Method for in situ forming lead-acid batteries having absorbent separators
First Claim
1. A method for in situ forming a lead-acid battery having an electrolyte-absorbent plate separator to produce lead and lead dioxide surfacing of lead metal plates on respective sides of said separator, for electrochemical reaction between said plates and resultant electrical energy production by said battery, comprising the steps of:
- a. cooling a supply of lead-acid battery electrolyte to below room temperature;
b. introducing into the battery a quantity of said cooled lead-acid battery electrolyte less than the one hundred percent electrolyte-saturated capacity of said plates and said separators;
c. charging said battery to oxidize and to reduce lead at the surfaces of respective plates to a preselected intermediate degree;
d. filling said battery with water and/or acid sufficiently to provide at least the one hundred percent electrolyte-saturated capacity of said plates and separators; and
e. further charging said battery to respectively further oxidize and reduce lead at said respective plates to a preselected degree defining a fully charged state of said battery.
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Accused Products
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.
44 Citations
25 Claims
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1. A method for in situ forming a lead-acid battery having an electrolyte-absorbent plate separator to produce lead and lead dioxide surfacing of lead metal plates on respective sides of said separator, for electrochemical reaction between said plates and resultant electrical energy production by said battery, comprising the steps of:
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a. cooling a supply of lead-acid battery electrolyte to below room temperature; b. introducing into the battery a quantity of said cooled lead-acid battery electrolyte less than the one hundred percent electrolyte-saturated capacity of said plates and said separators; c. charging said battery to oxidize and to reduce lead at the surfaces of respective plates to a preselected intermediate degree; d. filling said battery with water and/or acid sufficiently to provide at least the one hundred percent electrolyte-saturated capacity of said plates and separators; and e. further charging said battery to respectively further oxidize and reduce lead at said respective plates to a preselected degree defining a fully charged state of said battery. - View Dependent Claims (2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14)
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6. A method for preventing lead-dendrite shorting of adjacent lead metal plates during battery forming due to lead dendrite growth therebetween through electrolyte-absorbent separators between said adjacent plates while in situ forming said lead-acid battery, comprising:
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a. cooling a supply of sulfuric acid to below room temperature; b. introducing into the battery a quantity of said cooled sulfuric acid less than battery one hundred percent electrolyte-saturated capacity; and c. charging said battery to a preselected degree defining a fully charged state.
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15. A method for preventing lead dendrite shorting of relatively closely spaced adjacent lead metal plates during battery forming due to lead dendrite growth through liquid electrolyte-absorbent porous separators between said adjacent plates, said separators having up to 95% of separator surface area defined by pores of between about 2 to about 35 microns diameter, while in situ forming said battery to produce additional lead and lead dioxide surfacing of said plates on respective sides of said separators, for electrochemical reaction between said adjacent lead metal plates and resultant electrical energy production by said battery, comprising the steps of:
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a. cooling relatively high specific gravity lead-acid battery electrolyte to a temperature of between about 0 degrees F. and about 50 degrees F.; b. introducing into the battery said cooled lead-acid battery electrolyte, having a specific gravity of up to about 1.32 and in any event high enough to provide adequate lead sulfate to produce sufficient additional lead and lead dioxide surfacing of said plates according to rated capacity of the battery, in an amount equal to about two-thids of the electrolyte capacity of said battery plates and separators; c. permitting said cooled electrolyte to react with said lead metal plates and to inhabit said porous separators; d. charging said battery initially at a low rate and then at a higher rate to respectively oxidize and reduce lead at said plates to a preselected intermediate degree; e. filling said battery with water and/or acid thereby occupying said battery with at least the one hundred percent electrolyte-saturated capacity of said battery plates and separators; and f. further charging said battery to respectively further oxidize and reduce lead at said respective plates to a preselected final degree defining a fully charged state of said battery.
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16. A method for preventing lead-dendrite shorting of adjacent lead metal plates during battery forming due to lead dendrite growth therebetween through electrolyte-absorbent separators between said adjacent plates while in situ forming said lead-acid battery, comprising:
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a. cooling a supply of sulfuric acid to below room temperature; b. introducing into the battery a quantity of said cooled sulfuric acid less than battery one hundred percent electrolyte-saturated capacity; c. charging said battery to a preselected intermediate degree; d. filling said battery with sufficient water and/or sulfuric acid to provide about one hundred percent of electrolyte-saturated capacity at termination of battery charging; and e. continuing charging said battery to a preselected degree defining a fully charged state. - View Dependent Claims (17, 18)
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19. A method for in situ forming a battery having liquid electrolyte-absorbent separators to produce active material surfacing of metal plates on respective sides of said separators, for electrochemical reaction between said plates and resultant electrical energy production by said battery, comprising the steps of:
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a. introducing into the battery a quantity of electrolyte, at a temperature below about fifty degrees F., which is less than the one hundred percent electrolyte-saturated capacity of said plates and said separators; b. charging said battery to produce active material surfacing of said plates to a preselected intermediate degree; c. filling said battery sufficiently to provide at least the one hundred percent electrolyte-saturated capacity of said plates and separators; and d. further charging said battery to produce further active material surfacing at said plates. - View Dependent Claims (20, 21, 22, 23)
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24. A method for preventing shorting of adjacent metal plates during battery forming due to dendrite growth therebetween through electrolyte-absorbent separators between said adjacent plates, while in situ forming said battery, comprising:
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a. introducing into the battery a quantity of below room temperature electrolyte which is less than battery one hundred percent electrolyte-saturated capacity; and b. charging said battery. - View Dependent Claims (25)
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Specification