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 The slurry is withdrawn from the reactor (36) and fed to a belt press (67) which reduces the moisture content of the slurry to the desired level.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: A hydrostatic pump for application in a battery experiencing sudden changes in acceleration or direction such as in a golf cart. The cells of the battery are provided with hydrostatic pumps using the motion induced waves in the electrolyte to develop localized hydrostatic heads and create circulation in the electrolyte.

Abstract: A method of fabricating a metal pressure vessel for a metal oxide-hydrogen battery. A straight length of metal having a generally T-shape cross section is formed into circular configuration and the abutting ends of the strip are welded together to form a ring that includes a generally circular body portion and a flange or fin which projects radially outward from the body portion. The welded ring is expnded radially outward to precisely fit the open end of the shell of the vessel and the ring is then assembled with the open ends of the shell and head with the ends of the shell and head abutting the outwardly extending fin of the ring. The ends of the shell and head are then welded to the ring to complete the assembly.

Abstract: A battery thermal control system including a casing for the battery and a cover for enclosing the battery in the casing, the casing being provided with a number of ribs for supporting the battery in a spaced relation to the bottom of the casing and to the side walls of the casing, a fan connected to discharge air into the casing for circulation through the spaces between the battery and the casing and a bypass duct for connecting the fan to a warm air source for heating the battery in the winter. A timer circuit is provided for continuing the operation of the fan after the engine is turned off. The timing circuit including a temperature switch for activating the timer circuit when the temperature is above a preset minimum.

Abstract: An improved pressure vessel for a metal oxide-hydrogen battery which comprises an outer cylindrical shell and a battery cell is disposed centrally within the shell. A pair of sealed containers or tanks are located in the ends of the shell on either side of the cell and each container contains pressurized hydrogen. In a preferred form of the invention, a portion of each container constitutes a head of the vessel. Each container is provided with an opening which provides communication with the interior of the vessel, and a remotely controlled valve acts to open and close the opening. Opening of the valve permits hydrogen gas to contact the cell to generate an electron current in an exterior circuit. During recharging of the cell, hydrogen generated in the cell passes into the containers and is captured therein by closing of the valves, thereby minimizing self-discharge of the battery cell during standby periods.

Abstract: A method and apparatus for estimating the temperature of a vehicle battery, wherein the estimated temperature is used to control the voltage at which the vehicle battery is charged. The variables used to estimate the temperature of the vehicle battery can include a reference temperature sensed from one or more temperature sensors located apart from the battery, and a group of coefficients. Each type of vehicle using the vehicle battery temperature estimation method utilizes a group of coefficients tailored specifically for the vehicle. For a given type of vehicle, empirical data is compiled for determining the specific group of coefficients for the vehicle. This data is compiled by operating the vehicle, and periodically sampling and storing the vehicle speed, the reference temperature, the actual battery temperature, and the elapsed time between samplings. From this data a group of coefficient is determined for the vehicle.

Abstract: A metal oxide-hydrogen battery including an outer pressure vessel that contains a plurality of cell modules disposed in side-by-side relations. Adjacent cell modules are separated by heat transfer members that transfer heat from the cell modules to the outer vessel. Each heat transfer member includes a generally flat body or fin which is disposed between adjacent cell modules and a peripheral flange which is located in contact with the inner surface of the pressure vessel. The width of each cell module is greater than the length of the flange so that the flange of each heat transfer member is out of contact with the adjacent heat transfer member. The flanges are constructed and arranged to exert an outward radial force against the pressure vessel. Tie bars serve to clamp the cell modules and heat transfer members together in the form of a stack which is inserted into the pressure vessel.

Abstract: A nickel-hydrogen battery or cell having one or more pressure vessels containing hydrogen gas and a plurality of cell-modules therein. Each cell-module includes a configuration of cooperatively associated oxygen and electrolyte mangement and component alignment features. A cell-module having electrolyte includes a negative electrode, a positive electrode adapted to facilitate oxygen diffusion, a separator disposed between the positive and negative electrodes for separating them and holding electrolyte for ionic conductivity, an absorber engaging the surface of the positive electrode facing away from the separator for providing electrolyte to the positive electrode, and a pair of surface-channeled diffusion screens for enclosing the positive and negative electrodes, absorber, and separator and for maintaining proper alignment of these components.

Abstract: A charge management system and method, within a vehicle having a battery and generation subsystem, is disclosed which senses the temperature of electrolyte in the cells of the vehicle battery and the voltage across the terminals of the battery. The voltage indicates the probability of the existence of excess electrical capacity from the vehicle generation subsystem. In response to a cold temperature and excess power, the system uses the excess power of the vehicle generation subsystem to heat the battery to a desired level. Once the battery reaches the desired temperature level, the system dicontinues the heating of the battery. In the event that there is not excess power, then the system, by maintaining the battery heating element in an off position, does not interfere with the charging of the battery.

Abstract: A porous compressible plastic 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 is distributed to create a unique bimodal pore distribution, including a major proportion of small pores effective in attenuation and a minor proportion of large pores effective in gas and electrolyte management. Both open cell and fibrous materials may be utilized.

Abstract: An electrode suitable for use as a lead-acid battery plate contains an inorganic metal oxide additive which enhances the formation of the plate. The additive is electrically conductive, stable in aqueous solutions of sulfuric acid, but does not participate in the electrode reaction. Suitable metal oxides include barium metaplumbate and other ceramic perovskite materials having similar properties. The conductive ceramic may also be used in electrodes for bipolar lead-acid batteries and in an electrode, particularly an anode (positive electrode), used in electrolytic processes.

Abstract: A method of joining thermoplastic frames of a bipolar battery to form a leak-free battery stack. The battery includes a stack of generally rectangular thermoplastic frames, including a series of central frames and a pair of end frames. Each central frame has an opening and a bipolar plate, consisting of a positive electrode and a negative electrode, separated by an electrically conductive substrate, is mounted across the opening. The opposed surfaces of the frame project outwardly beyond the bipolar plate. To join the frames together, a pair of frames is mounted in spaced relation and a pair of back-to-back focused infrared heaters are positioned in the space between the frames and the focal point of each heater is directed into registry with the surface of the respective frame to melt or fuse the surface. The heating unit is then withdrawn and the frames are moved into contact with each other to weld the fused surfaces together.

Abstract: A battery thermal control system including a casing for the battery and a cover for enclosing the battery in the casing, the casing being provided with a number of ribs for supporting the battery in a spaced relation to the bottom of the casing and to the side walls of the casing, a fan connected to discharge air into the casing for circulation through the spaces between the battery and the casing and a bypass duct for connecting the fan to a warm air source for heating the battery in the winter. A timer circuit is provided for continuing the operation of the fan after the engine is turned off. The timing circuit including a temperature switch for activating the timer circuit when the temperature is above a preset minimum.

Abstract: A hydrostatic pump for application in a battery experiencing sudden changes in velocity or direction as in a golf cart. The cells of the battery are provided with hydrostatic pumps separated from the walls of the cell and using the motion induced surface waves in the electrolyte to develop localized hydrostatic heads and create circulation in the electrolyte. The structure of the pumps additionally nullifies the otherwise detrimental effect of upward surge of electrolyte cause by the same change in velocity or direction.

Abstract: An electrode suitable for use as a lead-acid battery plate contains an inorganic metal oxide additive which enhances the formation of the plate. The additive is electrically conductive, stable in aqueous solutions of sulfuric acid, but does not participate in the electrode reaction. Suitable metal oxides include conductive oxides such as TiO.sub.2-x, WO.sub.3-x, MoO.sub.3-x, V.sub.2 O.sub.5-x, Nb.sub.2 O.sub.5-x, wherein x is greater than 0 and less than or equal to 1, mixtures thereof and mixed conductive oxides of these elements. The conductive oxides may also be used in electrodes for bipolar lead-acid batteries.

Abstract: A thin, bipolar, lead-acid battery includes one or more cells, each of which is provided with a one-way vent for allowing release of gas generated during battery formation or overcharge. A planar spacer, having a cut out central portion, receives the electrode and separator components, and has one or more passageways formed therein extending from the wall of the cut out portion to the exterior of one of its edges. The spacer then resembles a frame for the battery components. Film sheets are applied to the opposed surfaces of the spacer and extend outwardly therefrom, at least in the vicinity of the spacer hole. The film is sealed, e.g. by heat, in all exterior areas except adjacent the hole. An oil, such as a silicone oil, is used between the film sheet in the non sealed area to form a one way "duck bill" type vent valve.

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) diposed 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). The circuit illustratively includes a diode (110) configured to permit current flow into the reserve battery (104) during recharging, but which prevents reserve battery drain during normal vehicle operation. A variable resistor (112) is disposed in series with the diode to limit the amount of power, and hence the amount of heat, dissipated by the diode.

Abstract: A light weight deflection-resistant end block is provided for a battery and comprises a base member of a light weight, chemically inert and electrically resistive material which has one or more cavities adapted to receive low density, substantially rigid inserts such as honey-combed aluminum.

Abstract: A battery module for insulating a battery from the heat of the engine of a motor vehicle, the module including a battery compartment, an air inlet and an air outlet, a first air flow path connecting the air inlet to the air outlet and a second air flow path around the outside of the battery compartment connecting the air inlet to the air outlet, a damper positioned in the housing for movement between a first position wherein the first air flow path is open and the second air flow path is closed and a second position wherein the first air flow path is closed and the second air flow path is open, a shape memory alloy member for moving the damper from the first position to the second position when the ambient temperature exceeds a predetermined minimum and a spring for biasing the damper to the first position when the ambient temperature is less than the predetermined temperature.

Abstract: A hydrostatic pump for application in a battery experiencing sudden changes in velocity or direction such as in a golf cart. The cells of the battery are provided with hydrostatic pumps using the motion induced surface waves in the electrolyte to develop localized hydrostatic heads and create circulation in the electrolyte. The structure of the pumps additionally nullifies the otherwise detrimental effect of upward surge of electrolyte caused by the same change in velocity or direction.