Quick welding storage battery busbar structure and manufacturing process

Abstract

The invention provides a rapid welding storage battery busbar structure and a manufacturing process, and relates to the field of lead-acid storage batteries, the rapid welding storage battery busbar structure comprises a plate group, a non-lead metal strip, a non-lead metal positive terminal and a non-lead metal negative terminal, the non-lead metal strip and the non-lead metal positive terminal are made of metal or alloy with the conductivity higher than that of lead, and the non-lead metal strip is electrified to be rapidly heated and is welded with the cluster group tab and the non-lead metal positive and negative terminals at the same time, and after being firmly welded, the non-lead metal strip is cut to form a busbar and is sealed by glue. According to the lead-acid storage battery, metal with the conductivity higher than that of lead is adopted to replace lead and lead-based alloy to serve as the busbar of the lead-acid storage battery, the gravimetric specific energy of the lead-acid storage battery is improved, the material cost of the lead-acid storage battery is reduced, the mode of welding by heating the metal strip is adopted to replace the technology of manufacturing the busbar through hot melting of lead, the production efficiency is improved, and the energy consumption is reduced; meanwhile, clean production is achieved, and lead pollution in the traditional production process is avoided.

Description

Technical Field

[0001] The invention relates to the field of lead-acid batteries, and in particular to a fast-welding battery busbar structure and a manufacturing process. Background Art

[0002] Most lead-acid batteries are 12V per battery, which is composed of 6 cells inside. Each cell consists of a positive and negative plate group. The positive and negative plate groups need to be welded together by parallel connection. The collectors after welding are collectively called bus. In order to ensure the service life and high-rate discharge characteristics of lead-acid batteries, the commonly used bus alloy is mainly welded by hot melting with lead-tin alloy. Due to the high resistivity of lead, the bus design often consumes more lead to ensure the cross-sectional area.

[0003] In the early days, traditional lead-acid battery busbars were produced by welding (fusing) the positive and negative electrode groups of the packed electrode groups together with lead and lead alloys through oxygen-acetylene hot melt mode to form a cluster. The resulting current collector is the busbar. After 2010, the production was gradually switched to machine casting and welding.

[0004] Patent document CN102891278A discloses a method for casting and welding a lead-acid battery busbar, wherein the battery plate is perpendicular to the ground in the width direction, and the tabs on the same side are sequentially placed in the tooth grooves of the busbar fixture; the lead supply pump injects the molten lead in the lead melting pot into the busbar fixture, and keeps it warm, and then the tabs are fused and welded sequentially with a heating rod. Although this invention replaces manual flame welding, it still uses a high-temperature furnace to melt the lead and heat the mold to weld the tabs. The production process cannot solve the environmental pollution of lead smoke and dust and the generation of lead slag, and does not belong to green production technology.

[0005] Patent document CN106549183A and patent document CN205752350U both proposed using copper or other non-lead metal materials as busbars, and connecting them to the tabs by mechanical fixing. Patent document CN110767869A also proposed a similar welding-free solution, which greatly improved production efficiency and reduced energy consumption and environmental pollution of traditional welding. However, in actual production, due to oxidation of the tabs and misalignment of the tabs, the actual production efficiency could not meet expectations. At the same time, due to poor reliability of mechanical connection and large interface resistance, the battery cannot support high current charging and discharging, affecting normal use, and is not used in production. Summary of the invention

[0006] The object of the present invention is to provide a structure for quickly welding battery busbars, which uses a metal with a higher conductivity than lead to replace lead as the material of the busbar, and adopts ultrasonic welding or busbar energized heating welding process. Compared with the traditional lead casting welding busbar process, it not only greatly improves the production efficiency, reduces energy consumption, but also realizes clean production, and avoids environmental pollution caused by lead fumes, lead dust, and lead slag generated during the traditional production process due to lead melting.

[0007] To achieve the above object, the present invention adopts the following technical solutions:

[0008] The present invention provides a manufacturing process for quickly welding battery busbars, including the following steps:

[0009] S1. Provide a pole group, a non-lead metal strip, non-lead metal positive and negative terminals, and a battery case. The pole group has pole ears; install the pole group in the battery case, and assemble the non-lead metal strip with the non-lead metal positive and negative terminals and the pole ears, so that the non-lead metal strip wraps around the top of the pole ears;

[0010] S2. Energize the non-lead metal strip to raise its temperature. After the non-lead metal positive and negative terminals and the pole ears come into contact with the non-lead metal strip, they melt, and the non-lead metal positive and negative terminals, the pole ears and the non-lead metal strip are welded together simultaneously;

[0011] S3. Take out the pole group, the non-lead metal positive and negative terminals and the non-lead metal strip obtained in step S2 from the battery case, and cut off the redundant part of the non-lead metal strip, thus forming a busbar;

[0012] S4. Install the pole group connected with the busbar obtained in step S3 in the battery case, seal it with glue, and cover it;

[0013] S5. After covering, cut the corresponding position on the top of the battery cover to expose the battery positive and negative terminals.

[0014] Wherein, in one embodiment, before assembling the non-lead metal strip with the pole ears in step S1, it further includes: cutting and shaping the pole ears.

[0015] Wherein, in one embodiment, the non-lead metal strip and the non-lead metal positive and negative terminals are made of a metal with a higher conductivity than lead.

[0016] Wherein, in one embodiment, the non-lead metal strip and the non-lead metal positive and negative terminals are made of one of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or their alloys.

[0017] In one embodiment, in step S2, the current passing through a single non-lead metal strip is 300-3000A, and the power-on time is 0.5-10s; and / or,

[0018] There are at least two non-lead metal strips. In step S2, after all the non-lead metal strips are connected in parallel, all the non-lead metal strips are energized at the same time.

[0019] The present invention also provides a fast-welded battery bus structure, characterized in that the battery bus structure is manufactured using the manufacturing process for the fast-welded battery bus as described in any of the preceding items.

[0020] In one embodiment, the non-lead metal strip is in a concave shape and surrounds the top of the pole ear.

[0021] In one embodiment, the non-lead metal strip is in a "concave" shape, surrounding the top of the pole ear, and the inner plane of the non-lead metal strip is provided with convex ridges.

[0022] In one embodiment, the non-lead metal strip is in the shape of a flat sheet; or, the non-lead metal strip is in the shape of a flat sheet with convex ridges.

[0023] In one embodiment, the non-lead metal positive and negative terminals are cylindrical structures with a single-side opening and a threaded interior.

[0024] The technical solution provided by the present invention has the following technical effects:

[0025] The present invention adopts metal with higher conductivity than lead to replace lead and lead-based alloy as busbars and terminals of lead-acid batteries, thereby improving the weight-to-energy ratio of lead-acid batteries and reducing the material cost of lead-acid batteries. Ultrasonic welding or metal strip heating welding is adopted to replace the hot-melt manufacturing method, thereby improving production efficiency, reducing energy consumption, and realizing clean production, thereby avoiding environmental pollution caused by lead smoke, lead dust and lead slag generated by lead melting in the traditional production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the process flow of an embodiment of the present invention;

[0027] Figure 2 A three-dimensional diagram of a semi-finished battery after welding and cutting to form a series busbar between cells according to an embodiment of the present invention;

[0028] Figure 3 It is a schematic diagram of assembling the non-lead metal strip and the electrode group and the electrode ear according to an embodiment of the present invention;

[0029] Figure 4A three-dimensional diagram of a semi-finished battery after welding and cutting to form a series busbar between cells according to another embodiment of the present invention;

[0030] Figure 5 It is a schematic diagram of assembling the non-lead metal strip and the electrode group and the electrode ear according to another embodiment of the present invention;

[0031] Figure 6 This is a schematic diagram of the operation of the metal strip heating welding scheme according to an embodiment of the present invention;

[0032] Figure 7 This is a schematic diagram of the operation of the ultrasonic welding scheme according to an embodiment of the present invention;

[0033] Figure 8 This is a schematic diagram of a finished product of a fast-welded busbar battery according to an embodiment of the present invention; DETAILED DESCRIPTION

[0034] To further illustrate the various embodiments, the present invention provides drawings. These drawings are part of the disclosure of the present invention, which are mainly used to illustrate the embodiments and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these contents, a person of ordinary skill in the art should be able to understand other possible implementations and advantages of the present invention. The components in the figures are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0035] The present invention will now be further described with reference to the accompanying drawings and specific implementation methods.

[0036] Reference Figure 1-Figure 8 The present embodiment provides a fast welding battery busbar structure, including a pole group 10, a positive pole terminal 20, a negative pole terminal 30 and a busbar 40. Each pole group 10 has a positive pole ear 11, a negative pole ear 12 and a separator 13. The pole group 10 can be provided with a plurality of Figure 1 In this embodiment, six pole groups 10 are provided. However, in other embodiments, more or fewer pole groups 10 may be provided, for example, at least one pole group 10 may be provided.

[0037] Reference Figure 2 , Figure 8 ,in Figure 8 The finished product of the storage battery 1 is shown. The storage battery 1 further includes a battery slot 50. The battery slot 50 can be used to install the electrode group 10.

[0038] Reference Figure 2-Figure 8 , focus on Figure 2 , Figure 3The busbar 40 can be formed by a non-lead metal strip 4. The non-lead metal strip 4 is made of a metal with a higher conductivity than lead. For example, the non-lead metal strip 4 is made of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or an alloy thereof. The positive terminal 20 and the negative terminal 30 can also be made of a non-lead metal.

[0039] Reference Figure 6 , the non-lead metal strip 4 is energized and quickly heated while being welded with the pole ears 11, 12 of the pole group 10 and the non-lead metal positive and negative terminals 20, 30, and after being firmly welded, it is cut to form a busbar 40. When the metal strip is energized and quickly heated welding process is used, the current passing through a single metal strip is 300-3000A, and the energization time is 0.5-10s.

[0040] Of course, in some other embodiments, such as Figure 7 As shown, an ultrasonic pressure welding machine and a corresponding welding die head 5 can also be used to weld the non-lead metal strip 4 to the pole ears 11 and 12 of the pole group 10, and after the welding is firm, the busbar 40 is formed by cutting. When the ultrasonic pressure welding process is used to weld the metal strip to the pole ears of the cluster group, the power of the ultrasonic generator is 3 to 20 kW.

[0041] Reference Figure 2 , Figure 3 The cross section of the non-lead metal strip 4 is in a "concave" shape, but it is not limited thereto. The non-lead metal strip 4 can also be in a flat sheet shape. The non-lead metal strip 4 surrounds the top of the tabs 11 and 12; the flat sheet non-lead metal strip 4 can be bent to surround the top of the tabs 11 and 12. The thickness of the non-lead metal strip 4 is 0.2 to 12 mm.

[0042] Further, see Figure 3 , Figure 4 The cross section of the non-lead metal strip 4' can also be a "concave" shape, the non-lead metal strip 4' surrounds the top of the pole ear, and the inner plane of the non-lead metal strip 4' is provided with a ridge 41. When the bus is heated or ultrasonically welded to the pole ear, the ridge is embedded in the pole ear, and the thickness of the metal strip is 0.2-12mm. Of course, in some other embodiments, the non-lead metal strip 4' can also be a flat sheet with ridges.

[0043] Furthermore, in the present embodiment, the non-lead metal positive and negative terminals 20, 30 are cylindrical structures with a single-side opening and a threaded interior.

[0044] Furthermore, the non-lead metal strip 4 is cut to form a busbar 40 and sealed with glue, and then the top plastic shell of the battery 1 is correspondingly cut to expose the non-lead metal positive and negative terminals 20 and 30.

[0045] Further, the non-lead metal strip 4, non-lead metal positive and negative terminals 20, 30 are made of one of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or their alloys.

[0046] Taking aluminum as an example, at a temperature of 20 °C, the resistivity of aluminum is 0.0283 Ω·mm 2 / m, and the resistivity of lead is 0.222 Ω·mm 2 / m. The resistance of a lead wire with the same length and cross-sectional area is 7.84 times that of an aluminum wire. Using highly conductive metals such as aluminum and aluminum alloys to replace lead and lead-based alloys as the busbars of lead-acid batteries, and finally using glue to seal the busbars to resist oxidation and corrosion. The glue includes but is not limited to epoxy resin glue and hot melt glue. Using highly conductive metals such as aluminum and aluminum alloys improves the weight specific energy of lead-acid batteries and reduces the material cost of lead-acid batteries. The manufacturing method of ultrasonic welding or electric heating welding replaces the hot melt manufacturing method, realizing clean production and avoiding environmental pollution caused by lead smoke and lead dust generated by lead melting in the traditional production process.

[0047] Example 1

[0048] As Figure 2 、 Figure 3 、 Figure 6 shown, the non-lead metal strip 4 is in a 'concave' shape. Two non-lead metal strips 4 are simultaneously energized with a current of 800 A for a time of 3 s to rapidly heat them up. At the same time, the tabs 11, 12 of the electrode group 10 and the non-lead metal positive and negative terminals 20, 30 melt after contacting the non-lead metal strip 4 and are quickly welded to the non-lead metal strip 4. Then, the redundant parts of the non-lead metal strip 4 are cut off to form the busbar 40. After the busbar 40 is formed, it is sealed with glue, and at the same time, the battery cover is completed. After capping, the corresponding positions on the top of the battery cover are cut to expose the battery positive and negative terminals.

[0049] Example 2

[0050] As Figure 4 、 Figure 5 、 Figure 7As shown, the non-lead metal strip 4' is in the shape of a "concave" character, wrapping around the top of the pole ear, and having a convex ridge 41 on the inner plane. An ultrasonic welder and a corresponding welding die head 5 are used, with a power of 8kW and a welding time of 1.2s, to weld the non-lead metal strip 4' and the non-lead metal positive and negative terminals 20, 30 and the pole ears 11, 12 firmly at the same time. At this time, the convex ridges inside the non-lead metal strip 4' are embedded in the pole ears 11, 12. After that, the excess part of the non-lead metal strip 4' is cut off to form a bus 40'. After the bus 40' is formed, it is sealed with glue, and the battery cover is completed at the same time. After the cover is sealed, the corresponding position on the top of the battery cover is cut to expose the positive and negative terminals of the battery. Of course, alternatively, a method similar to that in Example 1, two non-lead metal strips 4' are energized for heating and welding can also be adopted.

[0051] Example 3

[0052] Reference Figure 1-Figure 3 , Figure 6 , Figure 8 , focus on Figure 1 This embodiment provides a manufacturing process for a fast-welded battery busbar, which is characterized by comprising the following steps:

[0053] S1. Provide a pole group 10, a non-lead metal strip 4, non-lead metal positive and negative terminals 20, 30 and a battery slot 50, wherein the pole group 10 has pole ears 11, 12; install the pole group 10 in the battery slot 50, assemble the non-lead metal strip 4 with the non-lead metal positive and negative terminals 20, 30 and the pole ears 11, 12, so that the non-lead metal strip 4 surrounds the top of the pole ears 11, 12;

[0054] S2. The non-lead metal strip 4 is energized to heat the non-lead metal strip 4, and the non-lead metal positive and negative terminals 20, 30 and the tabs 11, 12 are melted after contacting the non-lead metal strip 4, and the tabs 11, 12 are welded together with the non-lead metal strip 4 at the same time;

[0055] S3. The electrode group 10, the non-lead metal positive and negative terminals 20, 30 and the non-lead metal strip 4 obtained in step S2 are removed from the battery compartment 50, and the excess portion of the non-lead metal strip 4 is cut off to form a bus 40;

[0056] S4. The electrode group 10 connected to the busbar 40 obtained in step S3 is installed in the battery compartment 50, sealed with glue, and covered;

[0057] S5. After sealing, the corresponding positions on the top of the battery cover are cut to expose the positive and negative terminals of the battery.

[0058] In this embodiment, the non-lead metal strip 4, the pole ears 11, 12 of the pole group 10, and the non-lead metal positive and negative terminals 20, 30 are welded simultaneously, which simplifies the steps and improves the welding production efficiency. Of course, in some other embodiments, the non-lead metal strip 4 can be welded to the pole ears 11, 12 first, and then welded to the non-lead metal positive and negative terminals 20, 30, or welded in the opposite order.

[0059] Furthermore, in step S1, before assembling the non-lead metal strip and the pole lug, it also includes: cutting and shaping the pole lug so that the shape of the pole lug is more compatible with the non-lead metal strip.

[0060] In step S2, the current passing through a single non-lead metal strip 4 is 300-3000A, and the power-on time is 0.5-10s; the non-lead metal strip 4 has at least two, and in this embodiment, the non-lead metal strip 4 has two. Figure 6 As shown, in step S2, after all the non-lead metal strips 4 are connected in parallel, all the non-lead metal strips 4 are energized at the same time for heating, which can further improve the welding production efficiency.

[0061] Furthermore, the non-lead metal strip 4 and the non-lead metal positive and negative terminals 20, 30 are made of metal having a higher electrical conductivity than lead. Specifically, the non-lead metal strip 4 and the non-lead metal positive and negative terminals 20, 30 are made of one of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or an alloy thereof, thereby improving the weight-to-energy ratio of the lead-acid battery and reducing the material cost of the lead-acid battery.

[0062] All lead-acid battery busbars produced by the above-mentioned method or by improving or varying the rapid welding mode on this scheme fall within the scope of protection of the claims of this patent.

[0063] Although the present invention has been specifically shown and described in conjunction with the preferred embodiments, it should be understood by those skilled in the art that various changes may be made to the present invention in form and details without departing from the spirit and scope of the present invention as defined by the appended claims, all of which are within the scope of protection of the present invention.

Claims

1. A manufacturing process for a fast-welded battery busbar, characterized in that: The following steps are involved: S1. Providing a pole group, a non-lead metal strip, a non-lead metal positive and negative terminals, and a battery slot, wherein the pole group has a pole ear; installing the pole group in the battery slot, assembling the non-lead metal strip with the non-lead metal positive and negative terminals and the pole ear, so that the non-lead metal strip surrounds the top of the pole ear; S2. The non-lead metal strip is electrified to heat the non-lead metal strip, and the non-lead metal positive and negative terminals and the tabs are melted after contacting the non-lead metal strip, and the non-lead metal positive and negative terminals and the tabs are welded together with the non-lead metal strip at the same time; S3. The electrode group, the non-lead metal positive and negative terminals and the non-lead metal strip obtained in step S2 are removed from the battery compartment, and the excess portion of the non-lead metal strip is cut off to form a busbar; S4. Install the electrode group connected to the bus obtained in step S3 in the battery slot, seal it with glue, and cover it; S5. After sealing, the corresponding positions on the top of the battery cover are cut to expose the positive and negative terminals of the battery.

2. The manufacturing process according to claim 1, characterized in that: In step S1, before assembling the non-lead metal strip and the pole lug, the step further includes: cutting and shaping the pole lug.

3. The manufacturing process according to claim 1, characterized in that: The non-lead metal strip and the non-lead metal positive and negative terminals are made of metal with higher electrical conductivity than lead.

4. The manufacturing process according to claim 3, characterized in that: The non-lead metal strip and the non-lead metal positive and negative terminals are made of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or an alloy thereof.

5. The manufacturing process according to claim 1, characterized in that: In step S2, the current passing through a single non-lead metal strip is 300-3000A, and the power-on time is 0.5-10s; and / or, There are at least two non-lead metal strips. In step S2, after all the non-lead metal strips are connected in parallel, all the non-lead metal strips are energized at the same time.

6. A fast-welded battery busbar structure, characterized in that: The battery bus structure is manufactured using the manufacturing process for the rapid welding battery bus as described in any one of claims 1-5.

7. The battery busbar structure according to claim 6, characterized in that: The non-lead metal strip is in a "concave" shape and surrounds the top of the pole ear.

8. The battery busbar structure according to claim 6, characterized in that: The non-lead metal strip is in a "concave" shape, surrounding the top of the pole ear, and the inner plane of the non-lead metal strip is provided with convex ridges.

9. The battery busbar structure according to claim 6, characterized in that: The non-lead metal strip is in the shape of a flat sheet; or, the non-lead metal strip is in the shape of a flat sheet with convex edges.

10. The battery busbar structure according to claim 6, characterized in that: The non-lead metal positive and negative terminals are cylindrical structures with single-side openings and threads inside.

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