Abstract: An integrated system for providing the motive power for trucks working in a hazardous environment including an explosion-proof enclosure having a body receiving the battery system and a separate fuse box compartment to which the battery system is connected, and the truck electrical system is connected to the battery system through the fuse box compartment.

Abstract: A battery including a rope handle which engages a handle bracket on a conventional battery container. The rope handle includes a grip and a rope, the proximal end of the rope being molded into, or otherwise secured to, the grip and a cylindrical plug molded on the distal end of the rope. The grip includes a retaining recess comprising a counterbore presenting a bearing surface, and lateral slot between the upper and lower surfaces of the grip and extending radially from the counterbore to present a substantially keyhole-shaped opening. In assembly, the distal end of the rope is advanced laterally through the slot portion of the keyhole-shaped opening until the counterbore is positioned subjacent the plug. The plug is then moved downward into the counterbore. To hide the rope ends in the preferred embodiment, a cover can be snapped in place over the top of the grip.

Abstract: A sealed lead-acid cell and positive plate for a sealed lead-acid cell are provided. The positive plate comprises a grid supporting structure having a layer of active material pasted thereto, the grid supporting structure comprising a lead-based alloy consisting essentially of lead, from about 0.02% to about 0.05% calcium, from about 1.5% to about 3.0% tin, and from about 0.01% to about 0.05% silver. A positive plate in accordance with the invention has excellent mechanical properties, and is satisfactory for use in a lead-acid cell.

Abstract: A sealed lead-acid cell utilizes a separator made with modified plastic microfibers having a contact angle of no more than 1.5° to the sulfuric acid electrolyte used and having a diameter of 1.1 to 5.0&mgr;, the separator having a porosity of 87 to 94%, a surface area of 1.0 to 2.2 meters2/gm., and a maximum pore diameter of 8 to 20&mgr; and a mean pore diameter of 1.2 to 5.0&mgr;.

Abstract: A method for making positive grids for lead-acid batteries from calcium-tin-silver lead-based alloys comprises casting an alloy strip and then rolling the strip at a temperature between about the solvus temperature and the peritectic temperature of the alloy, quenching the rolled strip, then, preferably, heat aging at a temperature of 200° F. to 500° F., and fabricating into the positive grid, such grids having enhanced mechanical and high temperature corrosion resistance characteristics.

Abstract: A lead-acid battery, which achieves a low profile while allowing grids of relative maximum height to be used, comprises a container having the terminal cells located adjacent the front of the battery so as to allow ready access to the battery when located in racks or the like in service, and a cover, preferably a two-piece cover, containing the terminals, interior surfaces of the cover and top surfaces of the container being sloped upwardly in a rearward direction from the front of the battery, thereby allowing the use of relatively tall grids.

Abstract: A method for making positive grids for lead-acid batteries from calcium-tin-silver lead-based alloys comprises casting an alloy strip and then rolling the strip at a temperature between about the solvus temperature and the peritectic temperature of the alloy, quenching the rolled strip, then, preferably, heat aging at a temperature of 200° F. to 500° F., and fabricating into the positive grid, such grids having enhanced mechanical and high temperature corrosion resistance characteristics.

Abstract: A battery including a container, a cover and an end wall stiffener block. The container is molded with a compartment between an outer and an inner end wall into which the stiffener block is inserted. The stiffener block is preferably made of a stiff plastic or of metal. The stiffener block and compartment are sized so that a contacting relationship is maintained between the inner wall, the block, and the outer wall. The inner wall also maintains a contacting relationship with the active internal components of the battery. During assembly, both the inner and the outer end walls are heat-sealed to the cover, such that the compartment is entirely sealed.

Abstract: A method of making lead-acid batteries uses a container standardized for a twelve-volt battery and dual flag straps in the inner cells so that batteries with voltages of two, four, six, or twelve can be preselected as desired, the more preferred embodiments having one terminal cell with either two terminal bases or dual flags so as to minimize the assembly equipment required.

Abstract: A plastic battery container for a recombinant sealed lead-acid battery having reduced end wall deflection, the end wall comprising a base portion from which extends a series of integrally molded ribs disposed at approximately +/−45° to the horizontal, substantially all intersection points of the ribs with the base portion having a rounded character to enhance processing characteristics.

Abstract: A lead-acid cell or battery includes positive plates made from a lead-based alloy containing calcium, tin, and silver in amounts selected based upon the type of application and the plate fabrication method utilized, starting, lighting and ignition battery grids being directly cast and having calcium present in an amount of 0.03% to 0.050%, tin in an amount of 0.65% to 1.25%, and silver in an amount of from 0.018% to 0.030%, and the grids used in sealed, lead-acid cells comprising, when made by gravity casting, from about 0.035% to 0.055% calcium, 0.95% to 1.45% tin, and 0.018% to 0.030% silver, and, when made by continuous strip casting, calcium in the range of from 0.030% to 0.050%, tin in the range of from 0.95% to 1.25%, and silver in the range of from 0.017% to 0.030%, all of the alloy percentages being based upon the total weight of the grid.

Abstract: A battery comprising a rope handle which engages a standard structure on a conventional battery container. The rope handle comprises end portions coupled to a rope portion, the end portions being adapted to engage substantially vertical, elongated channels which are standard structures in the end walls of the battery container. The end portions comprise downwardly extending leg portions from which arms extend outwardly. When the end portion is in position in the channel, the legs extend through the channel and the arms are disposed below the channel such that the end portion is secured to the battery container.

Abstract: A process for providing a leady oxide having reduced levels of undesired metallic impurities such as, for example, bismuth and/or silver, comprises roasting the leady oxide to convert part to orthorhombic PbO, exposing the roasted leady oxide to particle size reduction so that the tetragonal PbO can be separated from the orthorhombic PbO fraction, and recovering the orthorhombic fraction having the reduced level of impurities.

Abstract: The present invention provides for a wet, multicell, lead-acid electric storage battery comprising a venting system having vent plugs comprising an inventive sealing arrangement. Specifically, the vent plugs provide a seal to be molded onto the vent body as a permanently attached feature. The present invention consequently eliminates the need to separately manufacture and apply a gasket to a vent body, thus reducing manufacturing costs and greatly improving reliability and safety during both use and handling.

Abstract: A method for making a plurality of lead-acid cells requiring a constant width, a height varying from a maximum to a minimum to accommodate plates of varying height and a cell depth to accommodate a minimum to a maximum number of plates is disclosed which utilizes blow molding to form a jar precursor which is cut to the height desired, and, in its preferred aspects, including use of a mold and insert sets which simplify tooling and change-over time, as well as a cover and jar design which simplifies the heat sealing of these components.

Abstract: An electrically nonconductive cover system is provided which may be readily installed onto and removed from a cell tray assembly while minimizing the likelihood of accidental human contact with lead-acid cells or batteries. The cover system is reliable and secure and permits observation and maintenance of the cells without requiring cover removal.

Abstract: A removable battery handle and battery casing coupling structure wherein the handle is relatively rigid and includes a central portion, and two downwardly depending arms, the distal ends of the arms each including an attachment button which is supported on the inside surface of the distal end by a shaft, the button being received by a keyhole-shaped aperture in the battery casing end wall, which offers resistance as the shaft moves from the lower, larger portion to the upper, smaller portion of the aperture such that when the shaft is disposed in the upper, smaller portion, the handle is locked to the casing.

Abstract: A hydrometallurgical method involves treating a dross source containing typically both antimony and tin and treating the dross to a series of chemical operations to yield a soft lead precursor, suitable for making soft lead for lead-based alloys for batteries or other applications, which method includes utilizing sulfuric acid to decompose the dross source to provide a slurry in which the liquid contains the principal tin values and the solid phase contains the antimony and lead values, followed by treating of the separated solid phase so as to either separate the lead values from the antimony values via an antimony leach and a solid/liquid separation or by desulfurizing the solid phase, carrying out a solid/liquid separation, treating the solid phase with a lead leach to solubilize the lead values and carrying out a further solid/liquid separation to recover the lead-rich phase as the filtrate, separated from the antimony-rich solid phase.

Abstract: The present invention provides a method for treating rotary slag containing iron and sodium compounds. The method involves treating the slag in a sulfuric acid solution to convert the iron and sodium within the slag to iron sulfate and sodium sulfate. The iron sulfate (along with substantially all of the heavy metal contaminants) forms a precipitate, while the sodium sulfate remains in solution. The precipitate can then be separated from the solution.

Abstract: Sealed lead-acid cells are disclosed which include an internal cell restraint contacting the interior surface of the cover and positioned between the positive plates and the cover, the internal cell restraint cooperates with an external cell restraint, such as a coated metal face plate, to direct positive plate growth which occurs in service away from the cover, the features disclosed allowing plastic-to-plastic terminal post-cover seals to be used and allow cells of capacities of up to 2,000 Ampere Hours or more to be provided.