Abstract: A method and apparatus is disclosed for charging lead-acid batteries which includes periodic voltage sweeps to determine the charging voltage that should be used for the battery and then adjusting the charging voltage in accordance with that voltage sweep information so as to ensure that a highly efficient charging process is achieved which avoids undue gassing and inherently compensates for factors such as the temperature, type and service life history of the battery and resistance due to the interactive nature of the technique and apparatus.

Abstract: Apparatus and method for charging a battery, wherein a charging voltage is applied to a battery. The charging voltage depends on a base charging voltage which is continually adjusted in the direction that provides a more optimal level of charge acceptance. The direction of a more optimal charge acceptance is determined by adjusting the charging voltage in steps of predetermined magnitudes such that the steps provide an upper pair and a lower pair of spaced-apart charging levels. The current at each stepped voltage is measured, and used to calculate first and second current differentials corresponding to the upper and lower pairs. The base charging level is incremented or decremented to adjust the base charging level in the direction that provided the smaller differential. As the process is repeated, the charging level continually moves closer to a charging voltage level that minimizes the differential thereby providing a more optimal charge acceptance.

Abstract: Apparatus and method for charging a battery, wherein a target voltage is applied to a battery. During charging, the applied voltage is periodically increased and decreased a predetermined amount to modify the applied voltage by a small step in either direction. The charging input is measured as the current flow to the battery at each of the applied levels, and the target charging voltage is adjusted in the direction of the improved charge acceptance as indicated by the differentials of the input current flow at the increased and decreased levels. By repeating the process, the charging voltage is continually moved in the direction of an optimized charge acceptance level. Alternatively, a target current is applied and increased and decreased by a small step and adjusted in the direction of the improved charge acceptance, which corresponds to the differentials of the resulting voltages at the increased and decreased levels.

Abstract: A method of fabricating a modular, recombinant lead-acid battery is provided for. The method includes providing a plurality of thermoplastic frames, including at least two frames which support electrochemically active plates. The frames are adapted to be stacked and welded together such that the plates are spaced apart from each other a predetermined distance. One or more separators also are provided. The separators have an uncompressed state in which their thickness is equal to or greater than the predetermined distance between plates and a compressed state. The frames and separators are stacked such that a separator is disposed between adjacent plates in its compressed state. The frames then are successively vibration welded together, again while the separator is in its compressed state. The separator has a predetermined thickness in its compressed state effective to reduce damage to the separator caused by abrasion of the separators by the plates during vibration welding.

Abstract: A method and apparatus is disclosed for charging lead-acid batteries which comprises periodic voltage sweeps to determine the charging voltage that should be used for the battery and then adjusting the charging voltage in accordance with that voltage sweep information so as to ensure that a highly efficient charging process is achieved which avoids undue gassing and inherently compensates for factors such as the temperature, type and service life history of the battery and resistance due to the interactive nature of the technique and apparatus. One suitable technique for analysis and adjustment of the voltage sweep data involves analyzing the slope of the current versus the voltage sweep curve so as to determine certain slope values or changes in values.