Method for forming a dry charge-type battery itself

Claim 1

A method of manufacturing a lead-acid storage battery including a container having a plurality of cell compartments and a plurality of battery elements consisting of a plurality of positive and negative plates with separators positioned therebetween, the battery elements being electrically connected, to provide a battery capable of being stored and thereafter activated by the addition of activation electrolyte, and, if required, charging, which comprises forming the plates by bringing said plates into contact with a formation electrolyte and applying current thereto at levels and for time to reach the desired end-of-charge voltage, treating the battery elements such that sufficient acid will be retained in the elements to provide, upon activation, including the addition of activation electrolyte having a specific gravity of about 1.265, a battery operating electrolyte having a specific gravity in the range of from about 1.260 to 1.290, the formation electrolyte being drained from the battery and said treating being carried out by adding a development electrolyte and allowing the development electrolyte to diffuse into and saturate the battery elements and mix with the residual formation electrolyte therein, draining the battery leaving the battery elements substantially saturated, reducing the level of residual acid retained in the battery plates sufficiently below saturation so that, on standing, the retained acid will not migrate to the outer surfaces of the battery elements so as to form liquid bridges between the plates and separators that result in crystal growth and clusters of crystals creating internal shorts, and sealing the battery.

Claim 2

A method of manufacturing a lead-acid storage battery including a container having a plurality of cell compartments and a plurality of battery elements consisting of a plurality of positive and negative plates with separators positioned therebetween, the battery elements being electrically connected, to provide a battery capable of being stored and thereafter activated by the addition of activation electrolyte, and, if required, charging, which comprises forming the plates by bringing said plates into contact with a formation electrolyte and applying current thereto at levels and for time to reach the desired end-of-charge voltage, treating the battery elements such that sufficient acid will be retained in the elements to provide, upon activation, including the addition of activation electrolyte having a specific gravity of about 1.265, a battery operating electrolyte having a specific gravity in the range of from about 1.260 to 1.290, the formation electrolyte being drained from the battery and said treating being carried out by adding a development electrolyte and allowing the development electrolyte to diffuse into and saturate the battery elements and mix with the residual formation electrolyte therein, draining the battery leaving the battery elements substantially saturated, reducing the level of residual acid retained in the battery plates sufficiently below saturation so that, on standing, the retained acid will not migrate to the outer surfaces of the battery elements so as to form liquid bridges between the plates and separators that result in crystal growth and clusters of crystals creating internal shorts, and sealing the battery.

Claim 4

A method of manufacturing a lead-acid storage battery including a container having a plurality of cell compartments and a plurality of battery elements consisting of a plurality of positive and negative plates with separators positioned therebetween, the battery elements being electrically connected, to provide a battery capable of being stored and thereafter activated by the addition of activation electrolyte, and, if required, charging, which comprises forming the plates by bringing said plates into contact with a formation electrolyte and applying current thereto at levels and for time to reach the desired end-of-charge voltage, treating the battery elements such that sufficient acid will be retained in the elements to provide, upon activation, including the addition of activation electrolyte having a specific gravity of about 1.265, a battery operating electrolyte having a specific gravity in the range of from about 1.260 to 1.290, said treating being carried out by partially discharging the formed battery elements, draining the battery leaving the battery elements substantially saturated, reducing the level of residual acid retained in the battery plates sufficiently below saturation so that, on standing, the retained acid will not migrate to the outer surfaces of the battery elements so as to form liquid bridges between the plates and separators that result in crystal growth and clusters of crystals creating internal shorts, and sealing the battery.

Claim 5

A method of manufacturing a lead-acid storage battery including a container having a plurality of cell compartments and a plurality of battery elements consisting of a plurality of positive and negative plates with separators positioned therebetween, the battery elements being electrically connected, to provide a battery capable of being stored and thereafter activated by the addition of activation electrolyte, and, if required, charging, which comprises forming the plates by bringing said plates into contact with a formation electrolyte and applying current thereto at levels and for time to reach the desired end-of-charge voltage, treating the battery elements such that sufficient acid will be retained in the elements to provide, upon activation, including the addition of activation electrolyte having a specific gravity of about 1.265, a battery operating electrolyte having a specific gravity in the range of from about 1.260 to 1.290, said treating being carried out by partially discharging the formed battery elements, draining the battery leaving the battery elements substantially saturated, reducing the level of residual acid retained in the battery plates sufficiently below saturation so that, on standing, the retained acid will not migrate to the outer surfaces of the battery elements so as to form liquid bridges between the plates and separators that result in crystal growth and clusters of crystals creating internal shorts, and sealing the battery.