertently being used with other cover designs. The arrangement is particularly useful for batteries having terminal posts lying along the battery centerline. The cover utilizes external and internal gas pick-up systems and perpetual hill and infinite well concepts to control acid flow. A narrow channel reduces standing wave electrolyte surface violence.

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 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: 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: 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: 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: 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.