Lead acid battery and method of manufacturing the lead acid battery

Abstract

A lead acid battery and a method of manufacturing the lead acid battery is disclosed, the lead acid battery comprises a battery case, a cell positioned in the battery case a plurality of plates, the plates include positive plates and negative plates, a paste positioned on a grid of each plate with each grid having a first thickness, the paste has a second thickness, a separator is interweaved between the positive plates and the negative plates, the first thickness and the second thickness combine to compensate of a space within the cell, the compensation of the space provides an increased cycle life as compared to batteries of a same or similar size, a method of manufacturing the lead acid battery is disclosed as well, and a system and method of replacement of the battery based on cycle life is disclosed.

Description

LEAD ACID BATTERY AND METHOD OF MANUFACTURING 'THE LEAD ACID BATTERYFIELD

[0001] This application relates to the field of batteries. More specifically, this application relates to the field of lead acid batteries.BACKGROUND

[0002] Lead acid batteries are known. Lead acid batteries are made up of plates of lead and separate plates of lead dioxide, which are submerged into an electrolyte solution. The lead, lead dioxide and electrolyte provide a chemical means of storing electrical energy which can perform useful work when the terminals of the battery are connected to an external circuit

[0003] Flooded or wet cell lead acid batteries are common and economical These batteries require regular maintenance, e.g., refill of electrolyte. Such batteries often have a shorter cycle life than other lead acid batteries. For example, an Enhanced Flooded Battery (EFB) provides an improvement on cycle life and can withstand some of the cyclic demands of start-stop vehicles. EFB batteries are charged similar to standard flooded bateries and installed in a vertical position.

[0004] One type of lead acid batery is an AGM or Absorbent Glass Mat lead acid battery which is a sealed (e.g., maintenance-free), or more specifically a valve regulated battery in which the electrolyte is absorbed and retained in a mat that is wrapped around or interleaved with an electrode(s) or plate(s). AGM batteries are also known as recombinant batteries, that is, H₂ and O₂ generated during charging are recombined to water in the battery.

[0005] AGM lead acid batteries are advantageous over traditional starting, lighting and ignition (SLI) batteries, in that they are better suited to providing power in a vehicle with numerous electronic features or plug-in accessories. AGM batteries allow a greater depth of discharge, a faster recharge, and provide higher current than SLI and EFB batteries. AGM batteries are also a preferred solution for fuel saving start-stop vehicle technology.

[0006] Lead acid batteries for vehicles generally conform to an industry-standard “battery group size” which is a standard classification indicating features such as, among other things, physical battery dimensions. Standard battery group sizes are defined by various regional entities with a variety of different but equivalent nomenclature; i.e in North America battery group size is assigned by the Battery Council International (BCI), Europe EN (European Norm), DIN (German industrial norm), and BS (British standard) are commonly used. In the Far East, Japanese Industrial Standard (JIS) is applied Example designations include designations such as “I 15”, "Ho". “H7”, “H8”, “H9” and so forth or “LNl”, “LN2”, “LN3”, “LN4”, and so forth. Table 1 illustrates the general dimensions and certain standard specifications of some of the noted designations:TABLE 1

[0007] In the above table and as used herein:■ A=Amps» Ah=Amp hour» BCI===Batteiy Council International" CCA=Cold Cranking Amps• C20::::Energy a battery can deliver continuously for 20 hours at 80 degrees F. without falling below 10.5 volts« I - X European Norm" mrn=rnillimeters[0008| As each designation has a standard set of characteristics, the group size designation is often used to identify a type of battery that should be used in a particular vehicle application. For example, a battery group size may have a known or standard cycle life count capability. A smaller group size typically correlates with a smaller cycle life count capability.

[0009] As indicated, lead acid batteries are made up of plates of lead (lead alloy grid+active material) and lead dioxide. In addition, lead is used as a conductive connector between cells and to the battery terminals. Lead is a heavy metal and considered to be toxic. Lead exposed to the environment is a potential source of contamination. Use of lead is therefore prohibited in many applications. Certain governmental bodies are advancing tighter regulation of lead in lead acid batteries, including the European Union and the State of California, Uni ted States of America, which have explored regulations about lead exposure as it relates to lead acid batteries. For example, the Department of Toxic Substances Control's (DTSC) in California is actively evaluating whether it should identify lead acid batteries as a Priority Product under the Safer Consumer Products (SCP) program. Unfortunately, when lead is removed from the battery, the resistance goes up and CCA goes down. Accordingly, a reduction in the amount of lead in a lead acid battery without compromising performance is desirable.

[0010] In addition, lead and lead acid batteries are generally heavy products. For example, a standard H4 or LN 1 AGM lead acid battery may weigh approximately 14,930 grams while an H7 or LN4 AGM lead acid battery may weigh upwards of approximately 22,850 grams. In a vehicle, this weight impacts fuel efficiency and, in turn, vehicle emissions. Therefore, it is also desirable to reduce the weight of a lead acid battery in automotive applications without compromising performance of the batten'.

[0011] Likewise, it would be advantageous to reduce the overall lead weight of the lead acid battery without compromising performance to allow' for use in other applications.

[0012] AGM has various advantages over flooded lead acid battery technology, such as but. not limited to SLI and Enhanced Flooded Batteries (EFB). Examples include, but are not limited to improved cycling vs flooded battery; lower water loss at under hood temperatures, betterpartial state of charge operation in stop-start duty; better charge acceptance after a stop-start event; good warm engine cranking during a restart event, greatly reduced electrolyte stratification in immobilized glass mat; and resistance to active mass sulfation. Moreover, the unspillable absorbed acid allows mounting the battery in different locations, such as for example, behind the engine firewall, in the passenger compartment or in the trunk.

[0013] Accordingly, a need exists for a battery, such as an ACiM lead acid battery, that has a reduced amount of lead, a reduced physical size, and a reduced weight without compromising performance or with improved performance of the batter, / .SUMMARY

[0014] A lead acid battery is described herein which incorporates the advantages of an AGM lead acid battery with less weight and a smaller size. The battery described herein uses less lead to achieve improved cycle life, overcoming many of the drawbacks of flooded lead acid batteries, enhance flooded lead acid batteries (EFB) and sealed lead acid batteries (SLA), specifically traditional AGM lead acid batteries. and may provide such advantages in a smaller size. The invention seeks to reduce the amount of lead applied per plate in the lead acid battery / . In doing so, the amount of lead per grid is reduced. Further the amount of electrochemi cal paste applied is increased to provide for the necessary force and interaction between plates to provide for an improved cycle time performance of the battery as compared to batteries having a similar battery size.

[0015] An example lead acid battery is disclosed herein. The battery comprises the following including a battery case a battery case. A cell is positioned in the battery case having one or more grids. The grids have a first thickness. A paste is positioned on at least one of the grids. The paste has a second thickness. A sum of the first thickness and the second thickness is a compensation of a space within the cell, with the lead acid battery having an increased cycle life.

[0016] The example lead acid battery disclosed may further comprise a process to manufacture the lead acid battery. The process comprises the following including applying a predetermined amount of paste to a positive grid and a negative grid. The paste has a first thickness and each of the positive grid and the negative grid has a second thickness. Positioninga plurality of each of the positive grid and the negative grid in a battery cell. Interweaving a separator between the positive grid and the negative grid in the battery cell. Filling a void in the battery with the first thickness and the second thickness. Applying and electrolyte. The filling of the void increases cycle life of the battery.

[0017] Further, a second example of a lead acid battery is disclosed herein. The battery comprises the following including a battery case. A cell is positioned in the battery case having a positive plate and a negative plate. One or more plates of the positive plate and the negative plate has a first thickness. At least one of the positive plate and the negative plate comprise a paste. A separator interweaved between the positive plate and the negative plate, with the separator has a second thickness. The first thickness and the second thickness are a compensation of a space within the cell for an increased cycle life.

[0018] An example battery replacement system based on a cyclability of a battery is disclosed herein. The system comprises the following including a battery comprising a sensor to sense a parameter of a battery and a communication to a processor and memory operatively coupled to the sensor. A server is in communication with the battery for receipt of a battery information and the sensed parameter. The battery and / or the server has a cyclability calculation and a replacement determination for the battery based on the cyclability calculation.

[0019] An example method for communicating replacement determinations for a vehicle battery is disclosed herein. The method comprises the following including applying the system as previously disclosed. Receiving information from a battery. Determining a cyclability data for the battery based upon received information. Calculating a life estimation for the battery based upon the received information. Communicating a replacement determination based on a comparison based upon one of the life estimation and the cyclability data.

[0020] These and other features and advantages of devices, systems, and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.BRIEF DESCRIPTION OF DRAWINGS[00211 Various examples of embodiments of the systems, devices, and methods according to this invention will be described in detail, with reference to the following figures, wherein:

[0022] FIG. 1 is a perspective view of a vehicle having an AGM lead acid battery according to one or more examples of embodiments described herein.

[0023] FIG. 2 is a perspective view of an AGM lead acid battery according to one or more examples of embodiments described herein.

[0024] FIG 3 is a perspective view of the AGM lead acid battery shown in FIG. 2, with the cover removed to show cell elements or plate sets therein.

[0025] FIG 4 is an exploded view of an AGM lead acid battery according to one or more examples of embodiments described herein.

[0026] FIG. 5 is a side elevation view' of a cell element or plate set of an AGM lead acid battery according to one or more examples of embodiments described herein.

[0027] FIG. 6 is an elevation view' of a battery grid for use with an AGM lead acid battery according to one or more examples of embodiments described herein.

[0028] FIG. 7 is an additional elevation view of a battery grid for use with an AGM lead acid battery according to one or more examples of embodiments described herein.

[0029] FIG. 8 is an elevation view' of one or more examples of a plate having an imprint on the plate surface.

[0030] FIG. 9 A is a graph showing performance of an AGM lead acid battery described herein, w'hen tested at 17 5% DoD at 25C pursuant to design testing.

[0031] FIG. 9B is a graph showing performance of an AGM lead acid battery described herein, when tested at 17.5% DoD at 25C pursuant to verification testing.

[0032] FIG 10A is a graph showing performance of an AGM lead acid battery described herein, when tested at 17.5% DoD at 60C pursuant to design testing.

[0033] FIG. 1 OB is a graph showing performance of an AGM lead acid battery described herein, when tested at 17.5% DoD at 60C pursuant to verification testing.

[0034] FIG. 11 A is a graph showing performance of an AGM lead acid battery described herein, when tested at 50% DoD above 570 cycles, illustrating the voltage of the AGM lead acid battery pursuant to design testing.[00351 FIG. 1 IB is a graph showing performance of an AGM lead acid battery described herein, when tested at 50% DoD above 570 cycles, illustrating the voltage of the AGM lead acid battery pursuant to verification testing.

[0036] FIG. 12 A is a graph showing performance of an AGM lead acid battery described herein, illustrating an effect of sulfation up to substantially 300 cycles pursuant to design testing.

[0037] FIG. 12B is a graph showing performance of an AGM lead acid battery described herein, illustrating an effect of sulfation up to substantially 325 cycles pursuant to design testing.

[0038] FIG. 13 is a graph showing performance of an AGM lead acid battery described herein, illustrating an effect of sulfation up to 250 cycles.

[0039] FIG. 14 is a block diagram of a method of applying a battery replacement system based at least in part upon the cyclability of a battery.

[0040] FIG. 15 is a process of applying the battery replacement system.

[0041] FIG. 16 is a tiered block diagram of the battery replacement system, illustrating groupings of components of a battery monitoring system.

[0042] FIG. 17 is a tiered block diagram of the method as applied to the battery replacement system, illustrating functionalities of the groupings of components of the battery monitoring system.[0043| FIG. 18 is a block diagram of a relationship of the components of the battery monitoring system and the battery replacement system.

[0044] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

[0045] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, the following description, the claims, and / or the drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and all features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.DETAILED DESCRIPTION

[0046] A lead acid battery is described herein which incorporates the advantages of an AGM lead acid battery with less weight and a smaller size. The battery described herein uses less lead to achieve improved cycle life, overcoming many of the drawbacks of flooded lead acid batteries, enhance flooded lead acid batteries (EFB) and sealed lead acid batteries (SLA), specifically traditional AGM lead acid batteries, and may provide such advantages in a smaller size Proceeding forwarding traditional AGM batteries lead acid batteries are referenced as Standard AGM or Standard AGM batteries. The i nvention seeks to reduce the amount of lead applied per plate in the lead acid battery. In doing so, the amount of lead per grid is reduced. Further the amount of electrochemical paste applied is increased to provide for the necessary force and interaction between plates to provide for an improved cycle time performance of the battery as compared to batteries having a similar battery size.

[0047] Referring to the Figures, a battery 100 is disclosed. The lead-acid battery 100 may be one of many types of lead-acid batteries. Types of lead-acid batteries are for example floodedsealed lead-acid (SLA) batteries. SLA batteries are also referred to as valve regulated lead-acid (VRLA) batteries. Flooded batteries, also known as a wet battery, use a liquid electrolyte which covers the lead plates inside the battery cells housed in the battery. The plates, which will be described, of each battery cell are submerged in this electrolyte solution, allowing for the flow of electricity. Flooded batteries require regular maintenance, including monitoring the electrolyte level and adding distilled water as needed. SLA batteries are sealed batteries, not requiring monitoring of electrolyte levels. The SLA is referred to as a maintenance free battery as a result. The sealing prevents the release of gases. The prevention of the release of gases provides for recombination of compounds for maintaining battery performance without maintenance being required. Flooded batteries may be manufactured as multiple varieties. For example, a flooded battery may be a tradition flooded battery or starting, lighting, ignition (SLI) battery or an enhanced flooded battery (EFB). Characteristics of varieties of flooded batteries may interchange. The SLI battery provides increased power over the traditional flooded batteries for system or vehicle processes requiring increased power, for example start-up and operations of lighting in a vehicle. EFB batteries are enhanced SLI batteries and have increased lifespan over SLI batteries and more resistance to a partial discharge than SLI batteries. SLA batteries may be manufactured as multiple varieties. For example, SLA batteries may be SLI batteries, with the characteristics as described, or AGM lead acid batteries which includes Standard AGM batteries. Characteristics of varieties may interchange. AGM batteries use fiberglass mats to absorb electrolyte in the battery. The advantages of AGM batteries are longer lifespan, increased reliability in extreme temperatures, and increased performance for vehicles having multiple electrical systems. According to one or more examples of embodiments, the lead acid storage battery 100 described herein is preferably a sealed lead acid battery or AGM lead acid battery' and, to this end, may include an absorbent glass mat (AGM). While specific examples are described and illustrated, the battery may be any secondary battery suitable for the purposes provided.

[0048] A battery 100 is provided and shown in a vehicle 102 in FIG. 1. The batteries described herein may also be used to provide power to other energy storage / expending applications. Other example applications or environments include starting, cycling, and powering support applications; deep cycle primary power and motive power applications; and high rate and long duration reserve power applications. Example starting, cycling, and powering supportapplications include automotive, van and light duty’ commercial, heavy-duty truck, bus and utility, agriculture, construction, marine, residential vehicle (RV), po ’er sports including motorcycle, all-terrain vehicle (ATV), snowmobile, electric bicycle, genset, lawn and garden, rail, military, aerospace, and defense, etc. Example deep cycle primary power and motive power applications include heavy-duty load and lift gates, marine cycling, golf vehicles, motives such as forklift and guided vehicles, industrial such as scissor lift, scrubber, and pallet jack, wheelchairs, etc. Example high rate and long duration reserve power applications include uninterruptable power source such as for a data portion, critical power system, and emergency lighting; telecommunications such as wireline, wireless, broadband, and microwave; power generation and distribution; renewable energy; grid support including smart and distributed; safety, security, and traffic; etc. Such battery(s) may include one or more batteries, each battery having a housing and a number of battery? cells arranged within the housing, to provide particular voltages, currents, and / or power to the associated application.

[0049] Referring to FIGs. 2-4, the batery 100 is an AGM lead acid battery having positive and negative plates 104, 106 which are separated by an absorbent glass mat 108 (also referred to as “AGM”) that absorbs and holds the battery's acid or electrolyte and prevents it from flowing freely inside the battery 100. The AGM lead acid battery includes but is not limited to the Standard AGM, the First Embodiment AGM, and the Second Embodiment AGM. The working electrolyte saturation is at some value below 100% saturation to allow recombinant reactions of hydrogen and oxygen. More specifically, the AGM lead acid battery 100 includes several cell elements 110 which are provided in separate compartments 112 of a container or housing 114. The element stack may be compressed during insertion reducing the thickness of the separator for the purpose of improved performance. An electrolyte, which is typically sulfuric acid, may be provided within the container 114, and / or absorbed in the absorbent glass mat separator 108. A cover 116 is provided for the container or housing 114 and may be sealed to the housing. In various embodiments, the cover 116 includes battery terminals 118 (e.g. 118 a — pos, 118b — neg.). The battery’ cover 1 16 may also include one or more filler hole caps and / or vent assemblies 115 For example, six vent assemblies 115 or valves may be provided associated with the six compartments 112 of the container 114 to allow venting of each compartment.[0050| Referring to FIGs. 3-7, the plates (104, 106) include electrically conductive positive or negative grids or current collecting members (120, 122). Positive paste 124 is provided on the positive grid 120 and negative paste 126 is provided on the negative grid 122. More specifically, the positive plate 104 includes a positive grid 120 having or supporting a positive active material or paste 124 thereon. In some examples of embodiments may include a pasting paper or a scrim 133 (e g., a woven or non-woven sheet material comprised of fibers. The negative plate 106 includes a negative grid 122 having or supporting a negative active material or paste 126 thereon In some examples of embodiments may include a pasting paper or a scrim 133. Positioned between the positive and negative plates (104, 106) is a separator 108. In a retained electrolytetype battery system such as described herein, the separator may be a porous and absorbent glass mat (AGM) 108, In some examples, the absorbent glass mat 108 may also be used with an additional separator.

[0051] A plurality of positive plates 104 and a plurality of negative plates 106 (with separators 108) generally make up at least a portion of the electrochemical cell 110. As indicated, each plate set or cell may include one or more positive plates 104 and one or more negative plates 106. Thus, the batten' 100 includes a positive plate 104 and a negative plate 106, and more specifically a plurality of positive plates and a plurality of negative plates. Referring to FIG. 3, a plurality of plate sets or books or cells 110 may be electrically connected, e.g., electrically coupled in series or other configuration, according to the capacity of the lead acid storage battery’ 100. Each grid (120, 122) has a lug 128 (see FIGs. 4, 7). In FIGs. 3 and 4, one or more cast-on straps or intercell connectors 130 are provided which electrically couple the lugs 128 of like polarity in a plate set or cell 110 and to connect other respective plate sets or cells 110 in the battery' 100. The cast-on straps or intercell connectors 130 may be formed of a lead or lead alloy according to common commercial practices and may be arranged to connect the lugs 128 of the respective cells 110 in series according to known, traditional arrangements (see FIGs.3 and 4). One or more positive and one or more negative terminal posts 132, and in particular one positive terminal post 132 and one negative terminal post 132 (FIGs. 2-4) are provided. The terminal posts 132 are electrically connected to the cells through the various intercell connectors 130 Such terminal posts 132 typically include portions which may extend through the cover 1 16 and / or container 114 wall, depending upon the battery design. It will be recognized that a varietyof terminal arrangements are possible, including top, side, front or comer configurations known in the art.

[0052] As described in various embodiments herein, the positive and negative plates (104, 106) (see FIG. 4) are paste-type electrodes. Thus, each plate (104, 106) comprises a grid (120, 122) pasted with an active material (124, 126). More specifically, the paste-type electrode includes a grid (120, 122) which acts as a substrate and an electrochemically active material or paste (124, 126) provided on the substrate In other words, each plate (104, 106) includes a grid (120, 122) that supports an electrochemically active material (124, 126). The grids (120, 122), including a positive grid 120 and a negative grid 122, provide an electrical contact between the positive and negative active materials (124, 126) or paste which may serve to conduct current.

[0053] In one or more examples of embodiments, the grid(s) (120, 122) may have a radial configuration similar to those disclosed in U. S. Pat. Nos. 5,582,936; 5,989,749; 6,203,948; 6,274,274; and 6,953,641 8,709,664, which are hereby incorporated by reference herein. To this end, the grids (120, 122) may be stamped or punched fully framed grids (120, 122) having a radial arrangement 134of grid wires 138 (see FIGs. 6 and 7). The radial arrangement 134 being defined by grid frame elements 137 which define the outer boundary of the grid wires 138. While specific examples or radial patterns are provided, variations thereon may also be acceptable for the intended purposes. According to one or more examples of embodiments, the grids (120, 122) may be the same or similar. In one example, both the positive grid(s) 120 and the negative grid(s) 122 may have the same or similar configuration or arrangement. However, it is contemplated that the grids may differ For example, the positive grid 120 may be a stamped or punched fully framed grid having a radial arrangement of grid wires 138. The negative grid 122 may be concast or, for example, expanded metal or gravity cast. The negative grid 122 maybe stamped or punched and fully framed but with a different pattern of grid wires from the positive grid 120 While specific examples of grid wire arrangements, patterns, and grid types are described for purposes of example, the invention is not limited thereto and any grid structure or arrangement suitable for the purposes of the battery may be substituted in place of the described grids.[0054| According to one or more examples of embodiments, the grid material may be composed of lead (Pb) or a lead alloy (or any conductive substrate, i.e. carbon fiber). The grid alloy may be a common commercially available alloy. The grid alloy may comprise or include one or more of lead, tin, silver, calcium, antimony, etc. in a variety of combinations and percentages. Both the positive grid 120 and the negative grid 122 may be formed of the same material. It is contemplated, however, that material composition may also vary between the positive grid 120 and negative grid 122.

[0055] In one example of embodiments, the positive and negative grids (120, 122) may be formed of different thickness. However, it is contemplated that the grids (120, 122) may be of the same thickness. The thickness of each grid (120, 122) may be varied based upon desired manufacturing and performance parameters. For instance, thickness or processability or corrosion resistance may be considered. Minimum manufacturing requirements or minimum requirements for paste adhesion, or other suitable parameters may be considered However, according to one or more examples, the grid material may comprise a minimal thickness.

[0056] Corrosion in the positive grid 120 may be counteracted by an increased thickness in the positive grid 120. Increased thickness of the positive grid resists grid growth as well as the likelihood of grid or batten,' failure due to high heat. Negative grids, and in particular AGM lead acid battery negative grids which are taller in height, may be difficult to paste when reduced in thickness. Preferably the grids (120, 122) are reduced in thickness over Standard AGM lead acid battery grids such that, when formed into battery plates, additional plates (104, 106) may be inserted into the battery 100 as described herein. For example, one or more battery grids (120, 122.) may be reduced in thickness by 0.1 to 0.5 millimeters. In one or more examples of embodiments, the thickness of the negative grid 122 may be less than the thickness of the positive grid 120. In fact, in one or more examples of embodiment, the thickness of the negative grid 122 may be very thin as compared to a standard or conventional lead acid grid To this end, the negative grid 122 may have a thickness ranging from 0.65 mm to 0.90 mm or approximately 0.65 mm to approximately 0.90 mm. In one example, lug width may also vary depending on manufacturing criteria or other factors, which may impact overall grid weight. For example, a wider lug (e.g., greater than 13 mm) may be used in some examples to help improve CCA performance or due to manufacturing specifications. In various examples, by reducing theamount of lead in the grid (120, 122), or the thickness of the grid (120, 122), the overall weight of the grid (120, 122) as well as the battery 100 including the one or more such grids is reduced

[0057] While specific examples are provided herein for purposes of illustration, variations thereon may be made to provide grid dimensions suitable for the particular application. Thus, the weight of the grid (120, 122), and ultimately the weight of the resulting battery 100 may be varied.

[0058] In more detail, the positive plate 104 contains a metal (e.g., lead alloy) grid 120 with lead dioxide active material or paste 12.4 thereon. Examples of lead-containing compositions which may be employed in the positive paste include, but are not limited to, finely divided elemental Pb, PbO (‘’litharge” or “massicot”), Pb3CM(“red lead”), PbSO4(“lead sulfate” with the term “PbSCh” being defined to also include its associated hydrates, and basic sulfates;! PbO. PbSO4, 3PbO. PbSO4. H2O, dPbO. PbSCE). and mixtures thereof. Different materials may be used in connection with the lead-containing paste composition, with the present invention not being restricted to any particular materials or mixtures (added fibers, or other constituents). These materials may be employed alone or in combination as determined by numerous factors, including for example, the intended use of the battery 100 and the other materials employed in the battery.

[0059] The negative plate 106 may be composed of a metal (e.g., lead alloy) grid 122 with a spongy lead active material or paste 126 thereon. The negative paste 126 may, in a preferred embodiment, be substantially similar to the positive paste 124 but may also vary. Example lead-containing compositions which may be employed in the negative paste include but are not limited to finely divided elemental Pb, PbO (“litharge” or “massicot”), PbsO fTed lead”), PbSO.-! (“lead sulfate” with the term “PbSCri” being defined to also include its associated hydrates, and basic sulfates: PbO. PbSC, jPbO. PbSO4. H2O, dPbO. PbSO ) and mixtures thereof. In addition, the negative active material may also contain fiber and “expander” additives to maintain the active material structure and improve performance characteristics, among other-reasons. These materials may be employed alone or in combination as determined by numerous factors, including for example, the intended use of the battery 100 and the other materials employed in the battery.

[0060] The positive and negative paste chemistries provided in the Second Embodiment AGM 100B, as described, is preferably tetra-basic paste chemistries, dPbO. PbSCfl. Atetra-basic chemistry comprises four sulfate per lead sulfate compound. The tetra-basic chemistry provides for increased manufacturing capacity of batteries as compared to batteries comprising tri -basic paste chemistries. Increased manufacturing capacity is defined as the amount of time to manufacture a respective battery. For example, batteries comprising a tetra basic chemistry take approximately 1 - 2 weeks to manufacture. By contrast, batteries comprising a tri-basic chemistry for the paste take approximately months to manufacture (where there are 12 months per years and approximately 52 weeks per year).

[0061] In one or more examples of embodiments, the pasted plates (with or without surface scrim 133) may be imprinted, or have an imprint 148 on the surface 150, such as a “waffle” print (such as shown in FIG. 8) or “riffle” print, to provide, for example, a plurality of grooves such as disclosed in United States Patent Publication No. 2015 / 0104715, the entire contents of which is hereby incorporated by reference in its entirety. As disclosed in said publication, the imprint or grooves may assist in electrolyte flow and gas (air, CO2, O2, He) removal, among other benefits. Additionally, the amount of paste added to the negative grid and the positive grid is increased in the Second Embodiment AGM 100B as compared to that of the Standard AGM battery. The paste is positioned on at least one positive plate having a weight of approximately 125 grams + / -3 grams. The paste is positioned on at least one negative plate having a weight of approximately 100 grams.

[0062] As indicated, the separator 108, made of a separator material, may be provided between each positive plate 104 and negative plate 106. The separator 108 may be an absorbent glass mat 108, and in one or more examples of embodiments may be wrapped around a portion of, or interleaved with / provided between one (or both) of the positive and negative plates (104, 106). A single or double layer of separator or AGM may be employed. The absorbent glass mat 108 may be constructed similar to and / or of a similar material to traditional absorbent glass mat separators, including thin glass fibers woven into a. mat (or more commonly non-woven deposited fibers). According to one or more examples of embodiments, the absorbent glass mat material may be thicker. In one example, the absorbent glass mat material may include more fiber material so as to increase the thickness of the absorbent glass mat separator 108. In one ormore examples of embodiments, the separator or absorbent glass mat separator 108 may comprise 100% glass fiber. In an alternative example of embodiments, the separator or absorbent glass mat separator 108 may comprise a glass fiber plus a second or additional fiber of a different type of material. As to the increased thickness of the separator, the separator increases in thickness as compared to the Standard AGM battery to a range from approximately 1.78 mm to approximately 1.82 mm.

[0063] In one or more preferred examples of embodiments, a first embodiment of an improved, AGM lead acid battery (First Embodiment AGM) 100 A has a decreased number of plates (104, 106) (of one or both polarities) over a conventional AGM lead acid battery in a given battery group size Table 2, below, shows a representative example of the number of positive plates 104 and the number of negative plates 106 in each plate set or cell element 110 in example AGM lead acid batteries As shown, in one example of a Standard “LN2 / H5” AGM lead acid battery, six (6) positive plates and seven (7) negative plates may be provided in stacks or plate sets or books or cell elements for producing a battery having a predetermined voltage, for example a 12-volt battery in a vehicle. As shown, in one example of a Standard “ LN l” AGM lead acid battery, five (5) positive plates and six (6) negative plates may be provided in stacks or plate sets or books or cell elements for producing a battery having a predetermined voltage, for example a 12-volt battery in a vehicle. In an alternative example of a Standard “LN3” AGM lead acid battery, seven (7) positive and eight (8) negative plates may be provided in stacks or plate sets or cell elements. In comparison, in one or more examples of embodiments of an AGM lead acid battery of the types described herein, additional plates may be removed from each set. For example, as shown in Table 2, an “LN2 / H5” First Embodiment AGM lead acid battery may have five (5) positive and six (6) negative plates provided in the plate groups or books or cells, an “LN 1” First Embodiment AGM lead acid batery 100A may have four (4) positive and five (5) negative plates provided in the plate groups or books or cells. An “LN3” First Embodiment AGM lead acid battery 100A may have six (6) positive plates and seven (7) negative plates in the plate sets or books or cells. While specific examples are provided, the number of stacks or plate sets may be varied It will also be obvious to those skilled in the art after reading this specification that the size and number of plates in any particular stack (including the size and number of the individual grids), and the number of stacks used to construct the battery may vary depending upon the desired end use. Additionally, while LN1 / H4, LN2 / FI5, LN3 / H6, LN4 / H7are specifically described herein and illustrated in the examples, one of skill in the art would appreciate that the same principles may be applied to additional or alternative size batteries, such as for example, LN5 / H8 and LN6 / H9, etc.

[0064] As illustrated with the “LN2 / H5” battery size, the invention provides for removal of plates in the First Embodiment AGM lead acid batten,'. With that, the plates (104, 106) in the First Embodiment AGM 100A described herein are thicker than those provided in a Standard AGM lead acid battery as previously discussed. The separator 108 provided in the First Embodiment AGM lead acid battery 100A described herein is also thicker than those provided in a conventional AGM lead acid battery. Thus, with removed plates, and the thicker separators within a Standard AGM lead acid battery (for example a battery size “LN1 / H5”) container 114, an unanticipated improved operation of the First Embodiment AGM 100 A is realized The improved operation regards improved cyclability of the First Embodiment AGM over the cyclability of the Standard AGM. With cyclability equating to the number of times (cycles) a battery may be charged and discharged before the battery is unable to hold a charge or a predetermined charge.

[0065] In making the above described design changes for the First Embodiment AGM 100A, the positive plate thickness increases from within the range of approximately 1.63 mm to 2.14 mm in the Standard AGM battery to within a range of approximately 2.53 mm and approximately 2.77 mm in the First Embodiment AGM lead acid battery’ 100. Further, the negative plate increases from a thickness from within the range of approximately 1.29 mm to 1.53 mm in the Standard AGM battery to within a range of approximately 1.63 to approximately 1.81 mm in the First Embodiment AGM lead acid battery 100.

[0066] Advantageously, the combination of the above-described removal of plates, thicker plates, and thicker separator provides an increase in surface area for the same or approximately the same weight and / or size of battery. (Surface area in this case is calculated by height / w'idth / nurnber of plates in battery). As stated, this leads to, among other things, increased cycle life count capability of the First Embodiment AGM as compared to the Standard AGM battery of a respective battery size, e.g LN2 / H5.TABLE 2Example Comparison Data of One Example of a First Embodiment AGM Lead Acid Battery and an Example Standard AGM Lead Acid Battery

[0067] With that, a second embodiment of an improved AGM lead acid battery (Second Embodiment AGM) 100B is disclosed. It is understood, the Second Embodiment AGM incorporates and shares at least one aspect of the First Embodiment AGM 100A. Specifically, but not limited to such, the Second Embodiment AGM 100B incorporates the reduces plate numbers (positive and negative plates) as described in the First Embodiment AGM 100A. In the Second Embodiment AGM: 100B, the dimensional comparisons of the grid 120 and the plate (104, 106) of a Second Embodiment AGM 100B as compared to the grid 120 and the plate (104, 106) of a Standard AGM are as described in Table 3. Specifically, Table 3 illustrates the differentiation between the plate dimensions, grid dimensions, paste thickness, and separator thickness between the Second Embodiment AGM 100B, for example an eAGM battery, and a Standard AGM batters'. The Standard AGM battery does not apply the reduced number of plates as disclosed for the improvements in the Second Embodiment AGM 100B.

[0068] A standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery for example the Standard AGM battery and / or First Embodiment AGM 100A, does not apply at least one of the positive paste 124 or the negative paste 126 in an increased thickness as that in the Second Embodiment AGM 100B. The combination of the paste (124, 126 ), grid (120, 122), and separators 108 of the standard or conventional lead acid battery, and / or other exemplified embodiments of an AGM battery, making up the plates (104, 106) of the respectivebattery results in a first compression between the plates ( 104, 106) housed in the respective battery with a first value range. By contrast, the combination of the paste (124, 126), grid (120, 122), and separators 108 of the Second Embodiment AGM 100 A making up the plates (104, 106) of the respective battery' results in a second compression between the plates (104, 106) housed in the respective battery' of a second value range. The second value range is greater than the first value range for batteries of similar or the same size grouping 'The results of the second compression are illustrated in FIGs. 9A to 13. The increased second value range is due at least in part from the increased plate thickness of the plates (104, 106) in the Second Embodiment AGM 100B as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size. Additionally, a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, does not incorporate the paste chemistry in the paste (124, 126) of the paste chemistry’ in the paste (124, 126) in the Second Embodiment AGM 100B.

[0069] As represented in Table 3, in the Second Embodiment A GM 100B the range of the positive plate (104) thickness expands to a range from approximately 2.096 mm to approximately 2.51 mm as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery. With that, in the Second Embodiment AGM 100B for a Battery Group Size LN1 the positive plate (104) thickness may expand to a range from approximately 2.29 mm to approximately 2.51 mm. In the Second Embodiment AGM 100B for a Battery Group Size LN2 the positive plate (104) thickness may expand to a range from approximately 2.096 to approximately 2.316 mm In the Second Embodiment AGM 100B for a Battery' Group Size LN3 the positive plate (104) thickness may' expand to a range from approximately 2.096 to approximately 2.316 mm. In the Second Embodiment AGM 100B for a Battery Group Size LN4 the positive plate (104) thickness may expand to a range from approximately 2.096 to approximately 2.316 mm. In the Second Embodiment AGM 100B for a Batery Group Size LN5 the positive plate (104) thickness may expand to a range from approximately 2.096 to approximately 2.316 mm. Thus, the range of the positive plate (104) thickness in the Second Embodiment AGM 100B is one of an example, or combination, of approximately 2.096 - 2.144 mm; 2.096 - 2.196 mm; 2.096 - 2.248 mm; 2.096 - 2.300 mm; 2.096 - 2352 rnm; 2.096 - 2.404 mm; 2.096 - 2.456 mm; 2.096 - 2.510 mm; 2.144 - 2.196 mm; 2.144 -2.248 mm; 2.144 - 2.300 mm, 2.144 - 2.352 mm; 2.144 - 2.404 mm, 2.144 - 2.456 mm; 2.144 -2.510 mm; 2 196 2.248 mm, 2 196 ■■ 2.300 mm; 2.196 - 2.352 mm; 2.196 - 2404 mm; 2.196 - 2.456 mm, 2 196 - 2.510 mm, 2.248 - 2.248 mm; 2.248 - 2352 mm; 2.248 - 2.404 mm; 2.248 - 2.456 mm; 2.248 ■■ 2.510 mm; 2.300 ■■ 2.352 mm; 2.300 ■■ 2.404 mm; 2.300 ■■ 2.456 mm; 2.300 ■■ 2.510 mm; 2.352 - 2.404 mm; 2.352 - 2.456 mm; 2.352 - 2.510 mm; 2.404 - 2.456 mm; 2404 - 2.510 mm; and 2.456 - approximately 2.510 mm.

[0070] With that, the positive plate thickness is between approximately 0.28 mm and approximately 0.88 mm thicker than that, of the Standard AGM, and / or other exemplified embodiments of an AGM battery, positive plate thickness. Thus, the positive plate thickness is thicker than that of the Standard AGM battery positive plate thickness in an example, or combination, range of 0.28 - 0.324 mm; 0.28 - 0.382 mm, 0.28 - 0.44 mm; 0.28 - 0.498 mm; 0.28 - 0.556 mm; 0.28 ■■ 0.61 mm; 0.28 - 068 mm; 0.28 - 0.76 mm; 0.28 - 0.88 mm; 0324 ■■ 0.382 mm; 0.324 - 0.44 mm; 0.324 - 0.498 mm, 0324 - 0.556 mm, 0.324 - 0.61 mm; 0,324 - 068 mm; 0.324 - 0.76 mm; 0.324 - 0.88 mm; 0.382 - 0.44 mm; 0.382 - 0.498 mm; 0.382 - 0.556 mm; 0.382 - 0.61 mm; 0.44 - 0.498 mm; 0.44 - 0.556 mm; 0.44 - 0.61 mm, 0.44 - 068 mm; 0.44 -0.76 mm; 0.44 - 0.88 mm; 0.498 - 0.556 mm, 0.498 - 0.61 mm, 0.556 - 0.61 mm; 0.556 - 0.68 mm; 0.556 - 0.76 mm; 0.556 - 0.88 mm; 0.61 - 0.68 mm; 0.61 - 0.76 mm; 0.61 - 0.88 mm; 068 - 0.76 mm; 0.68 - 0.88 mm; and 0.76 - approximately 0.88 mm. The increased thickness of the positive plate in the Second Embodiment AGM 100B as compared to the positive plate thickness in the Standard AGM battery, and / or other exemplified embodiments of an AGM battery, adds to and provides for the benefit of increased compression in the second value range between the plates of the Second Embodiment AGM 100B. Reference to the Standard AGM includes other exemplified embodiments of the AGM battery. This increased compression provides for the unanticipated improved resultants, realized during experimentation, as illustrated in FIGs 9A -13 as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar batter}- size.

[0071] Further, as represented in Table 3, in the Second Embodiment AGM 100B the negative plate 106 thickness expands to a range from approximately 1.48 mm to approximately 1.72 mm as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery. Thus, the range is one of an example, or combination, of approximately 1.48 - 1.502 mm; 1.48 -• 1.524 mm; 1 48 - 1.546 mm; 1 48 - 1.568 mm, 1.48 -1.59 mm; 1.48 - 1.612 mm; 1.48 - 1.634 mm; 1.48 - 1.656 mm; 1.48 ■■ 1.678 mm; 1.48 1.7 mm; 1.502 - 1.524 mm; 1.502 - 1.546 mm; 1.502 - 1.568 mm; 1.502 - 1.59 mm; 1.502 - 1.612 mm, 1.502 - 1.634 mm; 1.502 - 1.656 mm; 1.502 - 1.678 mm; 1.502 - 1.7 mm; 1.524 - 1.546 mm; 1.524 - 1.568 mm; 1.524 - 1.59 mm; 1.502 - 1.612 mm; 1.502 - 1.634 mm; 1.502 - 1.656 mm; 1.502 - 1.678 mm, 1.502 - 1.7 mm; 1.568 - 1.59 mm; 1.568 - 1.612 mm; 1.568 - 1.634 mm, 1.568 - 1.656 mm; 1.568 - 1.678 mm; 1.568 - 1.7 mm, 1.59 - 1.612 mm; 1.59 - 1.634 mm; 1.59 - 1.656 mm; 1.59 - 1.678 mm; 1.59 - 1.7 mm; 1.612 - 1.634 mm; 1.612 - 1.656 mm; 1.612 - 1.678 mm, 1.612 - 1.7 mm; 1.634 - 1.656 mm; 1.634 - 1.678 mm; 1.634 - 1.7 mm; 1.656 - 1.678 mm, 1.656 - 1.7 mm; and 1.678 - approximately 1.72 mm

[0072] With that, the negative plate thickness is between approximately 0.01 mm and approximately 0.42 mm thicker than that of the Standard AGM, and / or other exemplified embodiments of an AGM battery, negative plate thickness Thus, the negative plate thickness is thicker than that of the Standard AGM battery negative plate thickness in an example, or combination, range of 0.01 - 0.082 mm; 0.01 - 0.104 mm; 0.01 - 0.126 mm, 0.01 - 0 148 mm; 0.01 - 0. 17 mm; 0.01 - 0.192 mm; 0.01 - 0.214 mm; 0.01 - 0.236 mm, 0.01 - 0.258 min, 0.01 -0.28 mm; 0.01 - 0.36 mm; 0.01 - 0.42mm;.082 - 0.104 mm; 0.082 - 0.126 mm; 0.082 - 0.148 mm; 0.082 - 0.17 mm; 0.082 - 0.192 mm; 0.082 - 0.214 mm; 0.082 - 0.236 mm; 0.082 - 0.258 mm; 0.082 - 0.28 mm; 0.082 - 0.36 mm; 0.082 - 0.42 mm;0.104 - 0.126 mm; 0.104 - 0.148 mm; 0.104 - 0.17 mm; 0.104 - 0.192 mm; 0.104 - 0.214 mm; 0.104 - 0.236 mm; 0.104 - 0.258 mm; 0.104 - 0.28 mm; 0.104 - 0.36 mm; 0.104 - 0.42mm; 0.126 - 0. 148 mm; 0.126 - 0.17 mm; 0.126 - 0.192 mm; 0.126 - 0.214 mm; 0.126 - 0.236 mm; 0.126 - 0.258 mm; 0.126 - 0.28 mm; 0.126 - 0.36 mm; 0.126 0.42mm; 0.148- 0.17 mm; 0. 148 - 0.192 mm; 0.148 - 0.214 mm; 0.148 -0.236 mm; 0.148 - 0.258 mm; 0.148 - 0.28 mm; 0.148 - 0.36 mm; 0.148 - 0.42mm; 0.17 - 0.192 mm, 0. 17 - 0.214 mm; 0.17 - 0.236 mm; 0.17 - 0.258 mm; 0.17 - 0.28 mm; 0.17 - 0.36 mm; 0.17 - 0.42mm; 0.192 - 0.214 mm; 0.192 - 0.236 mm; 0.192 - 0.258 mm; 0.192 - 0.28 mm; 0.192 - 0.36 mm; 0.192 - 0.42mm; 0.214 - 0.236 mm; 0.214 - 0.258 mm; 0.214 - 0.28 mm; 0.214 - 0.36 mm; 0.214 - 0.42mm; 0.236 - 0.258 mm; 0.236 - 0.28 mm; 0.236 - 0.36 mm; 0.236 - 0.42mm; 0.258 - 0.28 mm; 0.258 - 0.36 mm, 0.258 - 0.42mm; 0.28 - 0.36mm;0.28 - 0.42 mm; and 0.36 - approximately 0.42mm. The increased thickness of the negative plate in the Second Embodiment AGM 100B as compared to the negative plate thickness in the Standard AGM battery, and / or other exemplified embodiments of an AGM battery, adds to and provides for thebenefit of increased compression in the second value range between the plates of the Second Embodiment AGM 100B. This increased compression provides for the unanticipated improved resultants, realized during experimentation, as illustrated in FIGs 9A - 13 as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size.

[0073] Further, as represented in Table 3, in the Second Embodiment AGM 100B the positive grid thickness expands to a range from approximately 1.012 mm to approximately 1.088 mm as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery7. Thus, the range is one of an example, or combination, of approximately 1.012 - 1.022 mm; 1.012 - 1.032 mm, 1.012 - 1.042 mm, 1.012 - 1.052 mm; 1.012 - 1.062 mm; 1.012 - 1.072 mm; 1.012 - 1.082 mm; 1.012 — 1.088 mm; 1.022 - 1.032 mm; 1.022 - 1.042 mm; 1.022 - 1.052 mm; 1.022 - 1.062 mm; 1.022 - 1.072 mm; 1.022 - 1.082 mm; 1.022 - 1.088 mm; 1.032 - 1.042 mm; 1.032 - 1.052 mm; 1.032 - 1.062 mm; 1.032 - 1.072 mm; 1.032 - 1.082 mm; 1.032 - 1.088 mm; 1.042 - 1.052 mm; 1.042 - 1.062 mm; 1.042 - 1.072 mm; 1.042 - 1.082 mm; 1.042 - 1.088 mm, 1.052 - 1.062 mm, 1.052 - 1.072 mm; 1.052 - 1.082 mm; 1.052 - 1.088 mm; 1.062 - 1.072 mm; 1.062 - 1.082 mm; 1.062 - 1.088 mm; 1.072 - 1.082 mm; 1.072 - 1.088 mm; and 1.082 - approximately 1.088 mm

[0074] With that, the positive grid thickness in the Second Embodiment AGM 100B is between approximately 0.076 mm thinner than and approximately 0.997 mm thicker than the positive grid thickness of the Standard AGM battery, and / or other exemplified embodiments of an AG M battery, positive grid thickness. The positive grid thickness of the Second Embodiment AGM 100B, whether increased or decreased or the same as the positive grid thickness of the Standard AGM, and / or other exemplified embodiments of an AGM battery, provides for an increased positive paste thickness in view of the dimensional requirements of the battery. The positive grid thickness of the Second Embodiment AGM 100B, whether increased or decreased or the same as the positive gride thickness of the Standard AGM or other embodiments of the AGM, alternatively accommodates a decrease in positive paste thickness as compared to the Standard AGM, and / or other exemplified embodiments of an AGM batter}'. Thus, the positive grid thickness in combination with the positive paste thickness provides for the unanticipated benefit of increased compression in the second value range between the plates of the SecondEmbodiment AGM 100B. This increased compression provides the unanticipated improved resultants as illustrated in FIGs 9 - 13 A as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size.

[0075] Further, as represented in Table 3, in the Second Embodiment AGM 100B the negative grid thickness expands to a range from approximately 0.762 mm to approximately 0.838 mm as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery. Thus, the range is one of an example, or combination, of approximately 0.762 - 0.772 mm; 0.762 - 0.782 mm, 0.762 - 0.792 mm; 0.762 - 0.802 mm; 0.762 - 0.812 mm; 0.762 - 0.822 mm; 0.762 - 0.832 mm; 0.762 - 0.838 mm; 0.772 - 0.782 mm; 0.772 - 0.792 mm; 0.772 - 0.802 mm; 0.772 - 0.812 mm; 0.772 - 0.822 mm; 0.772 - 0.832 mm; 0.772 - 0.838 mm; 0.782 - 0.792 mm; 0.782 - 0.802 mm; 0.782 - 0.812 mm; 0.782 - 0.822 mm; 0.782 - 0.832 mm; 0.782 - 0.838 mm; 0.792 - 0.802 mm; 0.792 - 0.812 mm; 0.792 - 0.822 mm; 0.792 - 0.832 mm; 0.792 - 0.838 mm; 0.802 - 0.812 mm; 0.802 - 0.822 mm; 0.802 - 0.832 mm; 0.802 - 0.838 mm; 0.812 - 0.822 mm; 0.812 - 0.832 mm; 0.812. - 0.838 mm; 0.822 - 0.832 mm; 0.822 - 0.838 mm; and 0.832 - approximately 0.838 mm.

[0076] With that, the negative grid thickness is approximately 0.001 mm to approximately 0.176 mm thinner than that of the Standard AGM battery, and / or other exemplified embodiments of an AGM battery, positive plate thickness. Thus, the negative gird thickness is thinner than that of the Standard AGM battery negative grid thickness in an example, or combination, range of approximately 0.001 - 0.062 mm; 0.001 - 0.072 mm; 0.001 - 0.082 mm; 0.001 - 0.092 mm; 0.001 - 0.102 mm; 0.001 - 0.112 mm; 0.001 - 0.122 mm; 0.001 - 0.132 mm; 0.001 - 0. 138 mm; 0.001 - 0.150 mm, 0.001 - 0.165 mm; 0.001 - 0.176 mm; 0.062 - 0.072 mm; 0.062 - 0.082 mm; 0.062 - 0.092 mm; 0.062 - 0.102 mm; 0.062 - 0.112 mm; 0.062 - 0.122 mm; 0.062 - 0.132 mm; 0.062 - 0.138 mm; 0.062 - 0.150 mm; 0.062 - 0.165 mm; 0.062 - 0.176 mm; 0.072 - 0.082 mm; 0.072 - 0.092 mm; 0.072 - 0.102 mm, 0.072 - 0.112 mm, 0.072 - 0.122 mm; 0.072 - 0.132 mm, 0.072 - 0. 138 mm; 0.072 - 0.150 mm; 0.072 - 0.165 mm; 0.072 - 0.176 mm; 0.082 - 0.092 mm; 0.082 - 0.102 mm; 0.082 - 0.112 mm; 0.082 - 0.122 mm; 0.082 - 0.132 mm; 0.082 - 0.138 mm; 0.082 - 0.150 mm; 0.082 - 0.165 mm; 0.082 - 0.176 mm; 0.092 - 0.102 mm; 0.092 - 0.112 mm; 0.092 - 0.122 mm; 0.092 - 0.132 mm; 0.092 - 0.138 mm; 0.092 - 0.150 mm; 0.092 - 0.165 mm; 0.092 - 0.176 mm; 0.102 - 0.112 mm; 0.102 - 0.122 mm; 0.102 - 0.132 mm, 0.102 - 0.138 mm;0.102 - 0.150 mm; 0.102 - 0.165 mm; 0.102 - 0.176 mm; 0.102 - 0.150 mm; 0.102 - 0.165 mm; 0.102 -0.176 mm; 0.112 - 0.122 mm; 0.112 - 0.132 mm; 0.112 - 0.138 mm; 0.112 - 0.150 mm; 0.112 - 0.165 mm; 0.112 - 0.176 mm; 0.122 - 0.132 mm; 0.122 - 0.138 mm; 0.122 - 0.150 mm; 0.122 - 0.165 mm; 0.122 - 0.176 mm; 0.132 -0.138 mm; 0.132 - 0.150 mm; 0.132 - 0.165 mm; 0.132- 0.176 mm; 0.138 - 0.150 mm; 0.138 - 0.165 mm; 0.138 - 0.176 mm; 0.150 - 0.165 mm, 0.150 - 0.176 mm; and 0.165 - approximately 0.176 mm. The reduced negative grid thickness of the Second Embodiment AGM 100B, as compared to the negati ve grid thickness of the Standard AGM, and / or other exemplified embodiments of an AGM battery, provides for an increased negative paste thickness in view of the dimensional requirements of the battery. Thus, the negative grid thickness in combination with the negative paste thickness provides for the unanticipated benefit, realized during experimentation, of increased compression in the second value range between the plates of the Second Embodiment AGM 100B. This increased compression provides for the unanticipated improved resultants as illustrated in FIGs 9 - 13A as compared to a standard or conventional lead acid battery, and / or other exemplified embodiments of an AGM battery, of the same or similar battery size.

[0077] Further, as represented in Table 3, in the Second Embodiment AGM 100B the positive overpaste thickness expands to a range from approximately 1.086 mm to approximately 1.42 mm as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery. With that, in the Second Embodiment AGM 100B for a Battery Group Size LN1 the range of the positive, overpaste thickness may expand to a range from approximately 1.28 mm to approximately 1.42 mm. In the Second Embodiment AGM 100B for a Battery Group Size LN2 the range of the positive overpaste thickness may expand to a range from approximately 1.086 to approximately 1.226 mm. In the Second Embodiment AGM 100B for a Battery Group Size LN 3 the range of the positive overpaste thickness may expand to a range from approximately 1.086 to approximately 1.226 mm. In the Second Embodiment AGM 100B for a Battery Group Size LN4 the range of the positive overpaste thickness may expand to a range from approximately 0.086 to approximately 1.126 mm. In the Second Embodiment AGM 100B for a Battery Group Size LN5 the range of the positive overpaste thickness may expand to a range from approximately 0.086 to approximately 1.126 mm. Thus, the range of the positive overpaste thickness on the is one of an example, or combination, of approximately 1.086- 1.092 mm; 1.086 - 1.147 mm; 1.086 - 1.202 mm; 1.086 - 1.257 mm; 1.086 - 1.312 mm; 1.086 - 1.367mm; 1.086 - 1.42 mm; 1.092 - 1 147 mm; 1.092 - 1 202 mm; 1.092 - 1 257 mm; 1.092 - 1.312 mm; 1.092 - 1.367 mm; 1.092 - 1.42 mm; 1 147 - 1.202 mm, 1 147 - 1.257 mm, 1.147 - 1 312 mm; 1.147 - 1.367 mm; 1.147 - 1.42 mm; 1.202 - 1.257 mm; 1.202 - 1.312 mm; 1.202 - 1.367 mm, 1.202- 1.42 mm; 1.257 - 1 312 mm; 1.257 - 1.367 mm; 1.257 - 1.42 mm; 1.312 - 1.367 mm, 1.312 - 1.42 mm; and 1.367 - approximately 1.42 mm.

[0078] For the Second Embodiment AGM 100B for a Battery Group Size of LN1, the thicknesses of die overpaste applied to the positive grid, or positive overpaste, is approximately 0.36 mm to approximately 0.64 mm greater in thicknesses than the overpaste applied to the positive grid of the Standard AGM battery, and / or other exemplified embodiments of an AGM battery Thus, for the Second Embodiment AGM 100B for a Battery Group Size of LN1, the thickness of the overpaste applied to the positive grid is greater than the thicknesses of the overpaste applied to the positive grid of the Standard AGM battery by one of an example, or combination, of approximately 0.36 - 0.407 mm; 0.36 - 0.462 mm; 0.36 - 0.517 mm; 0.36 -0.57 mm; 0.36 - 0.64 mm; 0.407 - 0.462 mm; 0.407 - 0.517 mm; 0.407 - 0.57 mm; 0.407 - 0.64 mm, 0.462 - 0.517 mm; 0.462 - 0.57 mm; 0.407 - 0.64 mm; 0.517 - 0.57; 0.517 - 0.64 mm; and 0.57 - approximately 0.64 mm.

[0079] For the Second Embodiment AGM 100B for a Battery Group Size of LN2, LN3, and / or LN4, the thicknesses of the overpaste applied to the positive grid, or positive overpaste, is approximately 0.116 mm to approximately 0.446 mm greater in thicknesses than the overpaste applied to the positive grid of the Standard AGM battery, and / or other exemplified embodiments of an AGM battery. Thus, for the Second Embodiment AGM 100B for a Battery Group Size of LN2, LN3, and / or LN4, the thickness of the overpaste applied to the positive grid is greater than the thicknesses of the overpaste applied to the positive grid of the Standard AGM battery by one of an example, or combination, of approximately 0.116 - 0.132 mm, 0.116 - 0.187 mm, 0.116 - 0.242 mm; 0.132 - 0.297 mm; 0.116 - 0.357 mm; 0.116 - 0.407 mm; 0.116 - 0.446 mm; 0.132 - 0.187 mm; 0.132 - 0.242 mm; 0.132 - 0.297 mm; 0.132 - 0.357 mm; 0.132 - 0.407 mm; 0.132 - 0.446 mm, 0 187 - 0.242 mm, 0.187 - 0.297 mm, 0.187 - 0.357 mm, 0.187 - 0.407 mm, 0.187 - 0.446 mm; 0.242 - 0.297 mm; 0.242 - 0.357 mm; 0.242 - 0.407 mm; 0.242 - 0.446 mm; 0.297 - 0.357 mm; 0.297 - 0.407 mm; 0.297 - 0.446 mm; 0.357 - 0.407 mm; 0.357 - 0.446 mm; and 0.407 - approximately 0.446 mm.

[0080] For the Second Embodiment AGM 100B for a Battery Group Size of LN5, the thicknesses of the overpaste applied to the positive grid, or positive overpaste, is approximately 0.036 mm to approximately 0.316 mm greater in thicknesses than the overpaste applied to the positi ve grid of the Standard AGM battery, and / or other exemplified embodiments of an AGM battery. Thus, for the Second Embodiment AGM 100B for a Battery Group Size of LN5, the thickness of the overpaste applied to the positive grid is greater than the thicknesses of the overpaste applied to the positive grid of the Standard AGM battery by one of an example, or combination, of approximately 0.036 - 0.100 mm; 0.036 - 0.200 mm; 0.036 - 0.316 mm; 0.100 -0.200 mm; 0.100 - 0.316 mm; and 0.200 - approximately 0.316 mm.

[0081] The above increase in positive paste thickness is due to an increase in the amount of positive paste applied as compared to the amount of positive paste applied to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size. For the Second Embodiment AGM 100B, the range of the amount, or mass, of positive overpaste applied to a respective grid 120 expands to a range from approximately 10 grams to approximately 143 grams. Thus, in the Second Embodiment AGM 100B the amount, or mass, of positive overpaste applied to the respective positive grid is approximately 2 grams to approximately 51 grams greater than the overpaste applied to the positive grid of the Standard AGM battery, and / or other exemplified embodiments of an AGM battery With that, as noted the increased positive paste of the Second Embodiment AGM 100B over the Standard AGM battery, and / or exemplified embodiments of an AGM battery, in combination with the positive gird thickness provides for the unanticipated benefit of increased compression in the second value range between the plates of the Second Embodiment AGM 100B. This increased compression provides unanticipated improved resultants, realized during experimentation, as illustrated in FIGs 9 - 13A as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size

[0082] Further, as represented in Table 3, in the Second Embodiment AGM 100B the range of the negative overpaste thickness expands to a range from approximately 0.72 mm to approximately 0.87 mm a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery. Thus, the range of the negative overpaste thickness is one ofan example, or combination, of approximately 0.72 - 0.737 mm; 0.72 - 0.754 mm; 0.72 - 0771 mm; 0.72 - 0.788 mm; 0.72 - 0.805 mm, 0.72 - 0.822 mm, 0.72 - 0839 mm, 0.72 - 0.856 mm; 0.72 - 0.87 mm; 0.737 - 0.754 mm; 0.737 - 0.771 mm; 0.737 - 0.788 mm; 0.737 - 0.805 mm; 0.737 - 0822 mm; 0.737 - 0.839 mm; 0.737 - 0.856 mm; 0.737 - 0.87 mm; 0.754 - 0.771 mm; 0.754 - 0.788 mm; 0.754 - 0.805 mm, 0.754 - 0.822 mm, 0.754 - 0.839 mm; 0.754 - 0.856 mm; 0.754 - 0.87 mm; 0.771 - 0.788 mm; 0.771 - 0.805 mm; 0.771 - 0.822 mm; 0.771 - 0.839 mm; 0.771 - 0.856 mm; 0.771 - 0.87 mm; 0.788 - 0.805 mm; 0.788 - 0.822 mm; 0.788 - 0.839 mm; 0.788 - 0.856 mm; 0.788 - 0.87 mm; 0.805 - 0.822 mm; 0.805 - 0.839 mm; 0.805 - 0.856 mm; 0.805 - 0.87 mm; 0.822 - 0.839 mm; 0.822 - 0.856 mm; 0.822 - 0.87 mm; 0.839 - 0.856 mm; 0.839 - 0.87 mm; and 0.856 - approximately 0.87 mm.

[0083] Further, as represented in Table 3, in the Second Embodiment AGM 100B the thickness of the overpaste applied to the negative grid is approximately 0 13 mm to approximately 042 mm thicker than the overpaste applied to the negative grid of the Standard AGM battery, and / or other exemplified embodiments of an AGM battery. Thus, for the Second Embodiment AGM 100B, the thickness of the overpaste applied to the negative grid is greater than the thicknesses of the overpaste applied to the negative grid of the Standard AGM battery by one of an example, or combination, of approximately 0.13 - 0.214 mm; 0.13 - 0.228 mm; 0.13 -0.242 mm; 0.13 - 0.256 mm; 0.13 - 0.270 mm; 0.13 - 0.284 mm; 0.13 - 0.298 mm; 0.13 - 0.312 mm, 0.13 - 0.42 mm; 0.13 - 0.310 mm; 0.214 - 0.228 mm; 0.214 - 0.242 mm; 0.214 - 0.256 mm; 0.214 - 0.270 mm; 0.214 - 0.284 mm; 0.214 - 0.298 mm; 0.214 - 0.312 mm; 0.214 - 0.326 mm, 0.214 - 0.42 mm; 0.228 - 0.242 mm; 0.228 - 0.256 mm; 0.228 - 0.270 mm, 0.228 - 0.284 mm; 0.228 - 0.298 mm; 0.228 - 0.312 mm; 0.228 - 0.326 mm; 0.228 - 0.42 mm; 0.242 - 0.256 mm; 0.242 - 0.270 mm, 0.242 - 0.284 mm; 0.242 - 0.298 mm; 0.242 - 0.312 mm; 0.242 - 0.326 mm; 0.242 - 0.42 mm; 0.256 - 0.270 mm; 0.256 - 0.284 mm; 0.256 - 0.298 mm; 0.256 - 0.312 mm; 0.256 - 0.326 mm; 0.256 - 0.42 mm; 0.270 - 0.284 mm; 0.270 - 0.298 mm; 0.270 - 0.312 mm; 0.270 - 0.326 mm; 0.270 - 0.42 mm, 0284 - 0.298 mm; 0.284 - 0.312 mm, 0.284 - 0.326 mm, 0.284 - 0.42 mm; 0.298 - 0.312 mm; 0.298 - 0.326 mm; 0.298 - 0.42 mm; 0.312 - 0.326 mm; 0.312 - 0.42 mm; and 0.326 - approximately 0.42 mm.

[0084] The above increase in negative paste thickness is due to an increase in the amount of negative paste applied in the Second Embodiment AGM 100B as compared to the amount ofT1negative paste applied to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size. For the Second Embodiment AGM 100B, the range of the amount, or mass, of negative overpaste applied to a respective grid 122 expands to a range from approximately 95 grams to approximately 110 grams. Thus, in the Second Embodiment AGM 100B the amount, or mass, of negative overpaste applied to the respective positive grid is approximately 2 grams to approximately 29 grams greater than the overpaste applied to the negative grid of the Standard AGM battery. With that, as noted the increased negative paste of the Second Embodiment AGM 100B over the Standard AGM battery, and / or exemplified embodiments of an AGM battery, in combination with the negative gird thickness provides for the unanticipated benefit of increased compression in the second value range between the plates of the Second Embodiment AGM 100B, This i ncreased compression provides unanticipated improved resultants, realized during experimentation, as illustrated in FIGs 9 - 13A as compared to a standard or conventional lead acid battery, and / or other exemplified embodiments of an AGM battery, of the same or similar battery size.

[0085] The above combinations grids (120, 122) and overpastes (124, 126) in the Second Embodiment AGM 100B results in a reduced weight of metal in each respective plate in the Second Embodiment AGM 100B of 500 to 900 grams as compared to the Standard AGM More preferably the reduced weight of the metal in the plate is 400 - 450 grams; 400 - 500 grams; 400 - 550 grams, 400 - 600 grams; 400 - 650 grams; 400 - 700 grams; 400 - 750 grams; 400 -800 grams, 400 - 850 grams; 400 --- 900 grams; 400 --- 950 grams; 400 - 1000 grams; 450 - 500 grams, 450 - 550 grams; 450 - 600 grams; 450 - 650 grams; 450 - 700 grams; 450 - 750 grams; 450 -800 grams; 450 - 850 grams; 450 - 900 grams; 450 - 950 grams; 450 - 1000 grams; 500 - 550 grams; 500 - 600 grams; 500 - 650 grams; 500 - 700 grams, 500 - 750 grams, 500 - 800 grams; 500 - 850 grams; 500 - 900 grams; 500 - 950 grams; 500 - 1000 grams; 600 - 650 grams; 600 - 700 grams; 600 - 750 grams; 600 -800 grams; 600 - 850 grams; 600 - 900 grams; 600 - 950 grams; 600 - 1000 grams, 650 - 700 grams, 650 - 750 grams, 650 - 800 grams; 650 -850 grams; 650 - 900 grams; 650 - 950 grams; 550 - 1000 grams; 700 - 750 grams; 700 - 800 grams; 700 - 850 grams; 700 - 900 grams; 700 - 950 grams; 700 - 1000 grams; 750 - 800 grams; 750 - 850 grams; 750 - 900 grams; 750 - 950 grams; 750 - 1000 grams; 800 - 850 grams; 800 - 900 grams; 800 - 950 grams; 800 - 1000 grams; 850 - 900 grams; 850 - 950 grams, 850 -1000 grams; 900 - 950 grams, 900 --- 1000 grams, and 950 - 1000 grams.

[0086] As noted, the separator provides a benefit for increased cycle life For the Second Embodiment AGM 100B, the range of the thickness of the separator expands to a range from approximately 1.5 mm to approximately 1.9 mm. Thus, in the Second Embodiment AGM 100B the thickness of the separator applied is approximately 0.1 mm to approximately 0.5 mm greater than the thickness of the separator applied to the Standard AGM battery, and / or other exemplified embodiments of an AGM battery. With that, as noted the increase in the thickness of the separator applied to the Second Embodiment AGM 100B over the Standard AGM battery, and / or other exemplified embodiments, of an AGM battery provides for, or at least contributes to, the unanticipated benefit of increased compression in the second value range between the plates of the Second Embodiment AGM 100B. This increased compression provides for, or at least contributes to, the unanticipated improved resultants, realized during experimentation, as illustrated in FIGs 9 - 13 A as compared to a standard or conventional lead acid battery, and / or exemplified embodiments of an AGM battery, of the same or similar battery size.TABLE 3Drawing of grid (120) for the Positive Plate (104) and Negative Plate (106) for reference ofHeight and Width Directions as to the Grid

[0087] The amount of overpaste applied in the Second Embodiment AGM is dependent upon a number of variables with at least one being the Ampere hour (Ah) rating of the respective battery'. With Ah understood to be the length of time a battery' can supple 1 Ampere of current. For example, positive overpaste may generally be applied at approximately 10 - 11 grams / Ah.. Alternatively, positive overpaste may be applied at amount less than 10 - 11 grams / h and / or greater than 10 - 11 grams / Ah. For example, negative overpaste may generally be applied at. approximately 8 - 9 grams / Ah. Alternatively, negative overpaste may be applied at amount less than 8 - 9 grams / Ah and / or greater than 8 - 9 grams / Ah. The amount of positive overpaste added was found to have an increased impact, on the cycle life of the respective battery, as compared to batteries of the same or similar size, than the amount of negative overpaste applied.Alternatively, the amount of negative overpaste added may have the same or an increased impact on the cycle life of the respective battery, as compared to batteries of the same or similar size, than the amount of positive overpaste applied. In the Second Embodiment AGM, the amount of electrolyte applied is approximately 8-9 mL / Ah, including in respective plates (104, 106).

[0088] In sum, in the Second Embodiment AGM 100B, the increased thickness of the positive plate 104 results from a combination of the described components of the Second Embodiment AGM 100B as compared to the components of the Standard AGM and / or other exemplified embodiments of an AGM battery. These components include but are not limited to the positive grid thickness and positive paste thickness. Further, the increased thickness of the negative plate 106 results from a combination of the described components of the Second Embodiment AGM 100B as compared to the components of the Standard AGM and / or other exemplified embodiments of an AGM battery. These components include but are not limited to the negative grid thickness and negative paste thickness.

[0089] The described aspects of the Second Embodiment AGM 100B, including but not limited to the increased paste thickness, results in an increase in energy, as compared to Standard AGM batteries, and / or other exemplified embodiments of an AGM battery, provided by the Second Embodiment AGM 100B. The increased energy is translated as an increase in Ah / Wh. The increased energy resulting from the described novel design results in an increase in the cycle life of the Second Embodiment AGM 100B as compared to Standard AGM batteries, and / or other exemplified embodiments of an AGM battery.

[0090] The increased energy and cycle life results from the increased compressing forces between the plates in the Second Embodiment AGM 100B as compared to the Standard AGM, and / or other exemplified embodiments of an AGM battery. The increased compressive forces in the battery 100B as a whole are due to the reduced space between the respective cells 110 resulting from the increased thickness of the cells, as compared to the Standard AGM, and / or other exemplified embodiments of an AGM battery With that, the reduction in space in a respective cell is due to the increased thickness of the plates (104, 106) within the cell as described and the increased thickness of the separator 108. Space is defined as a distance and / or area between the respective cells and / or respective adjacent plates (104, 106) and / or a respective plate (104,106) and an adjacent separator 108.[00911 Benefits of the described increased compressive forces resulting from the described design of the Second Embodiment AGM 100B include but are not limited to the following. Increased compressive forces as described maintain the position of plates (104, 106) against an adjacent separator 108. This maintenance of position contains or holds or limits the active material (paste) (124, 126) to the grids (120, 122). As noted, compression as provided by the design of the Second Embodiment AGM 100B will improve battery cycle life as compared to a Standard AGM battery, and / or other exemplified embodiments of an AGM battery. During battery cycling plates are "breathing". Paste volume increases with discharge of the battery and reduces when recharging the battery. The plate breathing would result in active material breaking and shedding from the plate. The tight construction reduces the risk of paste shedding and therefore improve batery cycle life. Compression reduces battery internal resistance. Lowered internal resistance is due to improved paste to grid electrical contact as compared to a Standard AGM battery, and / or other exemplified embodiments of an AGM battery. Compression as described as provided by the Second Embodiment AGM 100B improves battery resistance to mechanical vibrations and shocks. Compression as described as provided by the Second Embodiment AGM 100B ensures good electrolyte distribution in the cell, which improves battery performance and life.

[0092] With that a method of production of a battery or battery module containing at least one of the components of First Embodiment AGM 100 A and / or the Second Embodiment AGM 100B is di sclosed. The method incorporates adding the plates (104, 106) of the thicknessesdescribed to a battery cell of a Standard AGM battery with standard referencing the size of the battery, for example LN1 to LN 5. A separator 108 as described is applied between the respective positive and negative plates. An acid electrolyte is added to the cell.

[0093] With attention to FIGs. 9 A and 9B, the increased life cycle benefits of the Second Embodiment AGM 100B lead acid battery are illustrated. FIG. 9 A illustrates design testing over time of two batteries having a batten,? size, for example LN2 / H5, in the configuration of the Second Embodiment AGM 100B. Two sample batteries were tested, see the green and orange capacity bars, (152, 153). The batteries were tested at 17.5% DoD at 25 degrees Celsius for a predetermined amount of cycles or time or units. For example a number of cycles over approximately 64 to 65 weeks for the first batery, representative with the first battery capacity 152, and over approximately 52 weeks for the second battery, representative with the second batery capacity 153 FIG 9 A illustrates discharge testing, for example eight five discharge tests, is performed every unit, for example every cycle.

[0094] The previously described design of the First Embodiment AGM 100A and the Second Embodiment AGM 100B lead acid battery allows for substantial retention of the capacity of the battery over time. Specifically, over approximately a 47 unit time period, for example 47 weeks, the capacity of each tested battery is maintained substantially near 100 percent. Substantially being defined as within approximately 5% to 10% of a 100 percent capacity (1 2, 153) of the battery' 100B over time are proximate to the 100 percent capacity' of charge. In doing so, the voltage of the battery in FIG. 9 A is maintained substantially proximate to 12 volts over the unit, time, duration for each unit from the predischarge voltage 154 to the voltage of the 85thdischarge for that unit, segment of time. Which is substanti ally proximate to the voltage of the 851hdischarge at 30 minutes, 155. Illustrating the voltage is maintained over a cycle performance. With that, in the eAGM 100B increasing plate thickness of the plates, while reducing the number of plates within the battery cell, increases the plate capacity (Amp-hour) compared to an application applying more plates with a thinner plate thicknesses. On the eAGM design 100B. as stated the plate count, is reduced and the amount of paste per plate, grid, is increased as compared to the Standard AGM: battery?. As a result, the cyclability improves as compared to the Standard AGM, as evidenced by FIG 9 A. The plates of the eAGM battery 100B operate at a lower Depth of Discharge (DoD) as compared to the Standard AGM battery. For example, a Standard AGMtheoretical positive plate capacity is for example 13.6 Ah where the eAGM theoretical positive plate capacity is higher, for exampl el 6.0 Ah.

[0095] As illustrated in FIG. 9B, the application illustrated in FIG 9A is illustrated under verification testing. Under design testing for 33 cycles. The improved cycle time performance of the battery 100B is further illustrated. With the capacity (152, 153) of the batteries proximate to and between 80 and 100% over approximately 33 cycles. Further the voltage of the battery in FIG. 9B is maintained substantially proximate to 12 volts over the unit, time, duration for each unit from the predischarge voltage 154 to the voltage of the 85ihdischarge for that unit, segment of time. Which is substantially proximate to the voltage of the 85thdischarge at 30 minutes, 155. Illustrating the voltage is maintained over a cycle performance.

[0096] With attention to FIGs. 10 / X and 10B, the increased life cycle benefits of the Second Embodiment AGM 100B lead acid battery are illustrated. FIG. 10 illustrates design testing over time of two batteries having a size, for example LN2 / H5, and the configuration of the First Embodiment AGM 100 and the Second Embodiment AGM 100B lead acid battery. As noted, two sample batteries were tested, a first battery capacity 152 and a second battery capacity 153. The batteries being tested at 17.5% DoD at 60 degrees Celsius for a predetermined amount of time, for example 21 weeks (units). FIG. 10A illustrates discharge testing, is performed every unit, for example every week. The previously described design of the Second Embodiment. AGM 100B lead acid battery allows for retention of the capacity of the battery over time, see the progression of bars 152 and 153 over time. However, as compared to FIG 9, the graphical illustrations of the capacity of the battery in FIG. 10A evidence temperature influences the amount of capacity retained in the battery. Specifically, over an approximate 21 week period the capacity of the battery to recharge to a full voltage rating drops from over 100 percent at week zero to substantially sixty (60) percent at approximately week 21, see bars 152 and 153 at between 19 and 20 weeks Substantially being defined as within approximately 5%. Further, the pre-discharge voltage varied substantial between the 30thminute, 85thdischarge, 155, and 2.5 hours discharge voltage 154 over time due in part to the temperature as stated Specifically, the temperature increased as compared to the tests in FIGs. 9A and 9B. The same or similar result was evident in verification testing of the respective battery, see FIG 10B.

[0097] With attention to FIGs. 11 A and 1 IB, the increased life cycle benefits of the Second Embodiment AGM 100B lead acid battery are illustrated. FIG. 11A illustrates design testing over a number of units or time of two batteries having a size LN2. / H5 and the configuration of the Second Embodiment AGM 100B lead acid battery. As noted, two sample batteries were tested as evidenced by the voltage graph line, 158. The battery is being tested at 50% DoD for a range up to between approximately 570 cycles and approximately 600 cycles. More preferably, the batter) / may be tested within one or a combination of the example cycle ranges: approximately 450 - 470 cycles, 450 - 490 cycles, 450 - 500 cycles, 450 - 510 cycles, 450 -530 cycles, 450 - 550 cycles, 450 - 570 cycles, 450 - 590 cycles, 450 - 610 cycles, 470 - 490 cycles, 470 - 500 cycles, 470 - 510 cycles, 470 - 530 cycles, 470 - 550 cycles, 470 - 570 cycles, 470 - 590 cycles, 470 - 610 cycles, 490 - 500 cycles, 490 - 510 cycles, 490 - 530 cycles, 490 -550 cycles, 490 - 570 cycles, 490 - 590 cycles, 490 - 610 cycles, 500 - 510 cycles, 500 - 530 cycles, 500 - 550 cycles, 500 - 570 cycles, 500 - 590 cycles, 500 - 610 cycles, 510 - 530 cycles, 510 - 550 cycles, 510 - 570 cycles, 510 - 590 cycles, 510 -610 cycles, 530 - 550 cycles, 530 -570 cycles, 530 - 590 cycles, 530 - 610 cycles, 550 - 570 cycles, 550 - 590 cycles, 550 - 610 cycles, 550 - 570 cycles, 550 - 590 cycles, 550 - 610 cycles, 570 - 590 cycles, 570 - 610 cycles, and 590 - approximately 610 cycles. FIG. 11 illustrates that the ability of the battery to recharge to a voltage range of approximately 11.1 to approximately 12.0 volts over the cycle range, for example 570 cycles. More preferably, the voltage for the cycle or range is within one or a combination of the following example ranges' approximately 11 1 - 11 3 volts; 11.1 - 11.5 volts; 11.1 - I I.7 volts; 11.1 - 11.9 volts; 11.1 - 12.0 volts; 11.3 - 11.5 volts, 11.3 - 11.7 volts; 11.3 -11.9 volts; 11.3 - 120 volts, 11 5 - 11.7 volts, 11 5 - 11.9 volts; 11.5 - 12.0 volts; 11.7 - 11.9 volts; 11.7 - 12.0 volts; and 11.9 - approximately 12.0 volts. With that, when discharging to 50% DoD with the same current, the eAGM plate, the Second Embodiment AGM 100B lead acid battery, is cycling longer as compared to a Standard AGM plate, battery, and / or other exemplified embodiments of an AGM battery’, due to the shallower or lower DoD causing the eAGM plate to not work as hard as the Standard AGM plate, battery, and / or other exemplified embodiments of an AGM battery’. The same or similar result was evident in verification testing of the respective battery, see FIG. 1 IB.

[0098] With attention to FIGs. 12 A and 12B, it is observed sulfation may be a factor in the new AGM battery. With that, the two tested batteries retained voltage upon recharge overapproximately 250 to approximately 300 cycles FIG. 12A illustrates design testing of the respective batteries. Specifically, the batteries recharged to a voltage between approximately 11.0 volts and approximately 12.2 volts over the cycle range see the voltage line 1 8A. More preferably for the cycle or range, the batteries recharged to a voltage within one or a combination of the following example ranges: approximately 11.0 - 11.4 volts; 11.0 - 11.8 volts, 11.0 - 12.2 volts; 11.4 - 11 8 volts, 11 4 - 12.2 volts; 11.8 - approximately 122 volts. The same or similar result was evident in verification testing of the respective battery, see FIG. 12B. FIG. 13 provides a focused view of the design testing illustrated in FIG. 12A.

[0099] With attention to FIGs. I - 18, and specifically FIGs. 14 to 18, a battery' replacement system and method are described for replacement of a battery pursuant to the cyclability of the battery (100, 100 A, 100B). Cyclability is calculated a / d / or determined by the system based upon factors previously described. For example, the cyclability calculated is based upon a grid thickness of a grid comprising the battery. Alternatively, the cyclability calculated is based upon a paste thickness of a paste positioned on the grid. Alternatively, the cyclability calculated is based upon a separator thickness of a separator positioned in the battery. Alternatively, the cyclability calculated is based upon a combination of two or more of the grid thickness, the paste thickness and the separator thickness. Alternatively, the cyclability calculated is based upon a plate thickness of a plate, with the plate compri sing the grid and the paste. The replacement determination is directed towards cyclability as to the battery and determining the point at which the cyclability of the battery decreases below operational levels of the battery.

[0100] As illustrated in FIG. 14, a battery replacement system 220 and method 350 described for replacement of batteries, and development of a maintenance schedule, may incorporate various components in the determination of the replacement of the battery (100, 100 A, 100B) based upon the application applied, such as cyclability of the battery. The system 220 and method 350 incorporate the battery (100, 100A, 100B) or battery module. Such a battery may require a Wi-Fi connection to operate with the battery system 220 and to operate pursuant to the method 350 as described. Alternatively, such communication is provided via direct wiring.

[0101] In a first application of the system and method the battery (100, 100A, 100B) receives battery sensor data 315, see FIG. 15, for the battery (100, 100A, 100B) or battery module onwhich at least one sensor 165 is coupled and applied for monitoring. In a smart battery (100, 100A, 100B), at least one battery diagnostic 320, for example cyclability of the battery, may be computed from the battery sensor data 315, see FIG. 15, with the battery sensor data being for example number of cycles and / or battery voltage per cycle, for the respective battery (100, 100A, 100B) on which the sensors are coupled and applied for monitoring. Further, the battery replacement system 220 and method may further incorporate an OBDII or equivalent technology 335, in place of the former applications or accompanying either or both application. Specifically, the OBDII or equivalent technology 335 may be a dongle for attachment to the vehicle 102 or an external system. The OBDII gathers battery sensor data 315, battery diagnostics 320, battery tester data 325, and vehicle diagnostics and telematics data 330. Further, the OBDII or equivalent technology 335 provides for data storage of at least one of battery sensor data 315, battery diagnostics 320, and vehicle diagnostics and telematic data, 330. Each application, the sensor 165, smart batter battery (100, 100A, 100B) or OBDII or equivalent technology 335 provides for a Bluetooth or equivalent connection to the cloud based aspect of the system 257.

[0102] The battery system containing the battery (100, 100A, 100B), using a sensor, applies testing and analysis of the battery, similar to that applied by the battery system or OBDII or equivalent technology 335, using the ECU. The testing and analysis applied includes transmission of at least one of battery sensor data 315, transmission of battery diagnostic data 320 and transmission of vehicle diagnostics or telematic data 330 to a cloud based aspect of the system 257. Such a connection to the cloud base system 257 is provided through an electrical link with the battery provider gateway device or a third-party gateway device. The cloud based aspect of the system 257 calculates and communicates a battery state marker 340 through at least one of a battery provider mobile application, web portal, and fleet ecosystem to at least one of the following entities 345: the vehicle 102 in which the battery(s) reside; the driver of the vehicle 102; the mechanic of the vehicle 102; a vendor of the battery module and / or other components of the vehicle 102; and a fleet 225 administrator managing the vehicle 102 in which the battery 100 resides. The fleet 225 may be an automotive fleet or a truck fleet. The fleet may have a size, which is the number of vehicles, or large as understood by those in the art or medium by those in the art, or small by those in the art. Alternatively, the entity 345 may be an individual user of the vehicle 102.

[0103] As illustrated in FIGS. 1 - 18, specifically FIGs. 15 - 18, the method 350 of applying the battery replacement system is described. The method 350 of application of the battery replacement system 220 which both alerts drivers and fleets to replace the battery before a failure event occurs through an API, Mobile App, or Portal Dashboard and develops maintenance scheduling is further described. This method 350 has a starting location or position 355. Step 360, the battery sensor 165, the battery module, and / or the OBDII 335 acquires the battery sensor data 315 as previously described as well as the battery tester data 325, and the electronic control unit (ECU) of the vehicle 102 or external system senses and acquires vehicle parameters. As noted, the battery sensor data 315 includes but is not exclusive to cycles of the battery, voltage, including voltage(s) per cycle, capacitance, and current of the respective battery. The battery tester data 325 includes data as to the condition of the testing unit of the battery whether incorporated in the smart battery module or extrinsic with respect to the battery module 100A. As to the ECU, the vehicle parameters include but are not exclusive to vehicle error codes, vehicle recall summary, Global Positioning System (GPS) data, speed of the vehicle 10, idle and / or start stop time of the vehicle 10, and tire pressure for the tires associated with and attached to the vehicle 10.

[0104] Step 365, the battery module and / or battery (100, 100A, 100B) then applies at least one of the battery sensor data 315 and the battery tester data 325 from battery module and / or battery (100, 100 A, 100B) for computation of battery diagnostics 320. The computation may be performed by one or a combination of a smart battery, computational device / battery system, or server 240 electrically coupled to the battery module and / or battery (100, 100A, 100B), or the OBDII 335. As noted, such battery diagnostics include but are exclusive to battery SOH, battery state of charge (SOC), battery state of function (SOF) and the cyclability of the battery. The ECU concurrently or proximate in time to the calculations of the battery diagnostics 320 computes the vehicle diagnostics and the telematics data 330 applying the vehicle parameters from the vehicle 102 or external system. Such vehicle diagnostics and telematics data 330 include but are not exclusive to vehicle speed, vehicle acceleration, vehicle engine and engine component data, vehicle transmission and transmission component data, vehicle brake and braking data, vehicle exhaust efficiency and component data, and data as to wear components on the vehicle. The ECLTmay acquire the following vehicle parameters as well exclusive to vehicle error codes, vehicle recall summary, Global Positioning System (GPS) data, speed of the vehicle 102, idle and / orstart stop time of the vehicle 102, and tire pressure for the tires associated with and attached to the vehicle 102.

[0105] Step 370, applying a combination of at least one of the ECU, the battery module and / or battery (100, 100A, 100B), and the OBDII 335, environmental parameters are retrieved. Environmental parameters includes but are not exclusive to location of the vehicle 102, brand or make of the vehicle, model of the vehicle, external temperatures, driving conditions (for example but not exclusive to whether an external surface on which the vehicle 102 operates has a topography that appear to be continuous or does the topography appear differentiating in height or whether the surface has a consistency promoting attraction of the wheels of the vehicle 102 or sliding of the wheels of the vehicle 102 against the external surface). It is noted environmental parameters, whether a portion of such or all such environmental parameters, can be captured by and or stored at the cloud based aspect of the system 257.

[0106] Step 375, at least one of the battery sensor data 315 and the battery tester data 325 of the battery module and / or battery (100, 100A, 100B) are transferred to the OBDII or equivalent technology 335 via a remote connection. In doing so, the battery module and / or battery (100, 100A, 100B) is electrically coupled to the OBDII or equivalent technology 335. It is observed a battery coupled to at least one sensor may be coupled to a communication device to provide for communication with the OBDII or equivalent technology 335. At least one of the vehicle parameters and the vehicle diagnostics and telematics data 330, are transferred to the OBDII or equivalent technology 335. In doing so, the vehicle 102 is electrically coupled to the OBDII 335 via remote connection or hardwire connection. The OBDII or equivalent technology 335 is electrically coupled to the cloud based aspect of the system 257, FIG. 13, via a Bluetooth connection between the OBDII or equivalent technology 335 and a remote device 245.Alternatively, a battery module and / or battery (100, 100A, 100B) may transfer at least one of the battery sensor data 315, the battery tester data 325, the vehicle parameters, the vehicle diagnostics, and telematics data 330 to the remote device 245, concurrent with, consecutive to, or in place of the OBDII 335. The remote device is electrically coupled to the cloud based aspect of the system 257, FIG. 13. The battery sensor data 315, the battery tester data 325, the vehicle parameters, and the vehicle diagnostics and telematics data 330 are electrically transferred from the remoted device to the cloud based aspect of the system 257 or directly from the batterymodule and / or battery (100, 100 A, 100B) and / or OBDII 335 to the cloud based aspect of the system 257.

[0107] Step 380, servers 240 and processors 242 providing for the cloud base system 257 further calculate data analytics. The cloud based aspect of the system 257 may recalculate all or some of such battery diagnostics 320 and vehicle diagnostics and telematics data 330 calculated by the battery module and / or battery (100, 100A, 100B) and / or the ECU, which includes the cyclability of the battery module and / or battery (100, 100A, 100B). Alternatively, the cloud based aspect of the system 257 may calculate all or some of battery diagnostics 320 and vehicle diagnostics and telematics data 330 not calculated by the battery module and / or battery (100, 100A, 100B) and / or the ECU, which includes the cyclability of the battery module and / or battery (100, 100A, 100B).

[0108] Step 385, The cloud based aspect of the system 257 monitors the battery diagnostics 320 and vehicle diagnostics and telematics data 330. In doing so, the cloud based aspect of the system 257 calculates at least one estimation for the health of the battery module and / or battery (100, 100A, 100B) based upon at least the cyclability of the battery module and / or battery (100, 100A, 100B). The health of the battery module and / or battery (100, 100A, 100B) is evidenced based upon the internal chemistry of the battery, the internal components of the battery, the vehicle 102 in or upon which the battery module and / or battery (100, 100A, 100B) is applied, the environmental conditions upon which the battery module and / or battery (100, 100 A, 100B) is applied, and the cyclability of the battery. Environmental conditions being the road surface conditions, as previously discussed, and the external climate or weather. Thus step 385 provides battery health services and predictive review as to the replacement of the battery module and / or battery (100, 100A, 100B).

[0109] Step 390, applying the calculation of the at least one estimation for the health of the battery module and / or battery (100, 100A, 100B) and the predictive review as to the replacement of the battery module and / or battery (100, 100A, 100B), the cloud based aspect of the system 257 applies a battery state marker 340 to the calculation of the at least one estimation for the health of battery module and / or battery (100, 100A, 100B) and the predictive review as to thereplacement of the battery module and / or battery (100, 100 A, 100B). The battery state marker 340 is at least one of the following.-GREEN: the calculation of the at least one estimation for the health of the battery module and / or battery (100, 100A, 100B) indicates that based at least in part on the cyclability of such the battery module and / or battery (100, 100A, 100B) is in a condition of health such that the battery module and / or battery (100, 100A, 100B) neither requires monitoring (wherein in monitoring is performed by the system) nor needs to be replaced prior to a next scheduled check in which the method 350 is applied.-YELLOW: the calculation of the at least one estimation for the health of the battery module and / or battery (100, 100A, 100B) indicates that based at least in part on the cyclability of such the battery module and / or battery (100, 100A, 100B) that the battery module and / or battery (100, 100A, 100B) is in a condition of health such that the battery module and / or battery (100, 100 A, 100B) requires monitoring (wherein in monitoring is performed by the system) prior to and up to the next scheduled check in which the method 350 is applied. Such monitoring includes repeating steps 360 to 390 for the respective battery. Yellow further indicates the battery may need to be replaced if the calculated condition of health such that the that based at least in part on the cyclability of such the battery module and / or battery (100, 100A, 100B) advances beyond a predetermined threshold in which the battery module and / or battery (100, 100 A, 100B) should be replaced.-RED: the calculation of the at least one estimation for the health of the battery module and / or battery (100, 100A, 100B) indicates that based at least in part on the cyclability of such the battery module and / or battery (100, 100A, 100B) that the battery module and / or battery (100, 100A, 100B) is in a condition of health such that the battery module and / or battery (100, 100 A, 100B) requires replacement prior to next scheduled check in which the method 350 is applied.

[0110] Step 395, the cloud based aspect of the system 257 communicates the battery state marker 340. This communication of step 395 is provided through at least one of a battery provider mobile application, web portal, and fleet ecosystem. Where any two or three of the battery provider mobile application, web portal, and fleet ecosystem may be working inconjunction and or cooperation with one another to provide for the communication of step 395. Such communication may be provided on the remote device 245.

[0111] Step 400, the cloud based aspect of the system 257 communicates the battery state marker 340 to at least one of the following entities 345: the vehicle 102 in which the battery module and / or battery (100, 100A, 100B) reside; the driver of the vehicle 102; the mechanic of the vehicle 102; a vendor of the battery module and / or battery (100, 100A, 100B) and / or other components of the vehicle 102; and a fleet administrator managing the vehicle 102 in which the battery module and / or battery (100, 100A, 100B) resides. In doing so, the battery module and / or battery (100, 100A, 100B), the battery module and / or battery (100, 100A, 100B) or ECU may lower or raise operational output of the respective battery and / or vehicle 102 based upon the calculation of the at least one estimation for the health of the battery module and / or battery (100, 100A, 100B) and the battery state marker 340. As a result, the operation of the battery module and / or battery (100, 100A, 100B) may be modified in order to address and / or accommodate for the health of the battery module and / or battery (100, 100A, 100B) due at least in part to the cyclability of the battery module and / or battery (100, 100A, 100B), conditions of the vehicle 102, and the external parameters. With that, the battery module and / or battery (100, 100A, 100B) and / or the ECU may perform one of the following.-Determine the battery module and / or battery (100, 100 A, 100B) is in a condition of health such that the battery neither requires monitoring nor needs to be replaced prior to the next scheduled check in which the method 350 is applied - Green indication.-Determine the battery module and / or battery (100, 100A, 100B) requires monitoring prior to and up to the next scheduled check in which the method 350 is applied. Such monitoring includes repeating steps 360 to 390 for the respective battery. Yellow further indicates the battery may need to be replaced if the calculated condition of health such that the battery module and / or battery (100, 100A, 100B) advances beyond a predetermined threshold in which a battery module and / or battery (100, 100A, 100B) should be replaced - Yellow indication.-Determine the battery module and / or battery (100, 100A, 100B) is in a condition of health such that the battery module and / or battery (100, 100A, 100B) requires replacement prior to next scheduled check in which the method 350 is applied - Red indication.

[0112] Step 405, the method 350 is completed. The method 350 is repeated at a predetermined interval throughout the operation of the battery module and / or battery (100, 100A, 100B) in the vehicle 102. Further, as described, the method 350 is repeated where a Yellow indication is provided by the cloud based aspect of the system 257 for the respective battery module and / or battery (100, 100A, 100B) which received the Yellow indication until the next predetermined interval application of the method 350 or such battery, or batteries, is removed from the vehicle 102.

[0113] With reference to FIGs. 1 - 18, the system 220 is further described. The system 220, which applies the method 350, as described may comprise three general components: 1) the battery module and / or battery (100, 100A, 100B) whether singularly or in a fleet; 2) connected infrastructure and operations 410; and 3) digital service offerings 415. It is understood the components as described may be combined into less than three components. It is understood the components as described may require collectively more than three components. The batteries battery module and / or battery (100, 100A, 100B) and fleets of batteries are as previously described. The connected infrastructure and operations 410 comprise the following: the communications module; cloud based aspect of the system 257, which may incorporate at least one processor and / or at least one database 242; and battery health prediction service 415 and battery as a service 417.

[0114] As previously described, the communications module provides for the communication of data information 375 to the cloud based aspect of the system 257. The communications module may comprise the communications module 160 of the battery system, containing the battery module and / or battery (100, 100A, 100B), or other aspect of the battery system, or an equivalent component in the battery module and / or battery (100, 100 A, 100B), and / or the OBDII or equivalent technology 335. The connected infrastructure and operations 410 further comprise a network and / or electrical communications components for electrical coupling to the cloud based aspect of the system 257 of the connected infrastructure and operations 410. It is understood a mobile device or dashboard 245 may receive the communication of data information 375 and transfer such communication to the cloud based aspect of the system 257. Further, the connected infrastructure and operations 410 includes the cloud based aspect of thesystem 257, which may incorporate the network and / or at least one processor and / or at least one database 242.

[0115] As previously stated, the cloud based aspects of the system 257, including the server, computes and determines for the battery module and / or battery (100, 100A, 100B) and / or battery fleet at least one of the battery health, the cyclability of the battery, the battery state marker 340, the battery health prediction, and a scheduling for service of the battery or fleet of batteries. The cloud based aspect of the system 257 then transfers at least one of the battery health, the cyclability of the battery, the battery state marker 340, the battery health prediction, and a scheduling for service of the battery or fleet of batteries to the mobile device or dashboard 245 for viewing by an operator. Such information may also be transferred through the communication module to the battery module and / or battery (100, 100A, 100B) and / or battery fleet to provide for optimization of a performance of at least one battery module and / or battery (100, 100A, 100B) and / or battery fleet. Such a system 220 and method 350 provides for the digital service offerings 415 and battery service 417 which calculates among other things the health of the battery module and / or battery (100, 100A, 100B) and / or battery fleet, and components of the vehicle 102 in which the battery resides, and provides for a service schedule, a calculation of the duration of time before replacement of the battery and / or fleet of batteries, and / or potential options for such replacement such as location and whether to purchase or exchange, etc.

[0116] As further illustrated in FIGs. 1 - 18, an illustration of the method 350 as applied to the system 220 is further provided. In method steps 360 to 370, the battery system, the battery module, battery (100, 100A, 100B), and / or the OBDII 335 receive the battery sensor data 315, the battery tester data 325, and / or the telematics and vehicle parameter data 330, with each incorporating at least one sensor 165. At least one of the battery system, the battery module, battery (100, 100A, 100B), and / or the OBDII 335 provides for calculations of the battery diagnostics 320 (including but not limited to SOC, SOH, and / or SOF of the battery) and other parameter data as previously described. Additionally, each of the at least one of the battery system, the battery module, battery (100, 100A, 100B), and / or the OBDII 335 may fulfill the functions as a battery management system (BMS) for managing the respective battery or fleet of batteries.

[0117] In doing so, computing on a component level is achieved for at least one battery diagnostic 320 is computed for a battery module and / or battery (100, 100A, 100B) and / or battery fleet. Further, system level computing of battery diagnostics 320 are performed for at least one battery in a system, for example a vehicle 102. Finally, vehicle level computation of at least one of the vehicle diagnostics and the telematics data 330 is performed for the particular system, for example a vehicle 102. In doing so, the OBDII or equivalent technology 335 may provide for the above stated management of a grouping of batteries in which a particular battery module and / or battery (100, 100A, 100B) is communicatively coupled and / or management of the vehicle 102 in which the battery module and / or battery (100, 100A, 100B) resides or the vehicles components of such vehicle 102. In method step 375, such information from the battery module and / or battery (100, 100A, 100B) and / or the OBDII or equivalent technology 335 maybe electrically transferred to the cloud based aspect of the system 257. In method steps 380-400, the cloud based aspect of the system 257 provides for artificial intelligence and machine learning integrated with internal programs of the cloud based aspect of the system 257 to provide for calculations of at least one of the battery health, the cyclability of the battery, the battery state marker 340, the battery health prediction, and a scheduling for service of the battery or fleet of batteries. Notably, the calculation of at least one of the battery health and cyclability of the battery may result calculation of the battery state marker 340. As stated, the system 220 may apply historical data as described in the calculations of battery health and the battery state marker 340. At least one mobile device and dashboard 245 may integrate communication between the battery or fleet of batteries and the cloud based aspect of the system 257 to provide for the digital service offerings 415 and battery service 417. The digital service offerings 415 and battery service 417 may provide for vehicle OEM software, automotive manufacture software, and / or automotive fleet software where a fleet is a grouping of cars applied for a similar purpose. Such software singularly or in combination provides for fleet energy management, BIP, and / or Battery-aaS.

[0118] The combination of the system 220 and method 350 provides for an umbrella relationship of such. The battery module and / or battery (100, 100A, 100B), with a sensor 165, communicates data to the cloud based aspect of the system 257. This communication may be performed through an OBDII or equivalent technology 335. The battery module and / or battery (100, 100A, 100B) may be systematically and methodically in electrical communication with thevehicle diagnostics. The cloud based aspect of the system 257, with application of at least one server 240 and at least one database 242, calculates a maintenance planner for the battery module and / or battery (100, 100A, 100B) or grouping of batteries pursuant to the battery data and OBDII or equivalent technology 335 data, which results in the battery state marker 340. This calculation may be performed applying historical battery data saved in the database and server for batteries of a same or similar type, same or similar size, same or similar model, and / or same or similar make. The maintenance plan is communicated through a mobile application and / or a web maintenance portal such that the automotive customer, truck operator, and / or fleet manager may manage the battery module and / or battery (100, 100A, 100B) or grouping of batteries in order to determine when a battery should be replaced.

[0119] Advantageously, the batten,? disclosed herein provides for the opportunity to substantially maintain or increase the cycle life of the battery. In doing so, a positive plate and a negative plate are removed from at least one cell of the battery. Further, additional paste is added to at least one plate of the battery’. With that, a separator applied has an increased thickness as compared to the separator of a Standard AGM battery. As a result of the described improvements to the AGM battery, an increased tightness arises in the at least one cell of the battery'. This increased tightness results in an increased cycle life of the battery Further, a method of replacing a battety (100, 100 A, 100B) and / or battery module and / or grouping of such is directed towards the novel cyclability increase and determining the point at which the cyclability of the battery decreases below operational levels of the battery?.

[0120] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described arid claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0121] It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

[0122] For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary' in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature

[0123] It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

[0124] While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and / or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention.Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and / or substantial equivalents.

[0125] The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

Claims

CLAIMSWhat is claimed is:

1. A lead acid battery, comprising:a battery case;a cell positioned in the battery case having one or more grids;the one or more grids having a first thickness;a paste positioned on at least one of the one or more grids, with the paste having a second thickness; anda sum of the first thickness and the second thickness being a compensation of a space within the cell, with the lead acid battery having an increased cycle life.

2. The lead acid battery of claim 1, wherein the compensation provides for one or more of a reduced internal resistance of the lead acid battery and an increased electrical contact, with increased electrical contact being between the grid and the paste.

3. The lead acid battery of claims 1 or 2, wherein the increase of the cycle life is to approximately 600 cycles.

4. The lead acid battery of one of claims 1 to 3, wherein the grid is one of a positive grid and a negative grid.

5. The lead acid battery of one of claims 1 to 4, wherein the first thickness is from approximately 1.012 mm to approximately 1.088 mm for the positive grid, and the first thickness is from approximately 0.762 mm to approximately 0.838 mm for the negative grid.

6. The lead acid battery of one of claims 1 to 5, wherein the paste is one of a positive paste and a negative paste, with the positive paste having a weight of approximately 120 grams to approximately 143 grams, with the negative paste having a weight of approximately 95 grams to approximately 110 grams.

7. The lead acid battery of one of claims 1 to 6, wherein the second thickness is from approximately 0.72 mm to approximately 0.87 mm for the negative paste, and the second thickness is from approximately 1.086 mm to approximately 1.42 mm for the positive paste.

8. The lead acid battery of one of claims 1 to 7, further comprising a separator, with the separator having a third thickness, with the third thickness being from approximately 1.5 mm to approximately 1.9 mm, with a combination of the first thickness and the second thickness and third thickness being a compensation of a space within the cell, with the lead acid battery having an increased cycle life.

9. The lead acid battery of one of claims 1 to 8, wherein a plate comprises the grid and the paste in combination, with a plate being one of a positive plate and a negative plate, with the plate having a fourth thickness, with the positive plate having the fourth thickness from approximately 2.096 mm to approximately 2.51 mm, and the negative plate having the fourth thickness from approximately 1.48 mm to approximately 1.72 mm.

10. The lead acid battery of one of claims 1 to 9, wherein a battery change is maintained above 11.5 volts in the lead acid battery at 50% DoD (Depth of Charge) for approximately 530 charge / discharge cycles.

11. The lead acid battery of one of claims 1 to 10, further comprising a 500 to 900 gram reduction in metal weight.

12. The lead acid battery of one of claims 1 to 11, wherein the battery case is of a DIN Group Size H5.

13. The lead acid battery of any one of claims 1 to 12, further comprising a process to manufacture the lead acid battery of any one of claims 1 to 12, the process comprising:applying a predetermined amount of paste to the positive grid and the negative grid, with the paste having the first thickness and each of the positive grid and the negative grid having the second thickness;positioning a plurality of each of the positive grid and the negative grid in the cell; interweaving the separator between the positive grid and the negative grid in the battery cell;applying an electrolyte; andfilling a void in the battery with the first thickness and the second thickness, with the filling the void increasing the cycle life of the battery.

14. The lead acid battery of any one of claims 1 to 13, further comprising providing for a reduced internal resistance of the lead acid battery and having an increased electrical contact.

15. The lead acid battery of any one of claims 1 to 14, further comprising increasing electrical contact between the paste and the grid.

16. A battery replacement system based on a cyclability of a battery, the system comprising: the battery comprising:a sensor to sense a parameter of a battery; anda communication to a processor and memory operatively coupled to the sensor; a server in communication with the battery for receipt of a battery information and the sensed parameter; andone of the battery and the server having a cyclability calculation and a replacement determination for the battery based on the cyclability calculation, with the cyclability calculation being based on a thickness of one or more of a grid, a paste, and a separator of the battery.

17. The system of claim 16, the memory includes further instructions executable by the processor.

18. The system of claims 16 or 17, wherein the further instructions being based at least in part on the cyclability of the battery.

19. The system of one of claims 16 to 18, wherein the server comprises a database.

20. The system of one of claims 16 to 19, wherein the database comprises an historical battery data as to cyclability.

21. The system of one of claims 16 to 20, wherein the cyclability calculated is based upon a grid thickness of a grid comprising the battery.

22. The system of one of claims 16 to 21, wherein the cyclability calculated is based upon a paste thickness of a paste positioned on the grid.

23. The system of one of claims 16 to 22, wherein the cyclability calculated is based upon a separator thickness of a separator positioned in the battery.

24. The system of one of claims 16 to 23, wherein the cyclability calculated is based upon a combination of two or more of the grid thickness, the paste thickness and the separator thickness.

25. The system of one of claims 16 to 24, wherein the cyclability calculated is based upon a plate thickness of a plate, with the plate comprising the grid and the paste.

26. The system of one of claims 16 to 25, wherein the replacement determination is directed towards cyclability as to the battery, with the cyclability of the battery decreases below operational levels of the battery.

27. The system of one of claims 16 to 26, wherein the cyclability calculated is applied to determine a health of the battery.

28. The system of one of claims 16 to 27, wherein a calculation of time before replacement of the battery is calculated based upon one or more of the battery health and the cyclability.

29. The system of one of claims 16 to 28, wherein a calculation of a location for replacement is calculated based upon one or more of the battery health and the cyclability.

30. The system of one of claims 16 to 29 having a method for communicating replacement determinations for a vehicle battery based upon application of the system, the method comprising:applying the system of one of claims 16 to 29;receiving information from a battery;determining a cyclability data for the battery based upon received information; calculating a life estimation for the battery based upon the received information; and communicating a replacement determination based on a comparison based upon one of the life estimation and the cyclability data.

31. A lead acid battery, comprising:a battery case;a cell positioned in the battery case having a positive plate and a negative plate, with one or more plates of the positive plate and the negative plate having a first thickness;at least one of the positive plate and the negative plate comprising a paste;a separator interweaved between the positive plate and the negative plate, with the separator having a second thickness; andthe first thickness and the second thickness being a compensation of a space within the cell for an increased cycle life.

32. The lead acid battery of claim 31, wherein the increase of the cycle life is to approximately 600 cycles.

33. The lead acid battery of claims 31 or 32, wherein the plate comprises a paste with the paste being one of a positive paste and a negative paste, with the positive plate having a weight of approximately 120 grams to approximately 143 grams and the negative paste having a weight of approximately 95 grams to approximately 110 grams.

34. The lead acid battery of one of claims 31 to 33, wherein the second thickness is in a range from approximately 1.5 mm to approximately 1.9 mm.

35. The lead acid battery of one of claims 31 to 34, wherein the positive plate having the first thickness from approximately 2.096 mm to approximately 2.51 mm, and the negative plate having the first thickness from approximately 1.48 mm to approximately 1.72 mm.