A battery cast-on-strap machine unloading apparatus includes a first and a second unit. Each unit includes a rotary drive mechanism; and, a pinion co-axial with and directly driveable by the rotary drive mechanism. The apparatus further includes an elongate rack. The rack includes teeth along a first side and an opposing second side. The first and second units are mounted adjacent to each other on the rack. Operation of each drive mechanism causes rotation of the respective pinion to be converted into linear motion of the respective unit along the rack. Adjacent rotary drive mechanisms are located on opposing sides of the rack, such that the pinion of the first unit meshes with the teeth along the first side of the rack, and the pinion of the adjacent second unit meshes with the teeth along the opposing second side of the rack.

A battery cast-on-strap machine unloading apparatus includes a first and a second unit. Each unit includes a rotary drive mechanism; and, a pinion co-axial with and directly driveable by the rotary drive mechanism. The apparatus further includes an elongate rack. The rack includes teeth along a first side and an opposing second side. The first and second units are mounted adjacent to each other on the rack. Operation of each drive mechanism causes rotation of the respective pinion to be converted into linear motion of the respective unit along the rack. Adjacent rotary drive mechanisms are located on opposing sides of the rack, such that the pinion of the first unit meshes with the teeth along the first side of the rack, and the pinion of the adjacent second unit meshes with the teeth along the opposing second side of the rack.

In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding, NAM shedding, electrode distortion, active material shedding, active material loss, and/or physical separation, electrode effectiveness, battery performance, battery life, and/or cycle life, and/or may provide new battery separators, new battery technology, and/or new battery methods and/or systems that address the challenges arising from current lead acid batteries or battery systems, especially new battery separators, new battery technology, and/or new battery methods and/or systems adapted to prevent or impede the shedding of active material from the electrodes, preferably or particularly in enhanced flooded lead acid batteries, PSoC batteries, ISS batteries, ESS batteries, and/or the like.

In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding, NAM shedding, electrode distortion, active material shedding, active material loss, and/or physical separation, electrode effectiveness, battery performance, battery life, and/or cycle life, and/or may provide new battery separators, new battery technology, and/or new battery methods and/or systems that address the challenges arising from current lead acid batteries or battery systems, especially new battery separators, new battery technology, and/or new battery methods and/or systems adapted to prevent or impede the shedding of active material from the electrodes, preferably or particularly in enhanced flooded lead acid batteries, PSoC batteries, ISS batteries, ESS batteries, and/or the like.

In at least select embodiments, the instant disclosure is directed to new or improved battery separators, components, materials, additives, surfactants, lead acid batteries, systems, vehicles, and/or related methods of production and/or use. In at least certain embodiments, the instant disclosure is directed to surfactants or other additives for use with a battery separator for use in a lead acid battery, to battery separators with a surfactant or other additive, and/or to batteries including such separators. In at least certain select embodiments, the instant disclosure relates to new or improved lead acid battery separators and/or systems including improved water loss technology and/or methods of manufacture and/or use thereof. In at least select embodiments, the instant disclosure is directed toward a new or improved lead acid battery separator or system with one or more surfactants and/or additives, and/or methods for constructing lead acid battery separators and batteries with such surfactants and/or additives for improving and/or reducing water loss from the battery.

In at least select embodiments, the instant disclosure is directed to new or improved battery separators, components, materials, additives, surfactants, lead acid batteries, systems, vehicles, and/or related methods of production and/or use. In at least certain embodiments, the instant disclosure is directed to surfactants or other additives for use with a battery separator for use in a lead acid battery, to battery separators with a surfactant or other additive, and/or to batteries including such separators. In at least certain select embodiments, the instant disclosure relates to new or improved lead acid battery separators and/or systems including improved water loss technology and/or methods of manufacture and/or use thereof. In at least select embodiments, the instant disclosure is directed toward a new or improved lead acid battery separator or system with one or more surfactants and/or additives, and/or methods for constructing lead acid battery separators and batteries with such surfactants and/or additives for improving and/or reducing water loss from the battery.

A battery separator including a porous membrane with a surfactant coating on at least one side thereof is described. The surfactant coating may include a non-ionic surfactant in a low amount, a blend of a non-ionic surfactant and an ionic surfactant, or the surfactant coating may contain only a compound having the following structures:

##STR00001##

##STR00002##

where n is an integer from 0 to 10, m is an integer from 0 to 10, n and m are the same or different, q is an integer from 0 to 10, r is an integer from 0 to 10, s is an integer from 0 to 10, and q, r, and s are the same or different, R1 is H, a C1 to C10 linear or branched, saturated or unsaturated alkyl group, a C1 to C10 fatty alcohol, a C1 to C10 alcohol, or an aromatic group, and R2 is H, a C1 to C10 linear or branched, saturated or unsaturated alkyl group, a C1 to C10 linear or branched, saturated or unsaturated fatty alcohol, a C1 to C10 linear or branched, saturated or unsaturated alcohol, or an aromatic group, n and m are the same or different, R1 and R2 are the same or different, R3 is hydrogen or methyl or a C1 to C5 alkyl group, R4 is hydrogen or methyl or a C1 to C5 alkyl group R3 and R4 are the same or different, and X is a negatively charged groups such as SO3—, COO—, PO4-2, and the like; and also a positively charged counterion. When the separator described herein is used in a battery, the battery may exhibit improved properties such as reduced grid corrosion, a lower black residue rating, longer discharge life, lower water loss, improved charge acceptance, longer life, etc.

The present invention discloses a method for lead carbon compression moulding comprising a first stacking step and a first compressing step so that a lead-carbon electrode is obtained through compressing a lead-carbon sandwich stacked of a lead material and a carbon material. Pressurization of the working environment or heating both the lead material and the carbon material is not required during the procedure. A massive production of lead-carbon electrode at room temperature can be anticipated. The lead-carbon electrode produced thereby enhance tolerance of the battery against instable electric current or voltage, and performance remains steady after multiple times of charge-discharge cycles. The lead-carbon electrode produced thereby demonstrates high potentials for application with low cost, low loss and high capacity.

The present invention discloses a method for lead carbon compression moulding comprising a first stacking step and a first compressing step so that a lead-carbon electrode is obtained through compressing a lead-carbon sandwich stacked of a lead material and a carbon material. Pressurization of the working environment or heating both the lead material and the carbon material is not required during the procedure. A massive production of lead-carbon electrode at room temperature can be anticipated. The lead-carbon electrode produced thereby enhance tolerance of the battery against instable electric current or voltage, and performance remains steady after multiple times of charge-discharge cycles. The lead-carbon electrode produced thereby demonstrates high potentials for application with low cost, low loss and high capacity.

Disclosed herein are novel or improved fibrous layers, composites, composite separators, separators, composite mat separators, composite mat separators containing fibers and silica particles, battery separators, lead acid battery separators, and/or flooded lead acid battery separators, and/or batteries, cells, and/or methods of manufacture and/or use of such fibrous layers, composites, composite separators, separators, battery separators, lead acid battery separators, cells, and/or batteries. In addition, disclosed herein are methods, systems, and battery separators for enhancing battery life, reducing internal resistance, reducing metalloid poisoning, reducing acid stratification, and/or improving uniformity in at least enhanced flooded batteries.