Abstract: A flat, rigid sheet of predetermined configuration is provided for insertion between each end cell element and the corresponding container end wall of a battery during production line manufacturing. The battery is thus protected from the harmful effects resulting from the flexing of the container end walls due to oscillating hydraulic pressure of the electrolyte contained within the outermost cells of the battery.

Abstract: A fibrous material is inserted into the head space above the cells in a storage battery to attenuate the explosion of combustible gases accumulating therein. The attenuation material preferably includes a proportion of fine fibers effective for attenuation and a proportion of heavier fibers effective for electrolyte management.

Abstract: An electric storage battery according to the invention has a porous explosion attenuating material disposed within a head space of the battery case over the electrode elements. The attenuating material forms a layer or lining on the inner surface of the top wall of the case, and preferably also on the inner surface of the upper ends of each side wall between the electrode elements and the top wall. The interior of the head space remains open. Such an explosion attenuating material is effective to limit pressure build-up resulting from ignition of said gases within the case.

Abstract: An apparatus for electrically connecting cell modules of a metal oxide-hydrogen battery. The battery includes an outer pressure vessel containing a plurality of cell modules which are each sealed in a plastic bag and each cell module is provided with a vent which is permeable to the flow of gas but impermeable to the flow of liquid electrolyte. A pair of annular electrical conductors are associated with each cell module and extend through aligned holes in the bag. The conductors of each cell module are electrically insulated from each other and are disposed around an insulating tie rod. One of the conductors is connected to the positive terminals of the cell module, while the other of the conductors is connected to the negative terminals. A series of spring washers are mounted on the tie rod and urge the portions of each bag bordering the holes therein into tight sealing relation with the flange of the respective conductor to prevent leakage of the electrolyte through the holes in the bag.

Abstract: Substrates for electrode systems, particularly those to be used for bipolar electrodes in zinc-bromine batteries, are disclosed. The substrates preferably include carbon-black as a conductive filler in a polymeric matrix, with reinforcing materials such as glass fibers. Warpage of the zinc-bromine electrodes which was experienced in the prior art and which was believed to be caused by physical expansion of the electrodes due to bromine absorption by the carbon-black, is substantially eliminated when new substrate fabrication techniques are employed. In the pesent invention, substrates are prepared using a lamination process known as glass mat reinforced thermoplastics technology or, in an alternate embodiment, the substrate is made using a slurry process.

Abstract: A metal oxygen-hydrogen battery having sealed cell modules with electrolyte containment and hydrogen venting. The battery includes an outer pressure vessel containing a plurality of cell modules, each having a positive and negative terminal and containing a liquid electrolyte such as potassium hydroxide. Each cell module is enclosed in a flexible sealed bag which is impervious to the flow of the electrolyte. The bag is a multi layer structure preferably composed of thermoplastic film. Each bag is provided with a vent which is permeable to the flow of hydrogen gas but impermeable to the flow of the electrolyte. Electrical leads are connected to the terminals of each cell module and extend in sealed relation through the bag.

Abstract: An improved metal oxide hydrogen battery including an outer pressure vessel and a plurality of cell modules are stacked in side-by-side relation in the vessel. Each cell module is generally rectangular in configuration and includes positive and negative terminals which are located centrally of the cell module. Each cell module is sealed within a rigid plastic casing and the casing is provided with a vent which permits the flow of gas but is impermeable to the flow of the liquid electrolyte contained within the cell module. A heat transfer member is disposed between adjacent cell modules and includes an outer cylindrical flange which is disposed in heat transfer relation with the inner wall of the pressure vessel. The peripheral edge of each casing is engaged with the inner surface of the respective flange to position the cell module within the vessel. Electrical conductors extend in sealed relation through the wall of the casing and connect the terminals of the cell modules in an electrical circuit.

Abstract: A metal oxide-hydrogen battery having an outer sealed pressure vessel including a generally cylindrical shell. A plurality of generally rectangular cell modules are disposed in the shell and extend longitudinally of the shell. Each cell module has at least one positive electrode and a negative electrode. Separating the cell modules are heat transfer fins composed of a material having a high coefficient of thermal conductivity. The opposed edges of each fin are provided with flexible flanges that engage and complement the inner surface of the cylindrical pressure vessel shell and serve to transfer heat from the cell modules to the vessel shell.

Abstract: The invention provides a vehicle battery system including a main and a reserve battery disposed within a battery housing (10) having conventional external dimensions and battery terminal locations. An illustrated embodiment includes a main battery, comprising a series of thin, flat cells (38) disposed along a first axis, and a reserve battery, comprising a series of cells (42) disposed along a second axis transverse to the first axis. An electrical circuit facilitates selective communication between the reserve battery and the vehicle starter in accordance with the position of a switch assembly (100). An electrically conductive fastener is disposed to simultaneously maintain electrical communication between a main battery termination and an external battery terminal and also between a reserve battery termination and the same external battery terminal.

Abstract: A simple, optimized lead-acid battery includes a stack of a plurality of film pouches, each containing positive and negative electrode elements and separators. The pouches are prepared by folding an elongate film strip, and collector tabs are provided for the electrodes at either end of the stack. Electrode pairs intermediate the ends of the stack are electrically connected through adjoining openings in the pouch walls, e.g. be welding. In the most preferred embodiment, an integral vent is formed from flaps cut in the film strip and the pouch edges and top are heat sealed for electrolyte containment.

Abstract: Improved formation efficiencies for positive pasted plates used in lead-acid batteries are provided by treatment of the positive plates with a stabilized aqueous alkaline persulfate solution to effect the conversion of lead monoxide to lead dioxide. Use of the alkaline persulfate solution enhances both formation and initial performance of the fabricated batteries. A stabilizing agent is added to the alkaline persulfate solution to stabilize the lead sulfate and basic lead sulfates in the paste. A preferred method for producing positive plates of a lead-acid battery comprises the steps of (a) heating the pasted plate, (b) spray coating with or dipping the plate in a persulfate solution, and (c) reheating the plate to accelerate the reaction of lead monoxide with persulfate to form lead dioxide. The persulfate treatment may be applied to uncured pasted plates and used with plate paste containing free lead, and the spray-coating procedure offers an easy and efficient manufacturing step.

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.

Abstract: A pouring system uses low pressure air to force molten lead into mold cavities. The pour spout is heated by the lead bath, and, preferably, a small gap is maintained between the pouring spout and a weir on the mold cavity to prevent stringers from being attached to the cast piece. At the completion of the lead pouring operation, excess metal is drained back through the spout and into the lead bath. Lead volume is controlled by adjusting pressure and timer settings, and a fill hole allows the pump to refill.

Abstract: A process for coating a solid substrate with a layer of barium metaplumbate includes steps of forming a layer of lead oxide on the substrate, if not already present, and then reacting this layer with a barium salt at an elevated temperature to form a layer of coating of barium metaplumbate. Reaction temperature is a key aspect of this process, along with use of a barium salt which will react at the temperature selected. In particular, the reaction temperature must be sufficiently high to allow the reaction to proceed, but lower than the melting point of the substrate. The described process eliminates the need to preform BaPbO.sub.3 prior to coating and can be conducted at a much lower range of temperatures than prior processes.

Abstract: A coaxial terminal construction for a sealed pressurized battery. The battery includes a sealed vessel containing a series of battery cells and positive and negative poles are connected to the cells. A pre-assembled terminal unit extends through an annular mounting flange that is secured within an opening in the vessel wall and the pre-assembled unit includes an inner electode, an outer electrode, which is disposed concentrically outward of the inner electrode and insulated therefrom, and an annular mounting member which is located concentrically outward of the outer electrode and insulated therefrom. All three concentric members have external threads of the same pitch. The terminal unit is installed by threading the mounting member in the mounting flange of the vessel and simultaneously threading the outer electrode with a nut connected to one of the poles and threading the inner electrode with a second nut connected to the other of the poles.

Abstract: A vent cap includes a hollow vent cover which is inserted into a battery vent hole and a flange which retains the vent cap from overinsertion into the vent hole. An aperture near the top of the vent cap communicates with the hollow interior of the vent cover and forms an exhaust path for discharge of gases from within the battery. A flame protection device, for example, a microporous disc, is disposed within the vent cover so that gases must pass through the disc in order to exit the battery through the aperture. A splash guard may be provided in the vent cover to reduce electrolyte leakage into the exhaust path and onto the flame arrestor, thereby inhibiting electrolyte leakage from the battery.

Abstract: A voltage monitor and method enables the monitoring of a DC input voltage. The input voltage is continuously scanned and compared to a predetermined threshold. The result of the comparison is periodically stored in a shift register along with previous scan results. When a predetermined number of stored scan results indicate an out of range input voltage, a digital output changes state to provide indication of the abnormal condition.

Abstract: A bipolar battery substrate includes overlying layers of binder material containing particulate conductive material. In the most preferred form, one layer includes carbon as the conductive material, while the conductive material for the other layer comprises a conductive form of a transition metal oxide. Electrode structures are also disclosed.

Abstract: A control system for starting an internal combustion engine including a control module for controlling the operation of a multi-cylinder multiple cycle engine, a storage battery, a manually operable switch for connecting said battery to said control module, a starter motor for cranking said engine when energized, an electronically actuated set of inlet and exhaust valves, a fuel injector and a spark plug connected to each cylinder of said engine and to said control module, said control module being programmed to monitor the rotary speed of the engine for activating the valves, injector and spark plug for one cylinder when said control module determines the presence of a sufficient inertia build up in the flywheel to start the engine.

Abstract: An electrode for a lead acid flow through battery, the grids including a plastic frame, a plate suspended from the top of the frame to hang freely in the plastic frame and a paste applied to the plate, the paste being free to allow for expansion in the planar direction of the grid.