Abstract: Sealed lead-acid storage cells are described, characterized by positive electrode means comprising one or more positive electrode assemblies. Each electrode assembly in turn comprises two positive electrode members lying in spaced apart relationship to one another and having an electrolyte reservoir located therebetween. In this manner it may be insured that sufficient electrolyte is present in the cells to more fully utilize the active material of the positive and negative electrodes, while still allowing the separators lying between the positive and negative electrodes to be as thin as possible and to be less than fully saturated with electrolyte. This less than fully saturated condition provides paths for oxygen transport between the positive and negative electrodes, thus facilitating recombination of oxygen, which may be evolved at the positive electrodes during charging, at the negative electrodes.

Abstract: Improved positive electrodes for lead-acid batteries are disclosed, in which the said electrodes are initially fabricated such that:(1) the ratio between a calculated weight of formed, dry active material filled into a tube member and the weight of its corresponding lead spine is restricted to a maximum value of 1.5:1;(2) the ratio between the lateral cross-sectional area enclosed by a tube member and the lateral cross-sectional area of its corresponding lead spine is restricted to a maximum value of 5:1; and(3) the distance between the inner surface of a tube wall and the surface of its corresponding lead spine is restricted to a maximum value of 2.5 mm; for electrodes designed for use at the 5-hour discharge rate or greater, this distance is restricted to a maximum value of 1.8 mm.Thereafter the electrodes are subjected to a deliberate electro-chemically-induced corrosion of outer surface of the spines, to produce zones of high-density PbO.sub.

Abstract: A lead-acid battery construction includes gridless reactively limited positive and negative electrode means combined with separator material and an electrolyte. Reactive limitation of the negative electrode means may be realized by providing the negative electrode means with inner portions comprising non-reactive (i.e. solid) lead and outer portions of reactive (i.e. porous) lead. Reactive limitation of the positive electrode means may be provided by the said negative electrode means. The positive electrode means comprises PbO.sub.2 which occurs in outer reacting portions and inner non-reacting portions. The battery having such reactively limited electrode means may only be discharged to the extent that the inner reactive lead portions of the negative electrode means become completely transformed into PbSO.sub.4, whereupon all electrochemical reaction in the battery will cease. That portion of the PbO.sub.2 of the positive electrode means which has not been transformed into PbSO.sub.

Abstract: Fabricated tubular bodies for use in a positive plate of a lead-acid battery are formed in a number of desirable ways from a mixture of fabrication components. In the invention methods the fabrication components are separated into differing sets of fabrication means, at least one of which sets consists of reinforced tapes. The mixture of fabrication components may, by braiding, cartridge-belt weaving or other processes, be arranged in predetermined relation to provide for highly effective retention and support of active material around current carrying grid portions of a positive plate when the said plate is immersed in an electrolyte of a lead-acid battery, to further provide preservation of dimensional stability and of said retention of active material over extended periods of operation of the said battery, and to still further provide for adequate communication between the active material and the electrolyte via tubular wall portions formed with a desirably controlled and predetermined porosity.

Abstract: A process for producing a microporous plastic member useful as a battery separator which comprises(a) forming a coherent dough by mixing a vinyl chloride resin with a plasticizing amount of a first solvent and with finely divided particles of a filler which contains volatilizable constituent releasable therefrom by heating and which shrinks substantially and irreversibly upon release of said volatilizable constituent therefrom, an example of which is hydrated silica;(b) forming the solvent-containing dough into a shaped member;(c) extracting the first solvent from the member before any substantial evaporation of solvent occurs by contacting it with a second solvent in a liquid bath at a temperature substantially below the boiling point of any liquid present, the second solvent being one which is capable of dissolving the first solvent without dissolving the resin and the filler, thereby deplasticizing the member by extractively removing the first solvent from the member; and(d) thereafter heating the member a

Abstract: Storage battery separators with greater security against short circuit due to pinholes are made by using at least two adjacent microporous sheets, each thinner than those normally used when one alone is present. Sawdust may be added to the composition of one or both of the sheets.

Abstract: A sheath for battery electrodes is made by introducing a fibrous tubular material along a mandrel. A perforated thermoplastic material is applied around the outside of the fibrous material. Subsequent to applying the fibrous material, the mandrel is heated, thereby heating the fibrous material. The latter heats and softens the inside of the thermoplastic material at their points of mutual contact. The thermoplastic material is then subjected to external pressing forces and external cooling temperatures to press the thermoplastic material against the fibrous material while cooling the thermoplastic material.

Abstract: Tube plate type electrode for a storage battery where the metal rod of said tube is held centrally in a surrounding sheath by spacing fins. The surface of the spacing fins is coated with a lacquer to reduce the peak effect caused by high current density to prolong the life of the tube sheath.

Abstract: A tube plate for a storage battery is formed from a grid of conductive rods that are surrounded by active material held in place by a sheath of insulating material. The conductive rods are centered in their respective sheaths by centering fins solely lying in the plane of the electrode. The conductive rods are centered in the perpendicular direction by placing the electrode in a jig which has cylindrical channels for receiving the sheaths. In each channel, two rows of needle-like elements are provided which penetrate the sheath and engage the rod surface during the period when the active material in powder form is loaded into the electrode.

Abstract: A sheath for tubular storage battery electrodes has an inner layer of an inert fibrous material and an outer layer of thermoplastic material in the form of a net, perforated foil, or the like. The two layers are mechanically joined by heating the fibrous layer to a temperature sufficient to soften the adjacent surface of the thermoplastic material and cause a portion of the fibrous layer to be embedded in the surface of the thermoplastic layer.

Abstract: A sheath for tubular storage battery electrodes has an inner layer of an inert fibrous material and an outer layer of thermoplastic material in the form of a net, perforated foil, or the like. The two layers are mechanically joined by heating the fibrous layer to a temperature sufficient to soften the adjacent surface of the thermoplastic material and cause a portion of the fibrous layer to be embedded in the surface of the thermoplastic layer.