Abstract: An electric vehicle cell featuring internal pressure relief and spring disengagement devices which vent various internal pressures to atmosphere to prevent cell bulging or explosion and which also internally interrupt current flow through the cell due to internal overheat, excessive current draw and the like. Internal reconnection of cell members reoccurs subsequent to internal thermal and other abnormalities. The electric vehicle cell contains an electrolyte which is introduced into the cell casing by a method involving the use of apparatus including a filling fixture having an electrolyte fill line and a vacuum line for vacuum assisted filling.

Abstract: A flexible welding board for a battery pack, which is a polyester film or polymer with prepunched holes and a laminated nickel alloy or other metal or metal material. The polyester film with a suitable polymer adhesive or other adhesive includes a laminated nickel or other metal thereon. The nickel alloy or other metal alloy or metal is subsequently imaged with a pattern, and etched providing a flexible welding board for the welding of components of a battery pack, including the battery cells, electrical components and the electromechanical components which are spot-welded thereto. The entire process can be done robotically providing a battery pack which has electromechanical integrity between the battery cells, components, flexible welding board and the battery pack housing.

Abstract: An electric vehicle cell featuring internal pressure relief and spring disengagement devices which vent various internal pressures to atmosphere to prevent cell bulging or explosion and which also internally interrupt current flow through the cell due to internal overheat, excessive current draw and the like. Internal reconnection of cell members reoccurs subsequent to internal thermal and other abnormalities. The electric vehicle cell contains an electrolyte which is introduced into the cell casing by a method involving the use of apparatus including a filling fixture having an electrolyte fill line and a vacuum line for vacuum assisted filling.

Abstract: A flexible welding board for a battery pack, which is a polyester film or polymer with prepunched holes and a laminated nickel allow or other metal or metal material. The polyester film with a suitable polymer adhesive or other adhesive includes a laminated nickel or other metal thereon. The nickel alloy or other metal alloy or metal is subsequently imaged with a pattern, and etched providing a flexible welding board for the welding of components of a battery pack, including the battery cells, electrical components and the electromechanical components which are spot-welded thereto. The entire process can be done robotically providing a battery pack which has electromechanical integrity between the battery cells, components, flexible welding board and the battery pack housing.

Abstract: A small battery cell including a pressure relief and spring disengagement device which vents various internal pressures to the atmosphere to prevent cell bulging or explosion, and also which internally interrupts current flow through the cell due to internal cell over heat, excessive current flow or the like. Internal reconnection of cell members reoccurs subsequent to internal thermal or other internal abnormalities. Alternate embodiments illustrate an apparatus and method for vacuum assisted filling and an apparatus for vacuum sealing of the small battery cell.

Abstract: A small battery cell including a pressure relief and spring disengagement device which vents various internal pressures to the atmosphere to prevent cell bulging or explosion, and also which internally interrupts current flow through the cell due to internal cell overheat, excessive current flow or the like. Internal reconnection of cell members reoccurs subsequent to internal thermal or other abnormalities.

Abstract: An electric vehicle cell featuring internal pressure relief and spring disengagement devices which vent various internal pressures to atmosphere to prevent cell bulging or explosion and which also internally interrupt current flow through the cell due to internal overheat, excessive current draw and the like. Internal reconnection of cell members reoccurs subsequent to internal thermal and other abnormalities.

Abstract: Laser inscribing system for one step labeling, dating or applying appropriate artwork to a plastic battery enclosure case. A computer controlled laser gun directs a laser beam to inscribe pertinent data on a plastic battery enclosure case.

Abstract: A flexible welding board for a battery pack, which is a polyester film with a laminated nickel alloy material. The polyester film with a co-extruded polymer adhesive includes a laminated nickel alloy thereon. The nickel alloy is subsequently silk screened with a pattern, and etched providing a flexible welding board for the welding of components of a battery pack, including the battery cells, electrical components and the electromechanical components which are spot-welded thereto. The entire process can be done robotically providing a battery pack which has electromechanical integrity between the battery cells, components, flexible welding board and the battery pack housing.

Abstract: Method and apparatus for measuring the voltage and state of charge of a secondary battery. The voltage and state of charge values are taken by a circuit every four (4) seconds by reading voltage, waiting two (2) seconds, reading current, waiting two (2) seconds, and repeating the voltage readings and the current readings. The circuit includes a 4-bit microprocessor, CMOS analog switches, and two operational amplifiers. The voltage and current readings are taken from dual-sloped converters, and the values determined by software algorithms in the microprocessor.

Abstract: A welding system for a battery pack utilizing three-phase 400 Hz power at low voltage over a short time period. In utilizing these parameters, there is minimal or no migration of materials between a welding area, welding electrodes, a metal member and a battery cell.

Abstract: Process for spot-welding a flexible welding board to at least one and preferably a battery cells to form a battery pack, such as a NiCad battery pack. The flexible welding board is a nickel alloy material, laminated to a polyester film by a co-extruded adhesive. The spot-welding is accomplished by one spot-welder, and preferably two spot-welders, which spot-weld in alternating time intervals so as to assure electrical and electromechanical contact with each end of the battery cells by the nickel alloy material. The spot-welding is by DC current and voltage. The electrodes are small enough to form a configuration between the flexible circuit and the end of the battery cell. Three spot-welding electrodes would assume a triangular configuration. Four spot-welding electrodes would form a rectangular configuration.

Abstract: Process for spot-welding a flexible bare backed welding board to at least one and preferably a plurality battery cells to form a battery pack, such as a NiCad battery pack. The flexible bare backed welding board is a nickel or other metal alloy material, laminated to a polyester film by a co-extruded or otherwise applied adhesive. The spot-welding is accomplished by one spot-welder, and preferably two spot-welders, which spot-weld in alternating time intervals so as to assure electrical and electromechanical contact with each end of the battery cells by the nickel alloy material. The spot-welding is by DC current and voltage or alternatively can be AC welded. The electrodes are small enough to form a configuration between the flexible circuit and the end of the battery cell. Three spot-welding electrodes would assume a triangular configuration. Four spot-welding electrodes would form a rectangular configuration.

Abstract: A battery maintenance system for charging, analyzing, discharging and conditioning of a NiCad battery. The system displays voltage and capacity to determine whether or not a NiCad battery has enough capacity to power equipment for an optimal time period. The system charges the battery using a negative delta voltage method of detecting full charge, while also displaying instantaneous battery voltage. The system also analyzes the battery in a charge, discharge and recharge mode of operation, and during the charge mode the instantaneous voltage is displayed. The discharge mode discharges the battery to one volt per cell while displaying voltage and accumulative capacity alternately. The system also conditions batteries by cycling a battery through three cycles of charging, discharging and a subsequent recharge cycle.

Abstract: Method and apparatus for measuring the voltage and state of charge of a secondary battery. The voltage and state of charge values are taken by a circuit every four (4) seconds by reading voltage, waiting two (2) seconds, reading current, waiting two (2) seconds, and repeating the voltage readings and the current readings. The circuit includes a 4-bit microprocessor, CMOS analog switches, and two operational amplifiers. The voltage and current readings are taken from dual-sloped converters, and the values determined by software algorithms in the microprocessor.