Abstract: An electrochemical storage device comprises a plurality of layer electrodes, wherein each layer electrode includes a first charged sector and a second charged sector, wherein the second charged sector is charged oppositely compared to the first charged sector, and wherein the plurality of layer electrodes are assembled with respect to each other such that the first charged sector of a first plate of the plurality of layer electrodes is laid below the second charged sector of a second plate of the plurality of layer electrodes located immediately above the first plate, wherein the charges of the first charged sectors of the first and second plates have a first sign and the charges of the second charged sectors of the first and second plates have a second sign that is opposite the first sign; a separator sector located, and enabling ionic charge exchange between the first charged sector of the first plate and the second charged sector of the second plate.

Abstract: An electrode and a lead-acid battery including the same are disclosed. The electrode comprises active material comprising lead and a carbon additive configured to increase a charge input of the lead-acid battery by at least 17%, relative to a negative electrode without the carbon additive.

Abstract: A press assembly and a method for bending electrical terminals of battery cells are provided. The assembly includes a supporting member that holds a body portion of a cell thereon. The cell has first and second electrical terminals. The assembly further includes a lower plate having first and second dies that hold the first and second electrical terminals, thereon. The assembly further includes an upper plate having third and fourth dies, and guide rods disposed between the lower plate and the upper plate. The upper plate moves vertically on the guide rods relative to the lower plate. The assembly further includes an actuation assembly moving the upper plate toward the lower plate such that the first electrical terminal is bent into a first predetermined shape between the first and third dies, and the second electrical terminal is bent into a second predetermined shape between the second and fourth dies.

Abstract: A lead-acid battery is disclosed, wherein the battery comprises battery modules connected in series, a sealed container, a positive terminal, and a negative terminal. A battery module, in turn, comprises one or more cell assemblies electrically connected in parallel. Next in the hierarchical design, each cell assembly comprises a plurality of electrochemical cells connected in series. Finally, each electrochemical cell comprises a cathode and an anode ionically connected via a separator. In some embodiments, the plurality of modules are disposed within a common cavity in fluid communication via a common fluid. In some embodiments, each battery module has an electric potential of approximately 12 V. In some embodiments, the battery comprises four battery modules and provides a minimum electric potential of approximately 48V.

Abstract: An electrochemical storage device comprises a plurality of layer electrodes each including a first charged sector and a second charged sector. The plurality of layer electrodes are assembled with respect to each other such that the first charged sector of a first plate of the plurality of layer electrodes is laid below the second charged sector of a second plate of the plurality of layer electrodes located immediately above the first plate. The charges of the first charged sectors of the first and second plates have a first sign and the charges of the second charged sectors of the first and second plates have a second sign that is opposite the first sign. The device also comprises a separator sector located, and enabling ionic charge exchange, between the first charged sector of the first plate and the second charged sector of the second plate.

Abstract: A battery cell assembly, a heat exchanger, and a method for manufacturing the heat exchanger are provided. The heat exchanger includes a rectangular-shaped sheet having first and second rectangular-shaped sheet portions coupled together at a bent edge such that the sheet portions are disposed proximate to one another. Outer edges of the first and second rectangular-shaped sheet portions are coupled together such that an interior region is formed between the first and second rectangular-shaped sheet portions. The bent edge has first and second apertures extending therethrough. The heat exchanger further includes a first inlet port disposed on the bent edge over the first aperture, and a second outlet port disposed on the bent edge over the second aperture, such that fluid can flow through the first inlet port and into the interior region and then through the outlet port.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a first battery cell, and a first cooling fin having a first panel portion and first and second rail portions that are disposed on first and second ends, respectively, of the first panel portion. The first battery cell is disposed adjacent to a first side of the first panel portion. The first and second rail portions have a thickness greater than the first panel portion. The first cooling fin conducts heat energy from the first battery cell into the first cooling fin to cool the first battery cell. The battery module further includes first and second conduits extending through the first and second rail portions, respectively, that receive a fluid that flows through the first and second conduits to conduct heat energy from the first cooling fin into the fluid.

Abstract: A battery cell assembly and a method for assembling the battery cell assembly are provided. The battery cell assembly includes first and second battery cells with a heat exchanger disposed between the first and second battery cells. The heat exchanger has a plastic frame and first and second thermally conductive layers. The plastic frame has an interior space extending therethrough. The first and second thermally conductive layers are disposed on opposite sides of the plastic frame to enclose the interior space, such that when a liquid is disposed in the interior space, heat energy is transferred from the first battery cell through the first thermally conductive layer to the liquid.

Abstract: The present disclosure includes a lead-acid battery having higher specific power and specific energy than prior known lead-acid batteries. A lead-acid electrochemical storage device is provided, comprising a specific power of between about 650 and about 3,050 Watts/kilogram; and a specific energy of between about 10 and about 80 Watt-hours/kilogram. In some embodiments, the device has a cycle life of greater than 150 cycles and is adapted for use in a vehicle application. The application comprises stop/start or the partial or complete electrification of the vehicle propulsion system. The device may have a bipolar or pseudo-bipolar design, multiple cells disposed within a common casing, and the cells are connected ionically within each cell and electronically between cells.

Abstract: A battery module for an electric vehicle or a hybrid electric vehicle having two or more battery components. An lead-acid electrochemical storage device is provided, comprising a specific power of between about 550 and about 1,900 Watts/kilogram; and a specific energy of between about 25 and about 80 Watt-hours/kilogram.

Abstract: An electrochemical cell includes an electrode assembly having a plurality of electrode plates. Each electrode plate includes a current collector having a first portion and a second portion, and each first and second portion having a first surface and a second surface opposing the first surface. The first and second surfaces of the first portion include a positively charged active material, and the first and second surfaces of the second portion include a negatively charged active material. In addition, the plurality of electrode plates includes at least two electrode plates, such that the electrochemical cell is arranged with a first portion of one plate electrochemically connected to a second portion of a second plate.

Abstract: An improved substrate is disclosed for an electrode of an electrochemical cell. The improved substrate includes a core material surrounded by a coating. The coating is amorphous such that the coating includes substantially no grain boundaries. The core material may be one of lead, fiber glass, and titanium. The coating may be one of lead, lead-dioxide, titanium nitride, and titanium dioxide. Further, an intermediate adhesion promoter surrounds the core material to enhance adhesion between the coating and the core material.

Abstract: A battery module having a cooling manifold is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers. The battery module further includes a first cooling manifold having a first inlet aperture extending therethrough and a first plurality of outlet apertures extending therethrough. The battery module further includes a first plurality of ported screws disposed through the first plurality of outlet apertures and configured to fluidly and physically couple the plurality of heat exchangers to the first cooling manifold.

Abstract: A test system for a battery module is provided. The system includes a housing having a bottom plate; and first, second, third and fourth side walls coupled to the bottom plate that defines an interior region. The system further includes a mounting fixture that fixedly holds the battery module thereon. The system further includes first, second, third and fourth coupling members. The system further includes a lid coupled to the housing utilizing the first, second, third and fourth coupling members. The system further includes a battery charging system that charges the battery module.

Abstract: A battery system and a method for increasing an operational life of a battery cell are provided. The battery system includes a voltage sensor that generates a first signal indicative of a voltage level output by the battery cell, and a current sensor that generates a second signal indicative of a level of electrical current flowing through the battery cell. The battery system further includes a microprocessor that calculates a resistance level of the battery cell based on the first and second signals, and generates a control signal to induce a fluid supply system to increase a pressure level of the coolant fluid being supplied to the heat exchanger to a first pressure level, based on the resistance level.

Abstract: A battery module having a cooling manifold is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers. The battery module further includes the cooling manifold operably coupled to the plurality of battery cell assemblies. The cooling manifold has a manifold portion and a cover plate. The manifold portion has a peripheral wall, a rear wall coupled to the peripheral wall, and a flow diverter. The peripheral wall has a top portion with an inlet aperture extending therethrough. The rear wall has a plurality of outlet apertures extending therethrough. The cover plate is coupled to the peripheral wall opposite to the rear wall. The flow diverter extends from the rear wall and is disposed below the inlet aperture.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a battery cell and a cooling fin disposed adjacent to the battery cell. The cooling fin has a solid plate and first and second tab portions extending from first and second edges, respectively, of the solid plate. The first and second tab portions are bent perpendicular to a front surface of the battery cell. The cooling fin extracts heat energy from the battery cell thereto. The battery module further includes a first cooling manifold that contacts the first tab portion of the cooling fin. The first cooling manifold has at least one flow channel extending therethrough that receives a fluid therethrough. The first cooling manifold conducts heat energy from the cooling fin into the fluid flowing through the first cooling manifold to cool the battery cell.

Abstract: A battery cell carrier assembly having a battery cell carrier for holding a battery cell is provided. The battery cell carrier includes a trapping member for holding the battery cell. The battery cell carrier has at least one aperture extending therethrough for allowing air to flow therethrough to contact the first side of the battery cell for cooling the battery cell. The battery cell carrier further includes a panel member configured to be coupled to the trapping member for holding the battery cell therebetween. The panel member has at least one aperture extending therethrough for allowing air to flow therethrough to contact the battery cell for cooling the battery cell.

Abstract: A battery system and a method for increasing an operational life of a battery cell are provided. The battery system includes a voltage sensor that generates a first signal indicative of a voltage level output by the battery cell, and a current sensor that generates a second signal indicative of a level of electrical current flowing through the battery cell. The battery system further includes a microprocessor that calculates a resistance level of the battery cell based on the first and second signals, and generates a control signal to induce a fluid supply system to increase a pressure level of the coolant fluid being supplied to the heat exchanger to a first pressure level, based on the resistance level.

Abstract: An ultrasonic welding system and a method are provided. The system includes an ultrasonic welding device having an ultrasonic welding horn. The system further includes a controller generating control signals for inducing the welding device to form a first weld joint. The system further includes a power adjusting unit that induces the ultrasonic welding controller to increase a power level output by the ultrasonic welding controller to the ultrasonic welding device if a first displacement of the welding horn is less than the desired displacement during partial completion of forming the first weld joint, such that upon completion of the first weld joint an ending position of the ultrasonic welding horn is at a desired ending position.