Abstract: A sealed gas recombining lead-acid cell with absorbed electrolyte is produced by assembling unformed plates and high porosity glass mat separator whose surface area is from 0.2-1.7 m.sup.2 /g, adding a limited quantity of acid into the cell, and then either prior to or after sealing of the cell electrochemically forming the plates of the cell in situ. High rate performance of the cell is significantly improved over cells using conventional high surface area glass separators.

Abstract: A sealed gas recombining lead-acid cell with absorbed electrolyte is produced by assembling unformed plates and high porosity glass mat separator whose surface area is from 0.2-1.7 m.sup.2 /g, adding a limited quantity of acid into the cell, and then either prior to or after sealing of the cell electrochemically forming the plates of the cell in situ. High rate performance of the cell is significantly improved over the cells using conventional high surface area glass separators.

Abstract: An electrode plate group combination insulator and vibration support at least partially envelopes a plate group connecting strap. The insulator and vibration support includes a comb-like portion which underlies the strap, having teeth which intermesh with tabs projecting from the plates, and a hood portion which overlies the strap. The insulator and vibration support is preferably attached to the walls of the cell of the battery to thereby support the battery plate group and withstand vibrational forces.

Abstract: An electrochemical cell of the limited electrolyte type is described having a cell pack comprised of the normal absorbent separator interleaved and compressed between positive and negative plates, the electrolyte absorbed within pores of the separator and plates, and a container encasing the cell pack. The cell pack has an edge or edges which abut against at least one wall portion of the container, forming an interface in which is formed channels providing passageways which promote uniform distribution of electrolyte within the cell pack at least during filling of the cell with electrolyte. Filling time is also substantially reduced.

Abstract: A multi-layered gas permeable separator for lead-acid maintenance-free batteries, particularly for sealed gas recombining type rechargeable lead-acid batteries, is disclosed. The outer separator layers, adapted to be positioned against the opposite polarity plates of the battery, are composed of ultrafine fibers particularly glass fibers of relatively high fiber surface area. A third layer is interposed between the outer layers and is comprised of ultrafine fibers particularly of fiber glass, but has a fiber surface area on an equivalent weight basis which is substantially less than that of at least one of the outer layers. High rate, low temperature discharge performance of the battery is enhanced.

Abstract: A recombining lead-acid battery with absorbed electrolyte is disclosed having multiple cells positioned in a sealed monobloc container, and cell partitioning members constructed to define a gas space common to all the cells of the battery. When the battery is overcharged imbalance in electrolyte fill among the cells is reduced as the amount of water in each cell tends to equalize through redistribution via gas recombination preferentially in the drier cells.

Abstract: A multicell sealed rechargeable battery is disclosed including an open mouth monobloc container formed of a plurality of cup-shaped cell holders interconnected at mutual tangent zones, electrochemical cells of the rechargeable type fitting into the cell holders and interconnected to form the battery, and a closure member attached to the mouth of the monobloc container.

Abstract: A unitary welded connection between a projecting leg of a cell connecting strap and collector tabs emanating from the plates of the cell is disclosed, the leg having boss protrusion(s) to eliminate bridge welds.

Abstract: Thermoplastic battery cover and container piece parts are fused together using vibratory energy, particularly ultrasonic welding, in which the horn has a depending skirt extending along an outer wall of the container and which serves to maintain the cover and container in mutual alignment and simultaneously contain the flow of the melt (flash). In another aspect, a particular interference joint between the components is described featuring a continuous ramp of 50-70 degrees and producing an interference fit for an improved weld. The invention is also directed to a cell or battery formed according to the method of the invention, as well as the horn.

Abstract: A unitary welded connection between a projecting leg of a cell connecting strap and collector tabs emanating from the plates of the cell is disclosed, the leg having boss protrusion(s) to eliminate bridge welds.

Abstract: A molded plastic lid for an electrochemical cell is provided with upstanding protuberant ribs or the like in a position to give direct mechanical support to a post connecting strap, which has been found to greatly improve cell vibration resistance.

Abstract: A method for producing a grid for a lead-acid battery is disclosed having a network of integrally interconnected strands of lead in which a portion of the strands are offset and project from one face of the grid while a second portion of the strands project and are offset to the other opposed face of the grid, to form upstanding projections and alternating depressions. The grids are useful as current collector substrates in Faure plates.

Abstract: A spirally wound element comprising opposite polarity plates and interleaved separator is described, for use in electrochemical cylindrical configured cells. The cell pack has a uniform predetermined cross section irrespective of variation in component thickness as long as such thicknesses are within specified tolerances. A dual head, belt-driven winder and method are also described for producing the spiral cell pack.

Abstract: A grid for a lead-acid battery is disclosed having a network of integrally interconnected strands of lead in which a portion of the strands are offset and project from one face of the grid while a second portion of the strands project and are offset to the other opposed face of the grid, to form upstanding projections and alternating depressions. The grids are useful as current collector substrates in Faure plates.

Abstract: A spirally wound element comprising opposite polarity plates and interleaved separator is described, for use in electrochemical cylindrically configured cells. The cell pack has a uniform predetermined cross section irrespective of variation in component thicknesses as long as such thicknesses are within specified tolerances. A dual head, belt-driven winder and method are also described for producing the spiral cell pack.

Abstract: A spirally wound element comprising opposite polarity plates and interleaved separator is described, for use in electrochemical cylindrically configured cells. The cell pack has a uniform predetermined cross section irrespective of variation in component thicknesses as long as such thicknesses are within specified tolerances. A dual head, belt-driven winder and method are also described for producing the spiral cell pack.

Abstract: A spirally wound element comprising opposite polarity plates and interleaved separator is described, for use in electrochemical cylindrically configured cells. The cell pack has a uniform predetermined cross section irrespective of variation in component thicknesses as long as such thicknesses are within specified tolerances. Dual head, belt-driven winder and method are also described for producing the spiral cell pack.

Abstract: Method and apparatus are disclosed for the pasting of foraminous battery plate substrates with viscous, thixotropic pastes using an extrusion type bifurcated nozzle.