Abstract: A method and apparatus for extruding materials, including electrolytically active materials, onto metallic substrates used in the production of electrodes. The method and apparatus facilitates the production of improved electrodes for use in energy storage devices, such as rechargeable batteries. A preferred device may include a base, a spreader, edge guides and wipers. The wipers, or doctor blades, clean a portion of the substrate during the extrusion process. This provides a clean edge on which a current collector can be welded. The clean edge enables an electrode that is more reliable, more easily used during the battery manufacturing process, and may also provide for lower internal resistance of the energy storage cell.

Abstract: The disclosure relates to increasing the performance of batteries by reducing the internal resistance of the electrodes and improving the adhesion of electrolytic materials to metal substrates used in the manufacture of electrodes for energy storage cells. In one embodiment, the present invention may be illustrated as a system and method for increasing battery performance by precoating the electrode plates with nickel, to improve the adherence of the metal hydrides, or other electrolytic materials, to the metallic substrate. For example, by precoating a nickel plated steel substrate with powdered nickel at or near the glass transition temperature of 1100° C., the adhesion of nickel metal hydride powder is improved, providing an electrode with reduced internal resistance, when compared to electrodes in which the metal substrate is not precoated with nickel.

Abstract: Disclosed is a system and method for increasing the rate at which an electrolyte permeates the micropores of an energy storage cell. In a preferred embodiment, an energy storage cell is filled with a quantity of an electrolyte which is then exposed to an electric field. The electrolyte is electrophoretically driven into the micropores of the energy cell at a rate that is greater than without the use of electrophoresis.

Abstract: Disclosed is a multiple-contact current collector for use in energy storage cells. The current collector of the present invention provides for lower internal resistance and higher conductivity than previous current collectors, thereby achieving increased current handling capacity, improved heat rejection, and lower discharge temperatures. The collector is characterized by a series of protrusions arranged around the perimeter of the plate that connect to the positive windings of the cell and are subsequently welded thereto. Additionally, the collector is provided with protrusions and dimples to increase the area of contact between the collector plate and the winding.

Abstract: Disclosed is a current collector and method for increasing the electrical conductivity between the collector, casing, and the winding in the cell. The current collector comprises a sheet of highly conductive metal, such as pure nickel, having a plurality of protruding tabs arranged about its periphery. The tabs are folded upwardly to receive the winding and to fit inside the casing. The tabs are then welded to the casing, using a series welding technique through the outside of the casing.

Abstract: A collector to terminal conductive element, or tab, for use with multiple-contact current collectors in the manufacture and use of energy storage cells. The collector to terminal conductive element of the present invention provides for lower internal resistance and higher conductivity than previous positive devices, thereby achieving higher current handling capacity and lower discharge temperatures. The conductive element of the present invention is manufactured separately from the collector itself, to avoid problems with alignment during the process of connecting the collector to the energy storage device and to facilitate the tab's connection to the cell terminal. In one preferred embodiment, the terminal to collector conductive element is useful for creating current paths between the anode of a coiled cell energy storage device and a battery terminal.

Abstract: The invention relates to a gasket for single or multi-cell rechargeable batteries and provides an improved seal between multiple cells in a battery or between a cell and the vent of a pressure vessel. In particular, the invention illustratively is described as having at least two alternating sectional profiles, each different section being fabricated to permit greater equalization of pressure between cells and the other section fabricated to retain electrolyte within the cell.

Abstract: An adaptive architecture for electric motors, generators and other electric machines. An adaptive electric machine provides optimal performance by dynamically adapting its controls to changes in user inputs, machine operating conditions and machine operating parameters. Isolating the machine's electromagnetic circuits allows effective control of more independent machine parameters, enabling greater freedom to optimize and providing adaptive motors and generators that are cheaper, smaller, lighter, more powerful, and more efficient than conventional designs. An electric vehicle with in-wheel adaptive motors enables delivery of higher power with lower unsprung mass, giving better torque-density. The motor control system can adapt to the vehicle's operating conditions, including starting, accelerating, turning, braking, and cruising at high speeds, thereby consistently providing higher efficiency. A wind powered adaptive generator can adapt to changing wind conditions, consistently providing optimal performance.

Abstract: A distributed architecture for electric motors and generators. This distributed architecture motor can deliver high power at low voltage and low phase current. It works by distributing total current across several “phases,” or electromagnetic circuits of the motor. That creates several advantages. These motors can deliver the high power needed by an electric car at 50 volts or less, which is safer for humans. They improve safety by allowing a motor to operate in an emergency even when one or more phases has a fault. Low voltage motors in electric vehicles allow batteries and fuel cells to have fewer cells. The low voltage and distributed current makes heat easier to handle. The distributed architecture lowers cost by allowing cheaper power electronics to be used. The distributed architecture allows smaller, lighter motors to be made with light wiring, switches and connectors.

Abstract: A novel cruise control system is provided for adaptively controlling an electric vehicle to maintain desired speed under variable driving conditions. This system utilizes multiple motor control scheme for controlling the motor using various waveform profiles of the control current, and involves phase advance angle adjustment provided for adaptively controlling a phase advance angle between the control current and back-EMF in response to changes in driving conditions to produce the control current sufficient to achieve the desired speed. A motor control scheme selection circuit enables the cruise control system to select a current waveform profile appropriate for present driving conditions. A selected current waveform profile is modified, if the control current with the adjusted phase advance angle is not sufficient to achieve the desired speed.

Abstract: A novel system for adaptively controlling an electric vehicle to maintain desired speed under variable driving conditions. The system includes a control circuit for producing a control signal to control an electric motor of the vehicle. The control signal is formed based on a control current required to achieve the desired speed. The control strategy selection circuit is configured in the system to determine a motor control scheme that provides an appropriate waveform profile of the control current.

Abstract: An electrically powered vehicle, for example a bicycle, has a motor, controller and power supply contained within a wheel compartment. A cylindrical stator frame is fixed on the wheel axle, with an inner surface of the stator frame defining a space for housing the power supply and controller circuitry. A plurality of electromagnet stator segments are mounted on an outer surface of the stator frame. A cylindrical rotor frame is coupled to the axle through bearings. An inner surface of the rotor frame supports a plurality of permanent magnets that surround the stator segments to form a radial air gap therebetween. Mounted to the outer surface of the rotor frame by appropriate supporting structure is a vehicle tire.

Abstract: A rotary brushless electric motor is formed within a cylindrical rotor housing structure that surrounds an annular stator ring. The stator is formed of a plurality of individual power modules and corresponding core segments, each module comprising electrical control and drive elements supplied by a power source incorporated within the stator. Such parallel architecture provides relatively independently controlled functionality for each module. Each module and stator core segment can be individually installed and removed without disturbing the other units. Should a particular module or stator core segment fail, it can be easily removed for repair or replacement and reinstallation.