Abstract: The disclosure relates to packaging of an energy storage module containing a plurality of storage cells for use in mobile and stationary power generation. The storage cells are pressed into a block of thermally conductive material in order to manage the temperature of the cells. The storage cells are secured between a clamping plate and a chassis. The resulting package is suitable for use in heavy duty applications.

Abstract: A pack-bonded, multiphase composite material is provided. The multiphase composite material has at least two layers of a matrix material pack-bonded with at least one layer of a reinforcement material. The reinforcement material is oriented in a pack-bonded direction such that the reinforcement material is uniformly dispersed between the matrix materials. Additionally, the matrix materials and the reinforcement material are chemically dissimilar. The matrix material is selected from the group consisting of lead and lead alloys, and the reinforcement material is a plurality of non-conductive, large length-to-diameter ratio, low-density fibers.

Abstract: A plate making process for a lead acid battery which eliminates the need for steaming and curing steps to produce the active material. Mixing, reacting and crystallizing occur in a closed reactor under controlled temperature and mixing conditions to produce a paste having the desired crystal morphology. A polymer is then added to the paste to bind the crystals together and to produce desired rheological properties in the paste. The paste having the polymer addition is then pasted onto a grid where the paste is dried to form a battery plate of the lead acid battery. The process is applicable for both the positive and negative plates of a lead acid battery.

Abstract: A grid plate for high power lead acid battery having a plate (14) covered with a conductive polymeric matrix (10) of preferably polyaniline and its derivatives, which is then coated with nanoscale particles of active material (14) such as lead sulfate and basic lead sulfate complexes.

Abstract: A pack-bonded, multiphase composite material is provided. The multiphase composite material has at least two layers of a matrix material pack-bonded with at least one layer of a reinforcement material. The reinforcement material is oriented in a pack-bonded direction such that the reinforcement material is uniformly dispersed between the matrix materials. Additionally, the matrix materials and the reinforcement material are chemically dissimilar. The matrix material is selected from the group consisting of lead and lead alloys, and the reinforcement material is a plurality of non-conductive, large length-to-diameter ratio, low-density fibers.

Abstract: A grid plate for high power lead acid battery having a plate (14) covered with a conductive polymeric matrix (10) of preferably polyaniline and its derivatives, which is then coated with nanoscale particles of active material (14) such as lead sulfate and basic lead sulfate complexes.

Abstract: An apparatus and method for providing enhanced charging efficiency and a reduction in charge system cost when charging segmented batteries. A current switching device routes charging current from a charge source to a selected segment of the battery, while the remaining segments are in a relaxation mode and are not receiving charge current. A segment selection device periodically reconfigures the current switching device to route charging current to another segment of the battery. As a result, each of the series-connected cells of the battery are subject to alternating charging and relaxation periods until the battery has achieved a desired state of charge.

Abstract: Battery charging methods and associated chargers which are capable of rapidly charging a battery while subjecting it to reduced levels of overcharging. The methods described are capable of being utilized within numerous battery charging systems for batteries spanning a range of chemistries, such as lead-acid, nickel-based, and lithium-based batteries. Upon detection of the onset-of-overcharge during the charge process, a variable voltage lid is imposed (VLID=&ngr;(&phgr;)+&bgr;log&phgr;+&kgr;&phgr;) which reduces the maximum voltage that may be applied to the battery as a function of charge acceptance which is typically estimated by a calculation based on state-of-charge. Additionally, the voltage lid can be approximated with step-wise voltage lids which are responsive to the level of charge acceptance within the battery.

Abstract: A continuous paste making process for lead acid batteries that includes the steps of mixing water with a lead oxide, reaction an acid with the lead oxide in a mixture to produce lead acid compounds, and forming a paste including interlocking lead acid crystals from the lead acid compounds, where the mixing, reacting, and crystal forming steps occur in an extrusion apparatus. The method also includes the step of extruding the paste from the extrusion apparatus into a grid where the paste is dried to form a battery plate of the lead-acid battery.

Abstract: A plate making process for a lead acid battery which eliminates the need for steaming and curing steps to produce the active material. Mixing, reacting and crystallizing occur in a closed reactor under controlled temperature and mixing conditions to produce a paste having the desired crystal morphology. A polymer is then added to the paste to bind the crystals together and to produce desired rheological properties in the paste. The paste having the polymer addition is then pasted onto a grid where the paste is dried to form a battery plate of the lead acid battery. The process is applicable for both the positive and negative plates of a lead acid battery.

Abstract: An apparatus and methods for determining dynamic state-of-charge of a battery that is subject to periodic charging and discharging within a system. Correction factors &eegr; are determined for various operational conditions of current, temperature and state of charge which relate relative discharge and charge efficiency with a reference set of conditions. According to conditions, the correction factor, either calculated in real-time or retrieved as a stored value, is then applied periodically to the charge and discharge currents of the battery to adjust an estimated state-of-charge value (SOC) for the battery within the given system.

Abstract: Melting and recrystallizing the surfaces of a wrought Pb--Ca--Sn alloy strip from which positive Pb-acid storage battery grids are punched or expanded. The alloy also contains an alloyant such as silver which, upon recrystallization, provides a higher concentration of alloyant-rich grain boundaries on the surface of the grid than the wrought grid for enhancing the conductivity of any oxidation layer formed on the surface of the grid during high temperature cycling of the battery.