Abstract: A circuit assembly for forming and testing batteries connected in parallel and in series includes a parallel test management device (PTMD) that connects to each battery and includes a main relay and a current transducer in series and an auxiliary relay in series with a current limiting resistor, which are parallel to the main relay. Parallel battery groups are formed by connecting multiple PTMD-battery combinations and a voltage equalizer in parallel. Multiple parallel battery groups are connected in series. A battery testing system (BTS) connects to the battery groups. The equalizers and the BTS pass current through the batteries simultaneously. The current through batteries and the voltage drop across the current transducer are about zero at the end of charge and discharge.

Abstract: A difference voltmeter (DVM) is used in a battery testing apparatus for determining values of open-circuit voltage, self-discharge, self-discharge rate and internal resistance of batteries. A reference voltage Vref is generated. A difference OCV relative to Vref is determined at times t1 and t2 as ?OCV1 and ?OCV2. The SD for a battery is determined as (?OCV2??OCV1), and the SDR is determined as SD/(t2?t1). The IR of a battery is determined by measuring voltage at two levels of direct current and calculating IR as equal to (?V2??V1)/(I2?I1). The smaller FSR of the DVM allows a more accurate measurement of OCV, which allows the time for determining the SDR to be reduced.

Abstract: A cabinet box comprises a plurality of independent, explosion-proof chambers. A battery wiring assembly for receiving and testing a battery is attached to an inner wall of an explosion-proof door, and an electrical connector is provided on an outer wall of the door. The assembly is placed inside a chamber, and the door seals the chamber. The temperature in each chamber is controlled independently, allowing batteries to be tested simultaneously at different temperatures. An air-circulating temperature-control module can be in a chamber, or a temperature controller with a refrigeration sheet can be integrated with the battery wiring assembly for direct battery contact. Separate, independent explosion-proof chambers effectively eliminate the possibility of a battery explosion in one chamber causing a chain-reaction explosion in another chamber. Modularity allows damaged parts to be replaced easily. An external battery testing machine can connected to the connector on each door.

Abstract: A circuit assembly for forming and testing batteries connected in parallel and in series includes a parallel test management device (PTMD) that connects to each battery and includes a main relay and a current transducer in series and an auxiliary relay in series with a current limiting resistor, which are parallel to the main relay. Parallel battery groups are formed by connecting multiple PTMD-battery combinations and a voltage equalizer in parallel. Multiple parallel battery groups are connected in series. A high-current, high-density battery testing system (BTS) connects to a battery formation rack that uses a double-sided PCB and double-polarity edge connector sockets for receiving a battery tray on a PCB having an edge connector for forming and testing over 1,000 batteries. This smart battery tray replaces a bulky, complicated engagement system and reduces the requirement for BTS channels and cables substantially. An aging rack monitors battery voltage on the smart battery tray.

Abstract: A cabinet box comprises a plurality of independent, explosion-proof chambers. A battery wiring assembly for receiving and testing a battery is attached to an inner wall of an explosion-proof door, and an electrical connector is provided on an outer wall of the door. The assembly is placed inside a chamber, and the door seals the chamber. The temperature in each chamber is controlled independently, allowing batteries to be tested simultaneously at different temperatures. An air-circulating temperature-control module can be in a chamber, or a temperature controller with a refrigeration sheet can be integrated with the battery wiring assembly for direct battery contact. Separate, independent explosion-proof chambers effectively eliminate the possibility of a battery explosion in one chamber causing a chain-reaction explosion in another chamber. Modularity allows damaged parts to be replaced easily. An external battery testing machine can connected to the connector on each door.

Abstract: An electrical contact device includes a tubular element, a crown spring in the tubular element, a solid or hollow cylinder slideably received in the crown spring and a coil spring engaged with the cylinder for applying force while the cylinder is pressed against a test item and for returning the cylinder to a relaxed position. The crown spring holds the cylinder in the tubular element and allows the cylinder to slide back and forth while providing electrical connectivity between the cylinder and the tubular element. An electrical contact device includes a rod-shaped probe having a contact end and a contact sheet fixed to the probe, where the contact sheet has a plurality of prongs bent over the contact end of the probe for providing a plurality of contact points between the probe and a test item.

Abstract: An electrical contact device includes a tubular element, a crown spring in the tubular element, a solid or hollow cylinder slideably received in the crown spring and a coil spring engaged with the cylinder for applying force while the cylinder is pressed against a test item and tor returning the cylinder to a relaxed position, The crown spring holds the cylinder in the tubular element and allows the cylinder to slide back and forth while providing electrical connectivity between the cylinder and the tubular element. An electrical contact device includes a rod-shaped probe having a contact end and a contact sheet fixed to the probe, where the contact sheet has a plurality of prongs bent over the contact end of the probe for providing a plurality of contact points between the probe and a test item.

Abstract: A self-adjusting contact includes a plurality of conductive fibers, such as wires, arrayed along an axis perpendicular to the major plane of the battery terminal. The contact may include straight or corrugated wires, aligned substantially along the axis. The wires may be arranged in a bundle and held within an electrically conductive holder, which may be cylindrical or bell-shaped, and the wire bundle may be soldered to the bottom of a well formed in the holder.

Abstract: A self-adjusting contact includes a plurality of conductive fibers, such as wires, arrayed along an axis perpendicular to the major plane of the battery terminal. The contact may include straight or corrugated wires, aligned substantially along the axis. The wires may be arranged in a bundle and held within an electrically conductive holder, which may be cylindrical or bell-shaped, and the wire bundle may be soldered to the bottom of a well formed in the holder.

Abstract: A method of humidifying gases to 100% relative humidity and a humidifier to carry out such a method are provided to humidify gases for fuel cells and for other applications. The humidification of gases is thermally controlled and thermal energy is managed to provide an efficient system. A pre-humidifier accommodates a wide range of flow rates of dry gas to initially humidify and pre-heat the gas, and a boiler provides steam to mix with the effluent from the pre-humidifier to humidify the gas to saturation. A thermal insulator between the boiler and bulk water and/or pre-humidifier enhances the steam generation from the boiler and prevents direct heating of water or gases by heat from the boiler. Above the boiler, bulk water, and pre-humidifier, a mixing chamber further functions as a condenser and water separator. The mixing chamber provides a space for mixing gases and steam and separates saturated gases from condensed water.

Abstract: A gas humidifier provides a continuous flow of gas through two stages of bubbling with an intermediate heating stage. Gas is introduced into an enclosure containing a quantity of bulk water by pumping the gas into a gas entry pipe or tube. The gas exits the gas entry pipe to bubble up through a bubbling evaporator. At the water surface of the bubbling evaporator, a heating element heats the gas-vapor mixture. The heated gas-vapor mixture then bubbles up through the bulk water, and the temperature of the bulk water determines the thermal cycles of the heating element. The gas-vapor mixture bubbles up through the bulk water, reaching saturation at the dew point. The saturated gas is then directed from the humidifier for use.

Abstract: A method of humidifying gases to 100% relative humidity and a humidifier to carry out such a method are provided to humidify gases for fuel cells and for other applications. The humidification of gases is thermally controlled and thermal energy is managed to provide an efficient system. A pre-humidifier accommodates a wide range of flow rates of dry gas to initially humidify and pre-heat the gas, and a boiler provides steam to mix with the effluent from the pre-humidifier to humidify the gas to saturation. A thermal insulator between the boiler and bulk water and/or pre-humidifier enhances the steam generation from the boiler and prevents direct heating of water or gases by heat from the boiler. Above the boiler, bulk water, and pre-humidifier, a mixing chamber further functions as a condenser and water separator. The mixing chamber provides a space for mixing gases and steam and separates saturated gases from condensed water.

Abstract: A gas humidifier provides a continuous flow of gas through two stages of bubbling with an intermediate heating stage. Gas is introduced into an enclosure containing a quantity of bulk water by pumping the gas into a gas entry pipe or tube. The gas exits the gas entry pipe to bubble up through a bubbling evaporator. At the water surface of the bubbling evaporator, a heating element heats the gas-vapor mixture. The heated gas-vapor mixture then bubbles up through the bulk water, and the temperature of the bulk water determines the thermal cycles of the heating element. The gas-vapor mixture bubbles up through the bulk water, reaching saturation at the dew point. The saturated gas is then directed from the humidifier for use.

Abstract: A method of PCB assembly with a heat sink is shown. Two fins on the heat sink define a gap receiving an industry standard IC housing. The fins clamp the IC so heat transfer is readily done. Further, the PCB has holes profiled to receive the IC housing therethrough with lead connections to adjacent pads.

Abstract: A circuit assembly for the formation and charging of secondary batteries, such as lithium ion and lithium-polymer cells, is provided. A parallel arrangement of cells eliminates the need for current regulation for each, thereby providing a mechanism for self-equalization of the cells configured in this way. Cells in parallel are governed by the same voltage profile, and each cell draws current from a voltage-regulating channel according to its state of health. A holder is also provided for connecting cells to the electronic instrument containing the voltage-regulating channel. This holder provides for reliable termination at the terminal tabs.

Abstract: This disclosure sets out a multiple battery tester having a tray loaded with a set of batteries. The tray is placed in a receptacle and end located terminals move vertically to clamp a battery. The contacts bear on the battery, establishing a current flow path. This loop connects in charge/discharge system for testing. Test routines can be varied and data is recorded over time.

Abstract: A battery test contact clamp assembly is set forth. In one embodiment, upper and lower printed circuit boards are spaced apart on four corner located mounting rods of conductive metal. The four rods pass through one of the boards and are held to it by a set of detents and four hubs located at corners to thereby define a rectangular structure where the boards can move closer together or further apart. Frictional mounting hubs are used for the four rods. They are connected electrically in a circuit which involves contact assemblies on the two boards and they are aligned with battery terminals for contact to thereby define an electrical flow path with a test circuit. The contacts are aligned with the battery terminals. Alternative embodiments include two boards with multiple conducting rods there between and they are connected in several independent test modules. Another embodiment features two test contacts mounted on a common board for testing of batteries having two terminals at one end of the battery.

Abstract: A method of making a rechargeable modified manganese-containing material is disclosed. The method includes mixing manganese nitrate with a doping material which may be a nitrate of a second metal and placing this mixture in an aqueous solution. Electrodes are then submerged in the solution and a current is passed through the electrodes to electrolyze the solution. This results in an electrolytic deposition of a first material on the cathode and a second material on the anode. The material deposited on the cathode is a rechargeable modified manganese-containing material in the discharge state. The material deposited on the anode is a modified manganese-dioxide material in the charged state. A battery employing the modified manganese-containing material is also disclosed.