Abstract: A rechargeable battery module is disclosed that is particularly well adapted for use in multi-module battery packs. The module includes top and bottom cover plates. At least a portion of each cover plate is formed from electrically conductive materials so that when the battery module is integrated into a stack, the contacts between adjacent battery units are formed by the cover plates. A positive plate that has a positive surface is placed in electrical contact with a first cover plate. A negative plate having a negative surface is also provided. The negative plate is arranged in electrical contact with the second cover plate. The battery includes a plurality of active paste layers. Each active paste layer is applied to an associated surface. One or more separators are provided to isolate the paste layers. The first and second cover plates are electrically isolated by at least the paste layers and the separator means. The cover plates may be ribbed to provide structural support.

Abstract: Lithium based electrical cells having a new anode electrode construction are described. The cells have a sandwich construction of lithium sheet, conductive foil and lithium sheet, wherein the anode tab is welded directly onto the conductive foil not onto the lithium. Alternatively, the tab is connected onto the lithium in an area where the lithium does not dissolve during discharge, so that the tab will not become disconnected from the anode sheet.

Abstract: A sealed lead acid battery including a container; a cover connected to the container; a plurality of plate groups disposed in the container, each of the plate groups comprising a plurality of pairs of positive plates and negative plates separated, each from the other, by separators; an upper space within the container extending from the plates to the cover; a pair of straps disposed in the upper space; each of the plates having an upstanding lug; each of the lugs extending from the negative plates being connected to one of the straps; each of the lugs extending from the positive plates being connected to the other of the straps; and foam polyurethane resin filling a sufficient amount of the upper space to control the possibility of an explosion occurring due to the collection of gases within the container, the foam polyurethane having an apparent specific gravity of from 2 g/l to 50 g/l and an open cell structure.

Abstract: A method for producing a gel form negative electrode of an alkaline battery while avoiding use of mercury enables uniform dispersion of zinc or zinc alloy powder and an effective metal which can be one or more of an oxide or hydroxide of indium, lead, gallium, bismuth, by stirring for a substantially reduced period. The method employs dry mixing of the zinc or zinc alloy powder and the effective metal in advance of mixing with a gel form alkaline electrolyte. Also, in order to obtain satisfactorily high vibration strength and impact resistance, fiber material can be added to the gel form negative electrode. The fiber material may be selected among rayon, vinylon, acryl, vinyon, polyamide, polypropylene, polyethylene, mercerized pulp, linter pulp.

Abstract: A bipolar electrode for a Pb-acid battery comprising a lead septum plate and a porous coating on at least one face of the septum plate for anchoring at least the positive active material paste to the septum. The porous coating comprises multiple layers of lead particles fused together and to the septum face so as to define a plurality of interconnected, interstitial pores therebetween. The particles are fused droplets of lead arc-sprayed into the surface of the septum. A particular bipolar and battery construction useful with the bipolar electrode is disclosed.

Abstract: Positive plates are prepared by forming partially oxidized tetrabasic lead sulfate (4 PbO.sub.n . PbSO.sub.4) having at least a part of the oxide (PbO.sub.n) portion in the form of alpha lead dioxide (.varies. - PbO.sub.n), and forming beta lead dioxide (B-PbO.sub.2). Next the oxidized tetrabasic lead sulfate (OXYTTB) and the beta lead dioxide are intermingled in a wet mixture. The wet mixture is applied to the oxidized surface of a lead support substrate. Then, it is heated and pressed for a time and at a temperature and compressive load sufficient to form an adhered or retained coating of active material on the substrate. The OXYTTB is formed by reaction of tetrabasic lead sulfate with magnesium hydroxide and sodium persulfate. Preferably, beta lead dioxide is formed by reacting red lead oxide (Pb.sub.3 O.sub.4) with nitric acid to provide an oxidation product, at least a major portion of which is beta PbO.sub.2, and which has a surface area of at least 10 m.sup.2 /gram.

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 storage battery of the lead-acid type has unipolar electrodes (6) and bipolar electrodes (7), having a tubular shape fastened preferably perpendicularly to walls (3, 4) made of an insulating material, which divide container into two or more adjacent cells (1) containing the electrolyte. In a preferred embodiment, each tubular electrode (6, 7) is formed by an axial bar (8) of lead or an alloy thereof, having a circular section, surrounded by active material (9), either positive or negative, in its turn enclosed by a coaxial tubular sheath (10) in porous synthetic and insulating material, and end plates (11, 12) of plastic material. The exteriorly extending ends (13), of the bars (8) of the unipolar tubular electrodes (6) of each of the end cells are connected to a respective external bus bar (14) for the current. The external bus bar (14) constitutes a pole of the storage battery.

Abstract: A battery is prepared by dipping battery elements (which may be surrounded by a thin, lightweight material, such as a plastic bag) into a liquid encapsulating, acid-resistant liquid material such as a rubber or resin. Individual elements can be connected either before or after hardening of the liquid to create a battery of the desired voltage. Heavy thermoplastic resin containers need not be used, and the weight of the resultant battery is thereby substantially reduced.

Abstract: Lead-acid battery plates are made by preparing alloys of lead with at least one additive metal that can be leached with an acid or an alkali from the alloy leaving a porous permeable lead matrix. The additive metal must be evenly and finely dispersed in the lead. A number of additive metals can be used but the additive metal is preferably magnesium or zinc and magnesium, each in a preferred amount in the range of about 3 to 15% by weight. The lead alloy is prepared by casting, preferably by rapid solidification casting, and subsequently pulverizing the alloy. The resulting lead alloy particles are applied to a conventional lead alloy battery grid by pressing, causing the formation of a coherent plate of grid and alloy. The plate is subsequently leached in an alkali or an acid which causes the substantial removal of additive metal from the alloy leaving a coherent porous permeable layer of substantially lead as active material. The preferred leachant is sulfuric acid.

Abstract: In a preferred method, an electrode for a lead-acid battery is prepared in a new continuous process without the conventional curing step. The general procedure for preparing electrodes includes preparing a mixture (paste) comprising an active material precursor and an inhibitor. The active material precursor includes lead oxides having at least 10% by weight lead oxide in the form of Pb.sub.3 O.sub.4 (red lead), and a BET surface area of at least about 0.8 m.sup.2 /gram; desirably about 1.00 to 1.50 m.sup.2 /gram and preferably about 1.0 to 1.25 m.sup.2 /gram. The inhibitor prevents formation of tribasic lead sulfate and tetrabasic lead sulfate from the precursor material, except at elevated temperature. The paste is applied to electrode grids and reacted at elevated temperatures for between about 5 and about 30 minutes, to form the active material of the electrode for both positive and negative electrodes. Plates are then assembled into batteries and charged.

Abstract: A method of making a rechargeable modified manganese-containing material is disclosed. The method includes mixing manganese nitrate with a doping material which may be a nitrate of a second metal and placing this mixture in an aqueous solution. Electrodes are then submerged in the solution and a current is passed through the electrodes to electrolyze the solution. This results in an electrolytic deposition of a first material on the cathode and a second material on the anode. The material deposited on the cathode is a rechargeable modified manganese-containing material in the discharge state. The material deposited on the anode is a modified manganese-dioxide material in the charged state. A battery employing the modified manganese-containing material is also disclosed.

Abstract: An assembled battery including a plurality of bipolar cells is disclosed. In one embodiment, the battery a plurality of conduits for introducing electrolyte into the bipolar cells, each of the conduits acting to introduce electrolyte into a different one of the bipolar cells. In another embodiment, the battery comprises at least one spacer element acting to maintain the spacing between plates and/or electrodes in the battery.

Abstract: A lead-acid battery in which the plates are fabricated from a paste containing principally lead oxide and a small amount of dimensionally isotropic graphite fiber of a specific type. The specific type of graphite fiber may be either a graphite fiber synthesized from a polyacrylonitrile (PAN) precursor or a graphite fiber synthesized from a pitch precursor.

Abstract: A lead-acid cell in which insert molded lead terminal connectors are provided with a surface layer of an elastic adhesive material bonded to the connector and making sealing contact with the enshrouding plastic molding. Electrolyte creepage and corrosion is suppressed.

Abstract: The present invention relates to batteries and battery systems. In particular, a battery is described which comprises a container which houses a plurality of cells. Each of the cells share a common negative terminal. Two or more positive terminal cells are provided. The specification also describes the use of such batteries to power the cranking and auxiliary circuits according to a cell discharge management scheme. Methods of forming such batteries are disclosed in which alternate positive and negative electrode plates are provided and methods of forming layered electrode plates are disclosed in which layered grids are provided and by varying the number of layers, thick and thin plates can be provided with different discharge characteristics.

Abstract: An electrically-powered vehicle wherein such vehicle is powered by storage batteries or fuel cells in which the plates of the batteries or cells, the spacing material between plates and the cases act as primary load-bearing members of the vehicle.

Abstract: A lead-acid battery using dilute sulfuric acid as the electrolyte, has a plate group composed of at least one positive plate, one negative plate and an intervening separator. Whiskers of at least one type selected from carbon, graphite and potassium titanate, having an electronic conductivity, with a diameter of 10 .mu.m or less and an aspect ratio of 50 or more, and a specific surface area of 2 m.sup.2 /g are mixed with at least one of the active materials of the positive and negative plates by 0.01 to 10 wt. % of the active material so as to connect the active material particles mutually and/or active material and current collector electronic conductively.

Abstract: A battery separator for use in deep cycle traction batteries, such as golf cart batteries. The separator is formed of a microporous, mainly polymeric layer, preferably in the form of a synthetic paper; a glass mat layer adjacent one surface of the microporous layer; and a coating on one or both sides of the mircoporous layer/glass mat combination. The coating is preferably formed of natural rubber which positively affects top-of-charge behavior and reduces the possibility of antimony poisoning, thus providing for longer and improved battery performance and life.

Abstract: Improvements are disclosed for electrochemical cells of the type comprising at least two bipolar electrodes, with a space occurring between adjacent electrodes which contains a liquid electrolyte. Improvement include forming improved plates for the electrodes from a thermoplastic polymer containing carbon black, wherein the electrodes are formed by dissolving the polymer in a suitable solvent, mixing carbon black with the solvent solution of the polymer, evaporating the solvent from the polymer solution containing the dispersed carbon black, pulverizing the resultant mixture of polymer and carbon black to form a powder, and pressing the powder at an elevated temperature into the improved plates. There is further disclosed, improvements in the formation of electrochemically active material on the plates of the bipolar electrodes, as well as improved separators for positioning between the bipolar electrodes and improved means for sealing the spaces between bipolar electrodes.

Abstract: A sealed lead-acid battery which includes a container accommodating an assembled element. The assembled element has at least one electrochemically formed positive plate having a grid of an antimony-free alloy, wherein the plate is made of porous active material. The assembled element also includes at least one electrochemically formed negative plate having a grid of an antimony-free lead alloy, wherein the plate is made of a porous active material. A separator, having a plurality of projections on one or both side thereof, is inserted between the positive and negative plates. A layer of powder is placed between the positive and negative plates and around the assembled element. The powder is composed of a closely packed powder, which is acid-resistant and hydrophilic, and has gas channels within its interior. The powder is immobilized with an acid-resistant porous layer placed above the powder, wherein the porous layer is permeable to gases and liquids, and impervious to particles of the powder.

Abstract: A binary lead-tin alloy substrate for support of the electrochemically active material in lead-acid cells is disclosed having a tin concentration from about 0.3 to about 0.9 weight percent, the balance being lead. The tin impedes the formation of a passivation layer at the interface between the grid material and the active material improving cell recovery from deep discharge and improving cold cranking amperes performance.

Abstract: A perforated retainer is installed just under the top surface of the gelled electrolyte in a lead-acid storage battery to prevent the gel from crumbling and separating from the element plates when the battery is mounted horizontally. The size and density of the perforations are such that the retainer does not impede the initial introduction of the electrolyte solution. An the solution "gels", it cannot penetrate back through the retainer, but normal gas migration is not impeded by the retainer.

Abstract: A method for the manufacture of lead-acid batteries and associated apparatus and a lead-acid battery design resulting therefrom is disclosed. The method involves providing a battery grid and pasting the grid with a battery paste such that a profiled and tapered battery plate is formed. This battery plate is wrapped onto a coil and cured in curing apparatus. A battery element is formed using coils of the finished plate stock, separator material, and winged end plate. After this, several battery elements are then placed into a battery container.

Abstract: A lead acid storage battery comprises a group of electrode plates, wherein a negative plate is enclosed in an enveloped separator joined together at its both edges by welding or mechanical sealing and a glass mat is separately provided between the separator and a positive plate, the glass mat having a width at least equal to the width of the separator except its both edges.

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: Methods of making Chevrel-phase materials suitable for use as battery cathodes by heating a precursor composition comprising one or more heat labile compounds of one or more non-molybdenum metals capale of forming a Chevrel-phase material, forming a reaction mixture with molybdenum and a chalcogen or compounds thereof, and further heating said reaction mixture. Chevrel-phase materials having two non-molybdenum metals in which one serves as a filler metal resistant to intercalation. Electrochemical cells incorporating the Chevrel-phase materials disclosed.

Abstract: A sealed lead-acid battery is provided containing a sulfuric acid electrolyte of a sufficient amount to perform charging and discharging of the battery which is impregnated and retained in fine particles of silica located and placed around an assembled element. In this way, an inexpensive sealed-lead acid battery which exhibits high discharging performance.

Abstract: A method for the vibration filling of foam-structure or fiber-structure electrode plaques for galvanic cells, particularly for electrical accumulators, totally immerses one or more electrode plaques in a vibrating paste of active mass which has an active mass content of about 25 to 60 vol %, a maximum granulometry of the active particles of about 0.04 mm and in the unvibrated state a yield value of about 10 to 120 Pa and a plastic viscosity of about 0.1 to 1 Pas at 20.degree. C. The paste is preferably set in vibration with a frequency of about 40 to 125 Hz and an amplitude of about 0.1 to 1.5 mm by a vibration transmitter fitted inside the tank containing the paste.

Abstract: A sealed lead-acid battery is improved in manufacturability by providing a container with a major side left open, and being sealed by a laminated sheet heat-bonded to side edges of the opening after the battery components have been inserted. The laminated sheet may include a metal layer to improve rigidity.

Abstract: In a gas-recombination lead accumulator, the electrolyte includes additives selected from the group consisting of ions of tin, selenium and bismuth and/or organic molecules selected from the group consisting of n-dodecylamine, 2,3,4-trimethoxybenzaldehyde, 3,5-diaminobenzoic acid, nicotinic acid and their sodium, potassium and magnesium salts. The presence of the aforesaid additives has the effect of inhibiting the discharge of hydrogen and/or promoting the reduction of oxygen at the negative electrode.

Abstract: A lead-acid battery having thixotropic gel electrolyte comprising a blend of alkali metal polysilica and sulfuric acid. A method for producing a lead-acid battery having thixotropic gel electrolyte may be a continuous or an intermittent process. An aqueous colloidal dispersion may be produced by blending dry alkali metal polysilica with water and the gel electrolyte is provided by combining the aqueous collodial dispersion of alkali metal polysilica with liquid sulfuric acid.

Abstract: The present invention relates to batteries and battery systems. In particular, a battery is described which comprises a container which houses a plurality of cells. Each of the cells share a common negative terminal. Two or more positive terminal cells are provided. The specification also describes the use of such batteries to power the cranking and auxiliary circuits according to a cell discharge management scheme. Methods of forming such batteries are disclosed in which alternate positive and negative electrode plates are provided and methods of forming such plates are disclosed in which laminated grids are provided and by varying the number of laminations thick and thin plates can be provided with different discharge characteristics.

Abstract: A quasi-bipolar lead-acid battery construction includes a plurality of bipolar cells disposed in side-by-side relation to form a stack, and a pair of monoplanar plates at opposite ends of the stack, the cell stack and monopolar plates being contained within a housing of the battery. Each bipolar cell is loaded with an electrolyte and composed of a bipolar electrode plate and a pair of separator plates disposed on opposite sides of the electrode plate and peripherally sealed thereto. Each bipolar electrode plate is composed of a partition sheet and two bipolar electrode elements folded into a hairpin configuration and applied over opposite edges of the partition sheet so as to cover the opposite surfaces of the opposite halves thereof.

Abstract: A reliable positive plate for deep cycle lead-acid batteries is provided by dispersing about 2 percent by volume of fine, short, lead-coated reinforcement fibers such as fiberglass in the positive active paste before being applied to the grid of a battery plate and cured. The fibers improve the structural integrity of the plate and also provide electrical paths in a discharged plate. This results in greater utilization of the lead dioxide active material by preventing charged portions of the plate from becoming electrically isolated.

Abstract: A recombinant electric storage battery which includes separators of multiple fiber electrolyte absorbency that retain a balanced amount of absorbed electrolyte, for controlled recombination and which are in contact with positive and negative plates, the negative plates being antimony free and the positive plates containing antimony in amount of 2 to 4 percent of total alloy weight, which provides considerably greater capacity and cycling life.

Abstract: A lead-acid battery having electrolytic-absorbent separator is formed in situ to produce sponge lead and lead dioxide active material. The method includes cooling the electrolyte to below room temperature, introducing a quantity of cooled electrolyte into the battery and charging the battery to a preselected degree. The battery is further filled with electrolyte to provide electrolyte saturated plates and separators and is further charged to a preselected degree defining a fully charged state.

Abstract: In a method for producing a battery element useful as at least a positive plate in a lead-acid battery, the element comprising a fluid impervious, electrically conductive matrix having mutually opposing first and second surfaces and positive active electrode material associated with the first surface of the matrix, the improvement which comprises:conditioning the first surface to enhance the association of the positive active electrode material and the first surface; andapplying and associating the positive active electrode material to the first surface.

Abstract: The invention concerns a storage battery (10), comprising one or several cells enclosed in a housing (11), each cell containing electrolyte and monopolar and bipolar plates (12,13) coated with positive and/or negative active mass and separated by means of separator plates (14), and requisite electrically conductive connectors connecting the plates and/or cells. The wall separating or sealing off each cell from adjacent cells and/or from the housing (11) has been formed by filling the spaces around and/or in the interstices of the plate stacks with an electrically insulating and electrolyte-impermeable substance (19) which has been cured directly in situ for forming tightly sealing and/or insulating walls.

Abstract: A normally sealed starved electrolyte recombinant lead-acid cell of high discharge rate capability whose plates have a thickness from about 0.007 to about 0.027 inches, and whose grids are formed of high hydrogen overvoltage lead with a thickness of from about 0.005 inches to no more than 0.019 inches, with an inter-plate spacing of typically from about 0.005 to about 0.020 inches.

Abstract: An enclosed type lead battery comprises in combination:a cap formed of a synthetic resin, which is integrally formed with anodec and cathodec terminals formed of lead or a lead alloy inserted therein and an exhaust portion to which a safety valve is attached,a plate stack having its ears connected to said terminals, andan enclosure formed of a film or sheet made of a synthetic resin, in which said plate stack is placed, and which is thermally fused at the peripheral edge of its opening to said cap.

Abstract: A lead-acid battery includes a case having an apertured cover with the aperture being for passage of a terminal post therethrough for electrically connecting electrodes within the battery case to apparatus outside the battery, with the terminal post extending through the aperture. A rubber layer, devoid of rubber fillers and plasticizers, circumferentially surrounds the post at the aperture. A rubber-bonding epoxy polymer is between the rubber layer and the aperture through the case.

Abstract: An electrochemical cell, e.g. a lead acid electric storage cell, comprises a positive electrode, a negative electrode, an aqueous electrolyte and, optionally, a porous cell component such as a cell separator interposed between the electrodes. To enhance access of electrolytes to one or both of the electrodes or to the component during operation of the cell and thereby improve cell performance, at least one of the component and the electrodes is porous and includes a promoter in the form of solid material other than graphite having, under the operating conditions of the cell, a zeta potential of such magnitude and polarity as to be capable of inducing electro-osmotic flow of electrolyte into the component or electrode when a current is flowing through electrolyte filled pores thereof. An example of such a material (termed an `electro-osmosis promoter`) is sulphonated polyvinylidene difluoride.

Abstract: The invention involves a sealed lead-acid battery comprising a cell element having positive plates, negative plates and separators, and electrolyte retained within micropore of the cell element.The micropores of both the plates is substantially filled with the electrolyte, while the micropores of the separators are not completely filled with the electrolyte.The voids formed partially in the micropores of the separators permit transport of the oxygen gas from the positive plates to the negative plates.Such a sealed lead-acid battery has long service life, and excels in ability to O.sub.2 absorb gases and reproduce water during overcharging and to recover by charging after a long overdischarged-state storage.

Abstract: A method for preparing lead-acid battery positive and negative plates for use in lead-acid batteries, comprising (a) providing battery grids, (b) applying wet leady oxide paste to the grids to form plates, (c) optionally wrapping the freshly pasted plates with an absorbent material, and (d) initiating formation of the lead-acid battery plates while the plates contain more than about 5 wt. % free lead in the paste and are generally damp from moisture existing in the paste from the time of plate pasting. Although conventional curing and drying of the plates is obviated and the plate formation is initiated merely hours after plate pasting, instead of a day or more after plate pasting as is the case with conventional battery plate processing, the cells and batteries containing plates prepared in accordance with the present invention exhibit a mechanical strength and deliver an overall electrical performance equivalent or superior to cells and batteries containing conventionally prepared plates.

Abstract: A battery electrode material comprising a non-stoichiometric electrode-active material which forms a redox pair with the battery electrolyte, an electrically conductive polymer present in the range of from about 2% by weight to about 5% by weight of the electrode-active material, and a binder. The conductive polymer provides improved proton or ion conductivity and is a ligand resulting in metal ion or negative ion vacancies of less than about 0.1 atom percent. Specific electrodes of nickel and lead are disclosed.

Abstract: The present invention relates to a composite material comprising a porous lead alloy containing from 0.7 to 1.0% silver or 0.1 to 1.0% calcium or 0.7 to 1.0% silver and 0.1 to 1.0% calcium and having its pores filled by a resin such as epoxy resin. The product has utility as a battery electrode and as a sound absorbing material.

Abstract: The present invention provides an enclosed lead storage battery comprising a plate assembly consisting of a positive plate, negative plates and a separator, an electrolyte held in position by the plate assembly, and a jacket made of film- or sheet-formed synthetic resin and surrounding the plate assembly and electrolyte. The jacket is of a multilayer laminate structure made by disposing a polyolefin film on the inside contacting the plate assembly and laminating a film of thermoplastic synthetic resin in two or more layers on the outside thereof. According to the present invention, the plate assembly can be encased with an unexpensive jacket of a simple construction, and the joint of the jacket to the pole posts of the plate assembly is strengthened to offer a leak-proof enclosed lead storage battery.

Abstract: A flow-through electrochemical cell for sequentially oxidizing and reducing an aryl compound. The cell includes a cell body forming a compartment to hold an aqueous electrolyte solution, a porous anodic electrode, and a porous cathodic electrode. The anodic electrode includes a first porous layer of a hydrophobic material, a second porous layer with an oxidation catalyst dispersed therein, and a current collector in electrical contact with the second layer. The cathodic electrode comprises a block of a porous, electrically-conductive material impregnated with lead particles. The cell is particularly useful for the preparation of aryl hydroquinones at very high current efficiencies, high current densities, and low voltages.

Abstract: This invention relates to an improvement on a sealed lead storage battery which comprises a case, positive and negative plates alternately disposed in a case, porous separators between the adjacent plates and electrolyte filled in the case so as to be retained at least in the porous separators.The sealed lead storage battery of the invention further comprises additional electrolyte porous retainer means disposed in an unoccupied space in the case so as to have increased amount of electrolyte. The additional electrolyte retainer means may be disposed in at least one of an upper space over the plate group, a lower space below the plate group and side spaces beside the plate group. The additional electrolyte retainer means may be of glass fine fiber mat, glass and synthetic fine fiber mat or gel. It may be integrally formed with the porous separators. Preferably, the positive and negative plates may be so porous that the electrolyte is retained in them.