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Method of assembling a bipolar lead-acid battery and the resulting bipolar battery

  • US 5,470,679 A
  • Filed: 05/20/1994
  • Issued: 11/28/1995
  • Est. Priority Date: 06/02/1993
  • Status: Expired due to Fees
First Claim
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1. A bipolar lead-acid battery having a desired voltage and capacity which comprises a set of end frames each having a solid exterior surface, top, bottom and side surfaces and an interior surface comprising a peripheral border defining a central open area sized to accommodate a first conductive metal substrate, said first conductive metal substrate being embedded in each of said end frames and positioned in said central open area, a first layer of positive or negative active material adhered to each of said first conductive metal substrates, a series of other frames having top, bottom and side surfaces and a peripheral border defining a central open area sized to accommodate a second conductive metal substrate, said second conductive metal substrate embedded in each of said other frames and positioned in the central open area, a second layer of either positive or negative active material adhered to each surface of each of said second conductive metal substrates embedded in said other frames, said end frames and said other frames being juxtaposed adjacent one another and comprising an electrochemical component unit having top, side and bottom surfaces corresponding to the respective top, side and bottom surfaces of said frames with the exterior surfaces of the end frames comprising the end surfaces of the electrochemical component unit and the peripheral surfaces of adjacent frames forming peripheral surfaces therebetween, the frames in the unit being assembled so as to have each layer of positive active material in said first and second layers adjacent a negative active material layer in said first and second layers, a separator positioned between adjacent positive and negative active material layers from said first and second layers, an electrolyte fill/vent hole in the top and bottom surfaces of said unit in communication with a separator, a panel sealed to the side surfaces of said electrochemical component unit, an electrolyte fill/vent box comprising a base divided into compartments equal in number to the number of separators and having electrolyte fill/vent holes in alignment with the holes in the top surface of said electrochemical component unit, a front panel having a series of apertures, one aperture communicating with each compartment and an open top, the base of said electrolyte fill/vent box being sealed to the top surface of the electrochemical component unit and an electrolyte fill/vent box cover being sealed thereto to close the open top, a vacuum box comprising a base divided into compartments equal in number to the number of separators having holes aligning with the holes in the bottom surface of the electrochemical component unit, a front panel having a series of apertures, one aperture communicating with each compartment and an open top, the base of said vacuum box being sealed to the bottom surface of the unit via the base, a manifold cover for the electrolyte fill/vent box sealed to the front panel of said electrolyte fill/vent box and a vacuum box cover being sealed thereto to close the open top, a vacuum box manifold cover having closures for blocking off the front panel vacuum box apertures and sealed to the vacuum box so that said closures block off the front panel vacuum box apertures, and electrolyte being positioned between adjacent active material layers of positive and negative active material.

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