Abstract: A valve-regulated lead acid (VRLA) battery cell (2,40) has positive and negative plates (10,11,41,42) separated by separator media (12,43) and held together under pressure. The separator is adapted to support therein an electrolyte. Each plate has a first single or plurality of tabs (12,13,46) on a first side and a second single or plurality of tabs (15,16,47) on a second side of the plate, each tab being connected to a busbar (17,18,49,50) to form positive and negative busbars on each of the first and second sides of the plate. The cell may be alternatively configured in a spirally-wound arrangement or in a prismatic arrangement of flat plates. The cell may be constructed of a plurality of such positive and negative plates. A VLRA battery (1, 40) may be constructed of one or a plurality of such VLRA cells, in which case the busbars of neighboring cells are connected by welded joints. The busbars are serviced by at least plural pairs of positive and negative terminals (24,25,33,34,52,53,54,55).

Abstract: A valve-regulated lead acid (VRLA) battery cell (2,40) has positive and negative plates (10,11,41,42) separated by separator media (12,43) and held together under pressure. The separator is adapted to support therein an electrolyte. Each plate has a first single or plurality of tabs (12,13,46) on a first side and a second single or plurality of tabs (15,16,47) on a second side of the plate, each tab being connected to a busbar (17,18,49,50) to form positive and negative busbars on each of the first and second sides of the plate. The cell may be alternatively configured in a spirally-wound arrangement or in a prismatic arrangement of flat plates. The cell may be constructed of a plurality of such positive and negative plates. A VLRA battery (1, 40) may be constructed of one or a plurality of such VLRA cells, in which case the busbars of neighboring cells are connected by welded joints. The busbars are serviced by at least plural pairs of positive and negative terminals (24,25,33,34,52,53,54,55).

Abstract: A winding assembly for a battery includes a positive electrode plate, a negative electrode plate, a separator sheet, and a current collector. The positive and negative plates and the separator sheet are wound in overlying relationship such that the separator sheet is positioned between the positive and negative plates, an exposed top edge of the positive electrode plate is spaced longitudinally from an adjacent unexposed top edge of the negative plate, and an exposed bottom edge of the negative electrode plate is spaced longitudinally from an unexposed bottom edge of said positive electrode plate. The current collector is connected to one of the exposed edges of one of the positive and negative electrode plates, and, accordingly, is spaced apart from the adjacent unexposed bottom edge of the other (i.e., the non-attached) electrode plate. The current collector includes a terminal mounting portion and a radially extending collecting web.

Abstract: A sealed, through partition terminal for an electrochemical cell featuring the use of gasketing material to prevent the spread of electrolyte past the terminal seal assembly is disclosed. An orifice formed in a lid of an electrochemical cell accepts a terminal member that is secured to the lid with a fastener threaded onto the terminal member. A shoulder molded on the bottom face of the lid and adjacent to the orifice prevents axial movement of the terminal member while torquing the fastener. A gap formed between the wall of the orifice and the terminal member is filled with gasketing material that is compressed by torquing the fastener. The compressed gasketing material seals any gaps between the terminal member and lid orifice preventing electrolyte leakage.

Abstract: A novel apparatus and method for constructing a stress resistant battery which allows the use low modulus materials through end wall rib reinforcements and a cover having a plurality of integral bosses which vertically project and connect to cast on straps. A plurality of baffles adapted to snap fit into the inner bottom portion of the cover and augment stress resistance through rigid contact against the battery plates. A plurality of cast on straps welded back to back in pairs through each of said electrochemical cell walls each having a seating boss so as to connect with each of the cover bosses.The battery of the present invention also includes means of affixing terminal connectors in a scalloped configuration thereby preventing over-torquing and failure of the cover during electrical-mechanical connection.

Abstract: A sealed, through partition terminal for an electrochemical cell featuring the use of gasketing material to prevent the spread of electrolyte past the terminal seal assembly. An orifice formed in an inner lid of an electrochemical cell accepts a terminal member that is secured to the inner lid with a fastener threaded onto the terminal member. A shoulder molded on the bottom face of the inner lid and adjacent to the orifice prevents axial movement of the terminal member while torquing the fastener. A gap formed between the wall of the orifice and the terminal member is filled with gasketing material that is compressed by torquing the fastener. The compressed gasketing material seals any gaps between the terminal member and inner lid orifice preventing electrolyte leakage.

Abstract: An up-and-through battery intercell connection for electrochemical batteries or cells is disclosed featuring battery partition wall extensions formed on battery partition walls located within a battery container through which lead intercell connector nuggets are secured to provide electrical connection between battery intercells. A battery container top is formed with recesses to accept the battery partition wall extensions. The container top is further formed with adhesive channels to accept a paste adhesive that allows the battery container top to be secured to the battery container without having to invert the battery during manufacture.

Abstract: In one aspect the invention is a lead-acid cell of the type having a container. The container has a jar and a lid. The jar has an upper perimeter defining an opening matingly engaging and closed by the lid. The container houses at least one positive electrode plate, at least one negative electrode plate, a separator interposed between the electrode plates, acid electrolyte absorbed in the electrode plates and separator, and electrical connections from the electrode plate(s) through the container to an output terminal location. The lid is sealed to the jar. The cell is improved by the lid and the jar including a mechanical means for retaining the mating relationship of the lid and with the jar, when the lid is placed upon the upper perimeter, of the jar.

Abstract: A sealed, through partition terminal for an electrochemical cell is disclosed featuring a high conductivity terminal member embedded in a lead strap current collector, penetrating a through hole in the partition wall. A cup-like well is formed around the hole to receive the terminal which is located and immobilized by the combination of a fastening member which grips the outer surface of the terminal, and by an epoxy contained within the cup-like well which embeds the fastening member and surrounds the terminal. An elastomeric sealing member is preferably compressed between the strap and the underside of the cup-like well.

Abstract: A normally sealed multi-cell, lead-acid battery of the starved electrolyte type has each cell filled with a metered quantity of electrolyte by drawing down a vacuum on one or more of the cells; releasing the vacuum; and simultaneously drawing, through a filling port in the lid of each cell under vacuum, the metered quantity of electrolyte. Each cell houses a cell pack comprising at least one porous positive plate; at least one porous negative plate; and a porous, relatively fragile microfiber glass mat separator interleaved between the plates. A deflector platform, integral with the lid and having a deflecting surface, is positioned between the filling port and the cell pack of each cell of the battery. During filling, the electrolyte impinges upon the deflecting surface and is deflected laterally so that the electrolyte does not directly impinge upon and damage the cell pack.