Abstract: A method and apparatus for efficiently charging lead-acid batteries applies small voltage steps to probe the charging efficiency of a battery being charged. The application of a voltage step causes the current to change from a base current to a surge current immediately after the voltage step, and to decay asymptotically to a plateau current after the surge current. A current ratio, defined as the difference between the plateau current and the base current divided by the difference between the surge current and the base current, is used as an indicator of the charging efficiency. The output voltage of the power supply charging the battery is then adjusted according to the measured current ratio. A current-voltage slope, defined as the difference between the plateau current and the base current divided by the magnitude of the voltage step, may also be used as an indicator of the charging efficiency for controlling the charging process.

Abstract: A lead-acid batteries having terminals designed to readily receive charging leads. The battery terminal and the charging cable lead utilize complementary configurations which interlock and provide an intimate and reliable connection between the terminal and lead. More specifically, an interlocking connection formed by a lead having two parallel legs which slide into slots formed in the wall of the side terminal has proven particularly effective. The interlocking terminal-lead connections eliminate the need of threadingly engaging and disengaging fasteners or adapters during charging that are normally necessary for side terminal batteries.

Abstract: An electric storage battery, preferably a lead-acid battery, such as used for starting, lighting and ignition of an automobile or the like, includes a handle attached to the cover of the battery through a pin-and-button structure which is attached to the battery by insertion into an insertion aperture and is then moved into an assembly position where the handle can be rotated from a rest position adjacent the side of the cover to an upright, service position for carrying the battery.

Abstract: A method of providing a molded plastic component for a bipolar battery comprising a metal substrate subject to warpage upon molding to form a plastic frame about the periphery of the metal substrate, and the molded plastic component itself, comprises preheating the metal substrate and then injecting a plastic having shrinkage characteristics which match those of the heated metal substrate so as to provide a plastic frame wherein the plastic-metal interface has a reliable seal and is free from residual stresses.

Abstract: An induction heating method and apparatus for simultaneously and efficiently fusing battery cell terminal posts and bushings in a battery production line. The apparatus includes an induction heating generator having a T-shaped bus bar for symmetrically supporting a plurality of pairs of induction heating coils, with one coil of each pair being supported on the forward side of a transverse bus bar section and the other coil of each pair being supported on a rear side of the transverse bus bar section. The coils each have respective mounting structures for permitting individual vertical adjustment of the coil with respect to the bus bar to enable uniform positioning of the coils with respect to a plurality of bushings and terminal posts for effecting uniform depth fusion of the plurality of posts and bushings.

Abstract: A bipolar cell, such as a lead-acid cell, comprising bipolar plates having a conductive metal substrate with a pre-cured active material grid comprising a mesh and positive active material in contact on one side of the conductive substrate and a negative active material grid unadhered to the conductive substrate and positioned in contact on the opposite side from the positive active material grid.

Abstract: A battery pack for providing electrical power to a commercial tractor/trailer vehicle has two 12-volt high-CCA batteries connected in parallel and two 6-volt deep-cycle batteries connected in series to power 12-volt electrical accessories such as devices for creature comforts. The two 12-volt high-CCA batteries provide sufficient cold cranking current for starting the engine of the vehicle. The two 6-volt deep-cycle batteries connected in series are used to power electrical accessories such as devices for creature comforts when the engine is not operating. A switch connects the serially connected 6-volt deep-cycle batteries in parallel with the 12-volt batteries for charging when the engine is running and isolates the 6-volt deep-cycle batteries from the 12-volt high-CCA batteries when the engine is off. The two 12-volt high-CCA batteries may alternatively be replaced with one large 12-volt high-CCA battery.

Abstract: A unitarily molded, snap-on heat shield for a standard automotive battery container having handle brackets extending from opposing side walls of the container, the heat shield having wedge-shaped coupling protrusions extending inwardly from cantilevered flaps in the heat shield side walls, the wedge-shaped protrusions riding along the handle brackets to cantilever the flaps away for the container side wall as the shield in moved downward over the container, the flaps snapping back inward toward the battery container as the protrusions pass the handle bracket to couple the heat shield to the battery container.

Abstract: A modular cell tray assembly comprising a series of cell trays stacked one upon the other and each containing a plurality of sealed lead-acid cells is disclosed in which the cell trays provide cell tray interlocks and load distribution structure that satisfy Zone 4 requirements, achieve cell tray interlocking by a boltless pin and provide frontal access to the cells.

Abstract: A method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.

Abstract: Positive grids for lead-acid batteries for SLI, industrial battery, and electric vehicle batteries are disclosed in which the positive active material paste pellet openings have a reduced area and the number per square inch of the grid area are increased, the individual areas and the number of paste pellets varying with the intended application, and the preferred embodiments including reduced distances from the center of the paste pellet to the adjacent grid wires, as well as an optimized amount of positive active material per area of the grid wire surface area so as to allow enhanced electrical performance, if desired, or substantial savings in grid weight while achieving electrical performance commensurate with conventional lead-acid cells and batteries.

Abstract: The use of a continuous process for making a directly cast strip to provide a thickness satisfactory for industrial cells and batteries for stationary and motive power applications is disclosed, the thickness of the strip being at least 0.060 inch, and the process providing a visually crack-free surface in the transverse direction of the directly cast strip, the strip being lead or a lead-based alloy, such as, for example, calcium-tin-silver.

Abstract: A method for fabricating bushings for lead-acid cells or batteries is provided which is amenable to automation and control and provides relatively porosity-free bushings comprising utilizing a mold having a cavity in the configuration of the bushing desired and a lead fill unit comprising a lead pot with the molten lead alloy for the bushing and a heated fill line and/or heated fill block wherein the mold and lead fill units are moved into alignment, heating such as induction heating to cause the solidified molten alloy at the end of the heated fill line or in the heated fill block orifice to become molten, gravity filling the mold and then moving the mold and lead fill unit out of alignment, the bushing preferably being cast in an upside-down orientation so as to minimize gas entrainment and/or particulate contamination.

Abstract: A multicell, lead-acid battery having spiral-wound cell elements and capacity adapters is disclosed, the battery comprising a container having a plurality of cell cavities, each cell cavity having a volume adapted to receive a spiral wound cell element of a specific maximum electrochemical capacity, a spiral-wound cell element being disposed in each cell cavity having a capacity less than the specific maximum capacity and of a size smaller than a cell element having the specific maximum capacity, thus creating a void volume in the cell cavity in which it is disposed, and a capacity adapter being disposed in each cell cavity which occupies at least a portion of the void volume.

Abstract: A method of making lead-acid cell-to-cell or battery-to-battery connections is disclosed which utilizes a non-conductive capture mold, made, for example, from polypropylene polymers, which capture mold has a base having holes allowing the capture mold to be placed over adjacent terminal posts of like polarity and upstanding walls having a height equal to that of the terminal posts, the capture mold serving to retain the lead alloy connector in place while the cell or battery connection is made, as by induction heating or the like.

Abstract: A lead acid storage battery and improved method of bonding battery cell terminal posts to cover bushings is disclosed. The battery cell terminal posts are made of lead alloy material and the cover bushings are made of solder alloy material having a significantly lower melting point than the terminal posts. The bushings are bonded to the terminal posts by heating the terminal posts and bushings to a temperature above the melting point of the material of the bushing, but below the melting point of the material of the post, to effect a secure and leak proof connection without melting of the terminal posts and with lesser chance for damage to the plastic cover. The plastic cover further includes integrally formed annular mold sections in the form of upstanding bosses which completely surround respective bushings and posts to contain melted material of the bushing during the heating operation and to form the terminals into final shape.

Abstract: An induction heating generator is disclosed. The generator controls the power delivered to a work coil via a plurality of resistor/bias control switches coupled in parallel and a controller, thereby eliminating the expensive and difficult to troubleshoot SCR control circuits associated with prior art generators. By sequentially switching the bias control switches, the controller can progressively lower the input voltage to a controlled switch to thereby alter its conducting state to provide stepped power increases to the work coil. The work coil is de-energized by opening the bias control switches in reverse sequential order.

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.

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 method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.