Abstract: An grid for a lead acid battery plate includes a central plate lug, the lug preferably having an expanded base for the collection of current and the grid being constructed in such a manner that the amount of metal is concentrated in the vicinity of the lug. A unique cast-on strap design for use with the grids is also disclosed. Substantial manufacturing advantages result from the use of such grids, and the performance of the battery can be increased to the point that individual battery plates may be eliminated, resulting in lighter weight batteries and material cost savings.

Abstract: An improved pressure vessel for a rechargeable metal oxide-hydrogen battery. The pressure vessel, which contains a plurality of cell modules, is composed of an inner liner of a material which is impervious to the passage of hydrogen gas and an outer layer of fiber reinforced thermosetting resin. The fibrous reinforcement is preferably in the form of substantially continuous, helically wound filaments. Dispersed within the resin matrix of the outer layer are a plurality of finely divided particles of a material having a high coefficient of thermal conductivity. The finely divided material can be in the form of powder or fibers, and can be composed of a metal or graphite. By incorporating the finely divided heat conductive particles in the resin, the heat dissipation through the pressure vessel is increased to thereby improve the performance of the battery.

Abstract: An electrode suitable for use as a lead-acid battery plate is formed of a paste composition which enhances the performance of the plate. The paste composition includes a basic lead sulfate, a persulfate and water. The paste may also include lead oxide and fibers. An electrode according to the invention is characterized by good strength in combination with high power density, porosity and surface area.

Abstract: A process for making a battery paste includes steps of forming an active material in an aqueous slurry, then dewatering the slurry to form a battery paste. In one described embodiment, a slurry containing one or more basic lead sulfates suitable for use as the active material in lead-acid battery electrodes is formed in a continuously stirred tank reactor (36). The slurry is withdrawn from the reactor (36) and fed to a belt press (67) which reduces the moisture content of the slurry to the desired level. Battery pastes produced according to the invention may be fed continuously to a paster (89) for mass production of positive and negative battery plates from grids (91).

Abstract: Flat pack rechargeable batteries which include internal support members are disclosed. In the most preferred form of the invention, an intermediate support extender plate is provided. The plate also includes holes to maintain a common path for electrolyte.

Abstract: The explosion attenuating vent cap for storage batteries according to the present invention features an electrolyte drain and baffle design adapted for maximizing return to the battery of any liquid which may enter the vent from vibration, tilting, overheating, overcharge and the like. The vent barrel(s) include a step to assist in closure of the fill openings, and baffles within the vent prevent accumulation of electrolyte within the cap. The arrangement of the entrance to the gas escape passage (leading through an explosion attenuation device such as a disc of microporous polymer) is located on the center lines of the barrel and at the highest possible location within the vent to minimize the intrusion of electrolyte into the attenuation material. This location of the entrance prevents accumulation of electrolyte at that location. Preferably, the vent cap is of the ganged variety, i.e. useful for simultaneously capping three or more fill openings of the battery.

Abstract: A lead-acid battery having an improved side terminal construction. The battery includes a case formed of dielectric material and a plurality of positive and negative plates are located within the case. Each group of plates is electrically connected to a strap. One end of an elongated conductor bar projects through the side wall of the case and is welded to each strap, while the opposite end of the bar projects outwardly of the case and is provided with a recess which receives a metal nut. A cable clamping ring is attached to the opposite end of the conductor bar by a bolt which is threaded in the nut. If a longer than required bolt is inadvertently threaded into the nut, the opposite end of the bar will be deflected or bent as the bolt is threaded down, but the welded connection between the conductor bar and the strap will not be adversely effected.

Abstract: A thermoplastic blend of a polyalkylene terephthalate, polyolefin and a functionalized elastomer has improved impact strength while maintaining other needed properties including tensile strength, tensile elongation, and flexural modulus. Recycled polypropylene and PET plastics can be combined with a relative small amount of the functionalized elastomer to provide a blend useful for molding battery containers and other plastic structural members such as automotive components.

Abstract: A battery is prepared by dipping battery elements (which may be surrounded by a thin, lightweight material, such as a plastic bag) into a liquid encapsulating, acid-resistant liquid material such as a rubber or resin. Individual elements can be connected either before or after hardening of the liquid to create a battery of the desired voltage. Heavy thermoplastic resin containers need not be used, and the weight of the resultant battery is thereby substantially reduced.

Abstract: A metal oxide-hydrogen battery incorporating a system for maintaining a substantial uniform range of pressure of hydrogen gas in the battery. The battery includes an outer pressure vessel and a plurality of cells are contained in the vessel. A liquid electrolyte is impregnated within the cells and the battery is charged with hydrogen gas. A conduit connects the interior of the vessel with a venting zone, preferably a closed chamber, containing a hydrogen absorbing material. A first valve is located in the conduit and is designed to open when the battery is discharged to a preselected level. A second pressure regulated valve is also mounted in the conduit and opens to vent hydrogen from the vessel to the chamber, if the hydrogen pressure exceeds a predetermined value at the preselected state of discharge. The sequential venting of hydrogen during cycling of the battery will maintain the pressure of hydrogen in the vessel within a given range.

Abstract: A metal oxide-hydrogen battery having an outer metal pressure vessel that contains a plurality of cell modules. The vessel is composed of a cylindrical shell and the open ends of the shell are enclosed by dome-shaped heads. In producing the vessel, a weld ring is positioned between each end of the shell and the respective head and each weld ring includes a base which is engaged with the inner surfaces of the shell and head and a radial fin which extends outwardly from the base and is located between the opposed ends of the shell and head. A weld is made interconnecting the weld ring with the head and shell. The weld ring is free of internal spokes and the radial thickness of the weld ring is from one to six times the thickness of the vessel wall. With this construction, the weld ring will flex with the shell during cycling of the battery to prevent undue stress at the welded joint.

Abstract: The preferred embodiment of the present invention relates to a sealed, oxygen recombinant lead-acid battery which includes a series of modules, e.g. 4-volt modules. The modules are prepared from frame and film assemblies which are easily stacked to the desired voltage or capacity. In the preferred embodiment, the assemblies include two 2.0 normal voltage cells, attached in series, three of which are then combined to form a 12-volt system. Modularity eliminates the need for expensive tooling and parts inventory and permits the creation of a wide variety of battery designs. Specially designed vents are employed to permit gas escape during overcharge or if recombination efficiencies are less than desired and to prevent entry of oxygen or moisture when the battery is in its recombinant mode.

Abstract: A battery system is disclosed which includes folded grids of expanded metal inserted through non-conductive substrates and pasted with electrochemically active materials. In the most preferred embodiment, a frame is provided with a plastic insert, and slots are provided in the latter to receive the expanded metal grid. After suitable coinage of the grid and insertion through the plastic film, the grid is sealed and pasted on opposite sides with positive and negative active material. A battery is assembled using one or a plurality of the resulting electrode elements, with separators, to produce a high-power, lead-acid battery. The folded grid provides many of the design benefits of standard bipolar construction.

Abstract: A dual battery system includes a first battery and a second battery electrically connected in parallel to positive and negative terminals. The first battery has an open circuit voltage greater than that of the second battery so that, as current is drawn from both batteries, the amount of current drawn from each respective battery at a given voltage level varies depending on the magnitude of the current. The first battery preferably supplies most of the current at low to moderate current loads, whereas the second battery provides a greater portion of the total current at high current loads. According to one aspect of the invention, wherein the batteries are each lead-acid batteries, the desired difference in open circuit voltage is provided by using sulfuric acid electrolytes of different specific gravities in the two batteries. For this purpose the electrolyte specific gravity of the second battery is preferably at least 0.03 less than that of the first battery.

Abstract: The present invention provides a method for maintaining the specific gravity of acid in a lead-acid battery within a predetermined range to prevent undesirable plate degradation and gassing during storage. Extended shelf-life is accomplished by employing a battery which is formed to the desired voltage and which is stored in a damp condition with the electrolyte maintained in a range which, in the most preferred embodiment, is between about 1.015 and 1.320. A desiccant, for example a gelled sulfuric acid desiccant, is placed in the battery housing, out of contact with the plates, to absorb the water vapor which is generated by the self-discharge reactions. The amount of desiccant is selected so that all the water vapor formed during such reactions is removed to maintain the specific gravity of the electrolyte in said range. Extended shelf-life results, and the desiccant can be used to form the battery electrolyte at the time it is desired to place the battery in service.

Abstract: A system and method for starting an internal combustion engine having multiple cylinders, each cylinder including an activating and deactivating system for independently activating and deactivating, each cylinder, one cylinder being initially activated to start the engine and the remaining cylinders being deactivated until ignition is sensed in the activated cylinder.

Abstract: A vent cap for use in a recombinant battery which includes a hollow barrel configured for gas-tight insertion into a vent hole in a battery cover. A retaining flange is formed at the closed end of the barrel, and a one-way relief valve formed on the barrel near its closed end. A layer of a polyalkylene explosion attenuating material surrounds the outside of the barrel below the flange and surrounding the relief valve. The polyalkylene material provides effective attenuation of explosions that occur in the vicinity of the relief valve. The invention further provides a vent cap assembly wherein the foregoing vent cap is mounted on a plastic vent cover of an otherwise conventional battery container.

Abstract: A metal oxide-hydrogen battery having an outer safety shell. The battery to be used in a confined area such as in an aircraft or manned spacecraft, and includes a pressure vessel that contains at least one cell module. Hydrogen gas under pressure is confined within the pressure vessel and is impregnated in the cell modules. An outer shell, preferably formed of molded plastic, is disposed around the pressure vessel and a vent conduit connects the space between the vessel and the shell with the exterior. Any hydrogen that accidentally leaks from the vessel is captured in the space and vented to the exterior.

Abstract: A battery thermal control system and method is provided which selectively heats or cools a storage battery in accordance with the battery temperature and state of charge. The thermal control system includes a battery housing having an internal airspace between the battery and the housing which extends between two openings in the battery housing, a reversible fan configured to generate an airstream along the airspace, a temperature sensor mounted to detect the temperature of the battery, and a control circuit for monitoring battery temperature and voltage and for controlling the operation of the fan. Battery state of charge is approximated by measuring battery voltage and monitored to prevent excessive battery discharge by the thermal control system. When the battery voltage exceeds a predetermined voltage and the battery temperature is outside of a predetermined range of suitable operating and storage temperatures, the thermal control system operates the fan to heat or cool the battery, as needed.

Abstract: A latching automatic dual battery switch employs a first comparator to determine that a condition requiring engagement of a secondary battery exists. For example, a primary battery voltage is below a predetermined threshold, current drawn from the primary battery exceeds a predetermined threshold or ambient temperature is below a predetermined threshold. Engagement of an ignition switch is detected and used to clock the output of the comparator to a trigger circuit. The trigger circuit activates the triggerable switch on the leading edge of a signal generated by the detector circuit to connect a secondary battery or power source in parallel with the primary power source. The trigger circuit is leading edge activated so that conditions immediately prior to engagement of the ignition switch determine if the secondary battery is engaged. This avoids engaging the secondary battery as a result of a load surge dragging down the voltage after activation of an ignition switch.