Abstract: A switch for controlling the supply of current from a battery cell in a cell cavity to a battery terminal in a battery casing is disclosed. The switch includes a mounting base, a first buss bar connected to the mounting base and connectable to the battery cell, a second buss bar connected to the mounting base and connectable to the battery terminal, and a relay having open and closed positions. The relay includes a third buss bar that places the first buss bar and the second buss bar in contact to provide current from the battery cell to the battery terminal when the relay is in the closed position. The relay is moved into a latched open position when a first winding of a coil of the relay is energized by electricity, and is moved back into a latched closed position when a second winding of the coil is energized.

Abstract: A method of forming battery grids or plates that includes the step of mechanically reshaping or refinishing battery grid wires to improve adhesion between the battery paste and the grid wires. The method is particularly useful in improving the paste adhesion to battery grids formed by a continuous battery grid making process (such as strip expansion, strip stamping, continuous casting) that produces grid wires and nodes with smooth surfaces and a rectangular cross-section. In a preferred version of the method, the grid wires of battery grids produced by a stamping process are deformed such that the grid wires have a cross-section other than the rectangular cross-section produced by the stamping process. The method increases the cycle life of a battery.

Abstract: A method of forming battery grids or plates that includes the step of mechanically reshaping or refinishing battery grid wires to improve adhesion between the battery paste and the grid wires. The method is particularly useful in improving the paste adhesion to battery grids formed by a continuous battery grid making process (such as strip expansion, strip stamping, continuous casting) that produces grid wires and nodes with smooth surfaces and a rectangular cross-section. In a preferred version of the method, the grid wires of battery grids produced by a stamping process are deformed such that the grid wires have a cross-section other than the rectangular cross-section produced by the stamping process. The method increases the cycle life of a battery.

Abstract: A battery grid, suitable for use in a lead-acid battery, with a grid upper portion having a grid wires defining a first grid pattern, and a grid lower portion electrically connected to the grid upper portion. The grid lower portion having grid wires defining a second grid pattern, wherein the first grid pattern is different from said second grid pattern to improve the conductivity of the grid.

Abstract: A stamped grid for a lead-acid battery having a grid pattern that is optimized for electrical performance. The stamped grid includes an electrically conductive grid body having opposed top and bottom frame elements, opposed first and second side frame elements and a plurality of interconnecting grid wire elements forming a grid pattern. The grid wire elements include a plurality of vertical wire elements connected to both top and bottom frame elements, a plurality of vertical wire elements connected to the top frame element and one of either the first or second side frame elements and a plurality of cross grid elements that interconnect the vertical wire elements. Each of the vertical grid elements that is connected to the top frame element and one of either the first or second side frame elements includes a plurality of the cross frame elements connected thereto at a substantially 90° angle.

Abstract: A stamped grid for a lead-acid battery having a grid pattern that is optimized for electrical performance. The stamped grid includes an electrically conductive grid body having opposed top and bottom frame elements, opposed first and second side frame elements and a plurality of interconnecting grid wire elements forming a grid pattern. The grid wire elements include a plurality of vertical wire elements electrically connected to both top and bottom frame elements, a plurality of vertical wire elements connected to the top frame element and one of either the first or second side frame elements and a plurality of cross grid elements that interconnect the vertical wire elements. Each of the vertical grid elements that is electrically connected to the top frame element and one of either the first or second side frame elements includes a plurality of the cross frame elements connected thereto at a substantially 90.degree. angle.

Abstract: A pasting operation for thin foils used in rechargeable electrochemical cells includes spraying a water based litharge on a lead foil substrate before the foil is wound to form a cylindrical electrode. To overcome problems with plate density, porosity and incomplete formation, the process would include the additional step of spraying an aqueous solution of an oxidant such as potassium persulfate on top of the litharge. The lag between spraying, the temperature and the concentrations are adjusted to cause the solution to mix into the damp paste and the litharge would be converted to conductive oxides. Improvements in plate density and increased porosity are noted and the process helps complete formation. Performance of the plates is also improved.

Abstract: A bipolar plate assembly includes a frame member having a center opening therethrough between parallel opposed surfaces, the opening being countersunk on one side of frame the member defining a mounting shoulder, and a bipolar element including a thin lead foil substrate having positive and negative active electrode material disposed on opposite surfaces, the bipolar element being mounted in the opening of the frame member with the marginal edge of the substrate located on the mounting shoulder and secured thereto by an adhesive resin, securing the bipolar element to said frame member, one or more such bipolar plate assemblies being stacked together between first and second terminal electrode assemblies to form a single or multi-element bipolar module having positive and negative terminals, and a plurality of the bipolar modules can be stacked together with their terminals electrically interconnected to form a multi-cell bipolar battery structure.

Abstract: A grid for a lead acid battery plate with a conductive frame having a top element and a bottom frame element, with conductive wires extending from the bottom element to the top element which includes an enlarged section beneath a current collection lug and being of a size and shape so as to optimize the current flow to the lug. Other features disclosed are the conductive wire shape and spacing so that the amount of conductive material such as lead is reduced where it has been predetermined that the current flow is minimal. In addition, the grid is designed to have equidistant potential points relative to the lug to optimize current flow. The advantage of such a grid is that it maximizes performance of the battery while keeping its weight at a minimum.

Abstract: A cast-on strap for use in connecting current collecting lugs in battery systems is disclosed. In the most preferred embodiment, the invention includes a caston strap formed of electrically conductive material, such as lead, having a first elongate portion in electrical contact with a line of spaced apart battery plate lugs. The connector strap includes a second portion lying in a plane which is perpendicular to that of the elongate portion so that the latter is laterally displaced. The preferred cast-on strap also includes an angularly extending portion between the elongate portion and the second portion. Increased current transfer efficiency is achieved using the strap of the present invention.

Abstract: A thermocell includes a negative electrode, such as a lead-acid electrode, and a porous oxygen (air) electrode disposed in a housing and separated by a separator. During discharge, oxygen is allowed to permeate through the oxygen electrode and separator to reach the negative electrode. Chemical oxidation of the negative electrode by oxygen in the presence of sulfuric acid yields water, lead sulfate, and heat. The heat can be used in many ways, such as warming up an adjoining automotive battery in winter, or as a personal heating pad. The heating rate is controlled by the rate of oxygen ingress. When not in use, the oxygen electrode is sealed by taping or by other means to stop ingress of oxygen. The used thermocell can be recharged by charging the negative electrode while evolving oxygen at the oxygen electrode.

Abstract: An grid for a lead acid battery plate includes a central plate lug, the lug preferably having an expanded base for the collection of current and the grid being constructed in such a manner that the amount of metal is concentrated in the vicinity of the lug. A unique cast-on strap design for use with the grids is also disclosed. Substantial manufacturing advantages result from the use of such grids, and the performance of the battery can be increased to the point that individual battery plates may be eliminated, resulting in lighter weight batteries and material cost savings.

Abstract: An electrode suitable for use as a lead-acid battery plate is formed of a paste composition which enhances the performance of the plate. The paste composition includes a basic lead sulfate, a persulfate and water. The paste may also include lead oxide and fibers. An electrode according to the invention is characterized by good strength in combination with high power density, porosity and surface area.

Abstract: A process for coating a solid substrate with a layer of barium metaplumbate includes steps of forming a layer of lead oxide on the substrate, if not already present, and then reacting this layer with a barium salt at an elevated temperature to form a layer of coating of barium metaplumbate. Reaction temperature is a key aspect of this process, along with use of a barium salt which will react at the temperature selected. In particular, the reaction temperature must be sufficiently high to allow the reaction to proceed, but lower than the melting point of the substrate. The described process eliminates the need to preform BaPbO.sub.3 prior to coating and can be conducted at a much lower range of temperatures than prior processes.

Abstract: An electrode suitable for use as a lead-acid battery plate contains an inorganic metal oxide additive which enhances the formation of the plate. The additive is electrically conductive, stable in aqueous solutions of sulfuric acid, but does not participate in the electrode reaction. Suitable metal oxides include barium metaplumbate and other ceramic perovskite materials having similar properties. The conductive ceramic may also be used in electrodes for bipolar lead-acid batteries and in an electrode, particularly an anode (positive electrode), used in electrolytic processes.

Abstract: Electrodes having high electrocatalytic activity are prepared by coating a base member of conductive material (preferably glassy carbon) with a layer of a porous polymeric material and then electrodepositing microparticles of metal within the polymeric layer by electrolysis using the electrode in a solution of the appropriate metal. The metal particles deposited within the polymer layer are typically less than about 100 nm. in diameter and their imbedding within the polymeric layer helps prevent poisoning of catalytically active metal by absorbed macromolecules.