A storage battery, a manufacturing method thereof, and a busbar forming process

Abstract

The application relates to a storage battery, a storage battery manufacturing method and a busbar forming process thereof, and comprises the following steps: S1, providing a plate group, a non-lead metal strip and a battery tank, installing the plate group in the battery tank to form a battery, and forming a lug cluster on the lug of the plate group, and the surface of the non-lead metal strip is provided with a solder; positioning the non-lead metal strip and the lug cluster; S2, using a resistance heating assembly to approach or contact the non-lead metal strip, or using a high-frequency induction heating assembly to heat the non-lead metal strip, then contacting the lug cluster and the non-lead metal strip, and melting the lug cluster and the solder, and after cooling, the lug cluster and the non-lead metal strip are welded together; S3, according to the series and parallel connection requirements of the battery, the non-lead metal strip welded with the lug cluster in the step S2 is cut, and the cut non-lead metal strip forms the final busbar of the storage battery. The process has high safety, the busbar is firmly welded, and the production cost of the storage battery is reduced.

Description

Technical Field

[0001] This invention belongs to the field of lead-acid battery manufacturing technology, and particularly relates to a battery, a battery manufacturing method and a busbar forming process. Background Technology

[0002] Most lead-acid batteries are 12V batteries, consisting of 6 cells. Each cell has positive and negative plates, which are then connected in parallel to weld together the tabs. The current collectors after welding are collectively called busbars. To ensure the lifespan and high-rate discharge characteristics of lead-acid batteries, busbars are generally made of lead-tin alloy and welded by hot melting. Because lead has a high resistivity, busbar design often requires more lead to ensure the cross-sectional area. At the same time, because lead has low hardness, lead terminals are usually formed at both ends of the lead busbar to ensure that the positive and negative terminals can be firmly welded to the lead busbar. Lead terminals further increase the amount of lead used and increase costs. Moreover, to ensure good overall conductivity, the positive and negative terminals usually need to use copper terminals, which are also relatively expensive. Therefore, the existing busbar structure can no longer meet the need to reduce costs.

[0003] Traditional lead-acid battery busbars were initially constructed by welding (fusion) the positive and negative electrode tabs together with lead and lead alloys using an oxygen-acetylene thermal fusion method to form a cluster, and the resulting current collector was the busbar.

[0004] Patent document CN102891278A discloses a method for casting and welding lead-acid battery busbars. The method involves placing battery plates perpendicular to the ground along their width, and sequentially inserting tabs located on the same side into the toothed grooves of a busbar fixture. Molten lead from a lead-melting pot is injected into the busbar fixture by a lead-supply pump and kept at a constant temperature. Then, heating rods are used to sequentially fuse and weld the tabs together. While this invention replaces manual flame welding, it still involves melting lead in a high-temperature furnace and heating the mold to weld the tabs. This high-temperature furnace needs to operate continuously for 24 hours, resulting in high energy consumption. Furthermore, the production process cannot solve the environmental pollution caused by lead fumes and dust, or the generation of lead slag. The generation of lead slag not only increases material waste but also places high demands on subsequent lead slag treatment. If the lead slag is not properly treated, it affects the welding quality of the subsequent battery busbars, ultimately causing quality problems for the entire battery.

[0005] Patent documents CN106549183A and CN205752350U both propose using copper or other non-lead metal materials as busbars and connecting them to the tabs via mechanical fixing. Patent document CN110767869A also proposes a similar solderless solution, which greatly improves production efficiency and reduces the energy consumption and environmental pollution of traditional welding. However, in actual production, due to tab oxidation and misalignment, the actual production efficiency cannot reach the expected level. Furthermore, because of the poor reliability of the mechanical connection and high interface resistance, the battery cannot support high-current charging and discharging, affecting normal use, and therefore it has not been used in production.

[0006] Patent document CN120033347A discloses a rapid welding battery busbar structure and manufacturing process. It proposes using non-lead metal strips made of metals or alloys with higher conductivity than lead, as well as non-lead metal positive and negative terminals. The non-lead metal strips are rapidly heated by electricity while being welded to the battery's tabs and the non-lead metal positive and negative terminals. After a strong weld, the busbar is formed by cutting and then sealed with glue. This solution improves the specific energy of lead-acid batteries, reduces material costs, increases production efficiency, reduces energy consumption, and reduces pollution. However, in actual production, the use of non-lead... Directly heating metal strips with electricity has several drawbacks. First, directly heating non-lead metal strips results in high surface temperatures and high currents, posing significant safety hazards. Second, direct heating and welding of non-lead and lead metals is incompatible; traditional fusion welding cannot form a reliable metallurgical bond, leading to poor weld strength and significantly reduced battery reliability. Finally, due to variations in internal resistance across the non-lead metal strip, uneven heating after energizing can cause incomplete soldering of individual tabs, affecting overall welding quality. Summary of the Invention

[0007] To address the aforementioned technical problems, the first objective of this invention is to provide a battery busbar forming process that offers high safety, ensures reliable busbar welding, and reduces battery production costs. The second objective of this invention is to provide a battery manufacturing method. The third objective of this invention is to provide a battery manufactured using the aforementioned method.

[0008] To achieve the first objective mentioned above, the present invention adopts the following technical solution:

[0009] A battery busbar forming process includes the following steps:

[0010] S1. Provide an electrode assembly, a lead-free metal strip, and a battery slot; install the electrode assembly in the battery slot to form a battery, and form a tab cluster on the electrode assembly; the surface of the lead-free metal strip is provided with brazing filler metal; position the lead-free metal strip and the tab cluster.

[0011] S2. Use a resistance heating element to approach or contact the lead-free metal strip to heat up the lead-free metal strip, or use a high-frequency induction heating element to heat up the lead-free metal strip and melt the brazing filler metal on the surface of the lead-free metal strip. Then, bring the tab cluster into contact with the lead-free metal strip, and part of the tab cluster is fused with the brazing filler metal. After cooling, the tab cluster is welded to the lead-free metal strip.

[0012] S3. The non-lead metal strips welded to the tab clusters in step S2 are cut according to the series and parallel connection requirements of the battery, and the cut-off part forms the final busbar of the storage battery.

[0013] The above-mentioned forming process uses prefabricated non-lead metal strips to replace liquid lead, with a low-melting-point brazing filler layer pre-applied to the surface. The brazing filler is close to the melting point of the tab and lower than that of the non-lead metal strip. The brazing filler layer acts as a medium to achieve a reliable connection with the tab at a temperature lower than that of the non-lead metal. This avoids the environmental pollution caused by lead fumes and dust generated when using liquid lead of the same material as the tab for welding, and also avoids the compatibility problems of direct welding of dissimilar metals.

[0014] The method of this invention employs heating methods such as heat conduction, heat convection, or heat radiation. It eliminates the need to consider differences in internal resistance across the lead-free metal strip, resulting in more uniform overall heating. Furthermore, the heating method does not generate current in the lead-free metal strip, improving overall safety. The uniform heating of the lead-free metal strip ensures complete melting of the brazing filler metal at all points, allowing for thorough contact and fusion with the tabs. This guarantees a firm weld between each tab and the lead-free metal strip, preventing issues such as incomplete soldering and improving welding quality.

[0015] As a preferred embodiment, the positioning process of the non-lead metal strip and the tab cluster in step S1 is as follows:

[0016] The battery is placed upside down on the workbench or conveyor belt with the tab clusters facing down; the workbench or conveyor belt has through holes to accommodate the tab clusters; a non-lead metal strip is placed on the welding station so that each row of tab clusters of each battery is directly opposite a non-lead metal strip.

[0017] By using an inverted tab cluster, the molten solder or tabs can be prevented from dripping into the battery during the welding process, which could damage the tabs or plates and thus affect the overall performance and quality of the battery.

[0018] As a preferred embodiment, the welding method for the non-lead metal strip and the tab cluster in step S2 is as follows:

[0019] A non-lead metal strip is placed on a welding station, which includes a lifting platform for raising and lowering the non-lead metal strip. A liftable heating element is also located below the non-lead metal strip on the lifting platform. The heating element is controlled to rise and approach or contact the non-lead metal strip, so that the non-lead metal strip is heated evenly through heat conduction or heat convection. At the same time, the entire lifting platform rises, bringing the heated non-lead metal strip into contact with the tab cluster. After the brazing filler metal layer on the outer surface of the non-lead metal strip and the tab cluster are fused together, the heating element descends and is removed. The non-lead metal strip and the tab cluster remain in a fused state. After the welding is completed by cooling, the lifting platform descends.

[0020] The above welding method utilizes a lifting platform to move the non-lead metal strip up and down, meeting the requirement of welding the non-lead metal strip to the electrode tab. At the same time, the heating element can also be raised and lowered independently. After the non-lead metal strip and the electrode tab melt, it can be promptly separated from the non-lead metal strip, stopping the heating of the non-lead metal strip and meeting the requirement of rapid cooling after the non-lead metal strip and the electrode tab melt, thus improving efficiency.

[0021] As a preferred embodiment, during the contact between the heated non-lead metal strip and the tab cluster, the lifting platform maintains a slow, incremental upward movement, and stops rising when the heating element descends. This slow upward movement of the lifting platform during welding compensates for the length of the molten tabs, preventing stringing and other issues that could affect the welding quality.

[0022] As a preferred embodiment, the welding method for the non-lead metal strip and the tab cluster in step S2 is as follows:

[0023] A non-lead metal strip is placed on a welding station, which includes a lifting platform for raising and lowering the non-lead metal strip. A high-frequency induction heating component is also installed around the non-lead metal strip on the lifting platform. The high-frequency induction heating component heats the non-lead metal strip evenly through thermal radiation. At the same time, the entire lifting platform rises, bringing the heated non-lead metal strip into contact with the tab cluster. After the brazing filler layer on the outer surface of the non-lead metal strip and the tab cluster are fused together, the high-frequency induction heating component stops heating. The non-lead metal strip and the tab cluster remain in a fused state. After the welding is completed by cooling, the lifting platform descends.

[0024] A high-frequency induction heating element is used to heat the non-lead metal strip. The eddy current loss caused by the electromagnetic field on the surface of the non-lead metal strip ensures that the non-lead metal strip is heated evenly. Moreover, the high-frequency induction heating element is a non-contact heating element, which has high heating efficiency and fast heating speed, resulting in less surface oxidation of the heated object. At the same time, after the high-frequency induction heating element stops heating, the non-lead metal strip cools down faster, which facilitates rapid solidification and shaping, thus improving welding efficiency.

[0025] As a preferred embodiment, the lead-free metal strip is a flat, elongated strip with a smooth surface. Its width is greater than or equal to the cross-sectional width of the battery tab cluster, and its thickness is 1mm to 3mm. The lead-free metal strip's width being slightly larger than the cross-sectional width of the tab cluster helps compensate for positioning deviations and allows the brazing filler metal to partially encapsulate the tabs during welding, resulting in a more reliable weld.

[0026] As a preferred embodiment, the lead-free metal strip is made of a metal with higher electrical conductivity than lead. Using a lead-free metal strip with higher conductivity than lead allows for a thinner and lighter busbar, reducing the material cost of lead-acid batteries.

[0027] As a preferred embodiment, the brazing filler metal is silver or tin, and is attached to the surface of a non-lead metal strip by electroplating.

[0028] As a preferred embodiment, in step S1, before positioning the non-lead metal strip with the tab cluster, the method further includes: applying flux to the surface of the non-lead metal strip to degrease and remove the oxide film.

[0029] As a preferred embodiment, in step S1, before positioning the non-lead metal strip with the tab cluster, the method further includes: cutting and polishing the tab cluster to remove surface oxidation.

[0030] As a preferred option, after the tab clusters are cut flat and the surface oxidation is removed by grinding, the flux is applied.

[0031] To achieve the second objective mentioned above, the present invention adopts the following technical solution:

[0032] A method for manufacturing a storage battery, employing any of the storage battery busbar welding processes described above.

[0033] As a preferred embodiment, after step S3, a step S4 is further included to weld the positive and negative terminals onto the busbar. The specific process is as follows: the busbar and / or the positive and negative terminals are heated, and then the positive and negative terminals are pressed to both ends of the busbar respectively, so that the positive and negative terminals are welded together with the busbar.

[0034] As a preferred embodiment, in step S4, a clamping device is used to grip the positive and negative terminals, and the contact point between the clamping device and the positive and negative terminals is a heating electrode. The heating electrode wraps around the positive and negative terminals. When the heating electrode is energized, the positive and negative terminals are heated. After heating, the positive and negative terminals are pressed into the busbar. After the solder layer on the outer surface of the busbar and the positive and negative terminals are fused together, the heating electrode is de-energized, maintaining the fused state between the busbar and the positive and negative terminals. After cooling and solidification, the clamping device is removed from the positive and negative terminals.

[0035] In traditional processes, due to the softness of lead bars, special lead terminals are required to weld to the positive and negative terminals. However, in this application, by replacing the lead busbar with a non-lead metal busbar, the overall hardness is increased, and the positive and negative terminals can be welded without the need for lead terminals, further reducing the amount of material used.

[0036] The reason for heating the positive and negative terminals instead of the busbar when welding them is as follows: the busbar and the tab cluster have already been welded together, and heating the busbar again is inconvenient and affects the welding quality of the busbar and the tab cluster. However, by heating the heating electrodes that wrap the positive and negative terminals with electricity, rapid and uniform heating can be achieved, avoiding heat damage. After welding, the heating electrodes are de-energized, and the positive and negative terminals can automatically cool and set.

[0037] As a preferred option, solder wire is fed to the welding joint simultaneously during the welding process of the positive and negative terminals and the busbar.

[0038] As a preferred option, flux is applied to the surface of the busbar at the point where the positive and negative terminals are to be welded before welding the positive and negative terminals.

[0039] As a preferred embodiment, after step S4, the following steps are also included:

[0040] S5. Seal the battery obtained in step S4 with glue and then cover it.

[0041] S6. After sealing the battery cover, cut the corresponding position on the top of the battery cover to expose the positive and negative terminals of the battery.

[0042] To achieve the third objective mentioned above, the present invention adopts the following technical solution:

[0043] A storage battery manufactured using any of the storage battery manufacturing methods described above.

[0044] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0045] The method of the present invention uses a prefabricated non-lead metal strip to replace liquid lead, and a low-melting-point solder layer is pre-placed on the surface. The solder layer serves as a medium to achieve a reliable connection with the lead electrode at a temperature lower than the melting point of the non-lead metal, thus avoiding the compatibility problem of direct welding of dissimilar metals.

[0046] The method of the present invention uses heat conduction, heat convection or heat radiation to make the non-lead metal strip heat up more evenly, so that the brazing filler metal on the non-lead metal strip can be completely melted and then fully contacted and fused with the tab cluster, resulting in a stronger weld. In addition, the above heating method makes it so that no current passes through the non-lead metal strip during the welding process, thus ensuring high overall safety.

[0047] The method of this invention uses contact heating or high-frequency induction heating to weld non-lead metal strips, replacing the traditional hot-melt lead and welding lead manufacturing process, achieving clean production and avoiding environmental pollution caused by lead fumes, lead dust and lead slag generated during lead melting in the traditional production process. Attached Figure Description

[0048] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.

[0049] Figure 1 This is a flowchart illustrating the method of the present invention;

[0050] Figure 2 This is a schematic diagram of the welding structure of the non-lead metal strip and the tab cluster of the present invention;

[0051] Figure 3 This is a schematic diagram of the welding structure of the non-lead metal strip and the positive and negative terminals of the present invention;

[0052] Figure 4 This is a schematic diagram of the battery structure in step S1 of the method of the present invention;

[0053] Figure 5 This is a schematic diagram of the structure after the battery and the non-lead metal strip are welded together in step S2 of the method of the present invention;

[0054] Figure 6 This is a schematic diagram of the structure after the battery, lead-free metal strip, and positive and negative terminals are welded together in step S4 of the method of the present invention.

[0055] Figure 7 This is a schematic diagram of the structure of the storage battery in step S6 of the method of the present invention.

[0056] The attached diagram is labeled as follows: 1. Battery; 11. Tab cluster; 2. Non-lead metal strip; 20. Busbar; 3. Lifting platform; 4. Heating element; 5. Positive and negative terminals; 6. Clamping device; 61. Metal electrode; 62. Graphite electrode; 7. Battery cover. Detailed Implementation

[0057] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0058] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0059] Furthermore, in the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0060] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more, unless explicitly defined otherwise.

[0061] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0062] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0063] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0064] like Figure 1 As shown, a method for manufacturing a storage battery includes the following steps:

[0065] S1. Provide a non-lead metal strip 2 and a battery 1, and position the two together;

[0066] The battery 1 includes an electrode plate assembly and a battery case. The electrode plate assembly is formed by multiple positive and negative electrode plates spaced apart, with partitions between adjacent positive and negative electrode plates. Each electrode plate also has a tab, and all the tabs on the entire electrode plate assembly form at least two rows of tab clusters 11. The electrode plate assembly is fixed in the battery case to form the battery 1. Depending on the battery specifications, there can be multiple electrode plate assemblies and multiple rows of tab clusters. In this embodiment, a battery with 6 electrode plate assemblies and two rows of tab clusters 11 is used as an example for explanation. Figure 4 As shown.

[0067] The tab cluster 11 in battery 1 is mechanically cut flat and polished to remove surface oxidation, and flux is brushed onto the tab cluster 11. At least one battery 1 is inverted on the operating table or conveyor belt so that the tab cluster 11 faces downward. The operating table or conveyor belt is provided with a groove or through hole to accommodate the tab cluster 11.

[0068] The surface of the non-lead metal strip 2 is provided with brazing filler metal; the non-lead metal strip 2 is made of one of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or an alloy thereof, and in this embodiment, aluminum is preferred. The brazing filler metal is tin or silver, and in this embodiment, tin is preferred. Tin is electroplated onto the surface of the aluminum strip to form a tin-plated aluminum strip; flux is applied to the surface of the tin-plated aluminum strip to degrease and remove the oxide film.

[0069] The lead-free metal strip is flat and elongated with a smooth surface. Its width is greater than or equal to the cross-sectional width of the battery tab cluster, and its thickness is 1mm to 3mm. The width of the lead-free metal strip is slightly larger than the cross-sectional width of the tab cluster, which helps to compensate for positioning deviations and allows the brazing filler metal to partially wrap around the tabs during welding, resulting in a more reliable weld.

[0070] The tin-plated aluminum strips are placed on the welding station so that the two rows of tab clusters 11 of each battery 1 are directly opposite the two tin-plated aluminum strips. By inverting the tab clusters 11, it is possible to prevent molten solder or tabs from dripping into the battery 1 during the welding process, which could damage the tabs or plates and thus affect the overall performance and quality of the battery.

[0071] S2. Heating the non-lead metal strip (tin-plated aluminum strip) to weld the non-lead metal strip (tin-plated aluminum strip) to the tab cluster (e.g.) Figure 2 (as shown)

[0072] The welding station includes a lifting platform 3. The top of the lifting platform 3 has a support frame that supports both ends of the tin-plated aluminum strips. Below the tin-plated aluminum strips on the lifting platform, a liftable heating element 4 is also installed. The heating element 4 is energized and heated, and then raised to approach or press against the two tin-plated aluminum strips. Through heat transfer or convection, the two tin-plated aluminum strips are heated evenly. Simultaneously, the entire lifting platform 3 rises, bringing the heated tin-plated aluminum strips into contact with the tab cluster 11. The tin plating layer on the outer surface of the tin-plated aluminum strips fuses with the lower part of the tab cluster 11. After welding, the heating element 4 descends and is removed, maintaining the welded state between the tin-plated aluminum strips and the tab cluster 11. After cooling, the lifting platform 3 descends, completing the welding process. The battery structure after welding is as follows: Figure 5 As shown.

[0073] The length of the heating element is slightly less than the length of the non-lead metal strips, and the width of the heating plate is greater than the sum of the widths of all the non-lead metal strips and the spacing between all the non-lead metal strips. After the heating element rises, it comes into close proximity or surface contact with the two non-lead metal strips, resulting in more uniform and stable heat transfer. Furthermore, due to the insulation of the outer shell of the heating plate, the entire process is safer.

[0074] The above structure ensures that the heating element assembly can fully cover and heat the non-lead metal strips, resulting in a more uniform heat field and preventing insufficient temperature of the non-lead metal strips at the edges; moreover, it can heat multiple non-lead metal strips at a time, greatly improving efficiency.

[0075] In this example, the heating element 4 is a resistance heating device with a process temperature between 350 and 450°C. In other embodiments, a high-frequency heating component can also be used to heat the tin-plated aluminum strip, and the welding of the tin-plated aluminum strip to the electrode tab of the battery 1 can also be achieved using a robotic arm or other device.

[0076] The specific process of heating a non-lead metal strip (tin-plated aluminum strip) using a high-frequency heating component is as follows: The non-lead metal strip is placed on a welding station, which includes a lifting platform for raising and lowering the non-lead metal strip. A high-frequency induction heating component is also installed around the non-lead metal strip on the lifting platform. The high-frequency induction heating component heats the non-lead metal strip evenly through thermal radiation. At the same time, the entire lifting platform rises, bringing the heated non-lead metal strip into contact with the tab cluster. After the brazing filler layer on the outer surface of the non-lead metal strip and the tab cluster are fused together, the high-frequency induction heating component stops heating. The non-lead metal strip and the tab cluster remain in a fused state. After cooling and completing the welding, the lifting platform descends.

[0077] A high-frequency induction heating element is used to heat the non-lead metal strip. The eddy current loss caused by the electromagnetic field on the surface of the non-lead metal strip ensures that the non-lead metal strip is heated evenly. Moreover, the high-frequency induction heating element is a non-contact heating element, which has high heating efficiency and fast heating speed, resulting in less surface oxidation of the heated object. At the same time, after the high-frequency induction heating element stops heating, the non-lead metal strip cools down faster, which facilitates rapid solidification and shaping, thus improving welding efficiency.

[0078] S3. The tin-plated aluminum strip that was welded to the tab cluster 11 in step S2 is cut according to the series and parallel connection requirements of the battery, and the cut-off part forms the final battery busbar 20.

[0079] S4. Weld positive and negative terminals (aluminum terminals) onto the busbar 20 formed in step S3.

[0080] Positive and negative terminals are provided, which are made of one of silver, copper, aluminum, calcium, beryllium, magnesium, zinc, nickel, tin, iron or their alloys. In this embodiment, aluminum terminals are preferred. The bus and / or the positive and negative terminals (aluminum terminals) are heated, and then the positive and negative terminals (aluminum terminals) are pressed to the two ends of the bus, so that the positive and negative terminals (aluminum terminals) are welded to the bus.

[0081] like Figure 3 As shown, in this example, a clamping device 6 is used to grip the positive and negative terminals (aluminum terminals). The contact point between the clamping device and the positive and negative terminals (aluminum terminals) is a graphite electrode 62. The graphite electrode 62 wraps around the positive and negative terminals (aluminum terminals). When the graphite electrode 62 is energized, the positive and negative terminals (aluminum terminals) are heated. After heating, the positive and negative terminals (aluminum terminals) are pressed against the busbar. After the tin plating layer on the outer surface of the busbar fuses with the positive and negative terminals (aluminum terminals), the graphite electrode 62 is de-energized, maintaining the busbar 20 in a fused state with the positive and negative terminals (aluminum terminals). After cooling and solidification, the clamping device is released from the positive and negative terminals (aluminum terminals). The battery after the positive and negative terminals are welded is shown below. Figure 6 As shown.

[0082] Replacing lead busbars with tin-plated aluminum busbars eliminates the need for electrode posts at both ends of the busbar before soldering aluminum terminals, further reducing material usage. Heating the aluminum terminals instead of the busbar itself avoids affecting the soldering quality between the busbar and the tabs. Furthermore, heating the graphite electrode surrounding the aluminum terminals via electricity enables rapid and uniform heating, preventing heat damage, and allows for automatic cooling and setting after soldering. Additionally, replacing lead strips with tin-plated aluminum strips improves conductivity, allowing the use of aluminum terminals instead of copper terminals in traditional processes, further contributing to cost reduction.

[0083] The aforementioned clamping device 6 employs a clamping cylinder. The graphite electrode 62 is fixed on the clamping jaws of the clamping cylinder, and the graphite electrode 62 is connected to a power source via a metal electrode 61. The heating time of the positive and negative terminals (aluminum terminals) is controlled according to the voltage and current applied to the graphite electrode. The DC current applied to the graphite electrode is between 30 and 100A. To improve the bonding strength between the positive and negative terminals (aluminum terminals) and the busbar, solder wire can be simultaneously fed to the bonding joint during the bonding process. In addition, flux needs to be applied to the surface of the busbar where the positive and negative terminals (aluminum terminals) are to be bonded before bonding.

[0084] S5. Seal the battery obtained in step S4 with glue and then cover it.

[0085] S6. After sealing, cut the corresponding position on the top of the battery cover 7 to expose the positive and negative terminals (aluminum terminals) of the battery.

[0086] The process of this invention uses tin-plated aluminum strips as the busbars for welding the tabs and aluminum terminals, avoiding the traditional hot-melt lead and lead welding manufacturing processes. This directly eliminates the traditional lead terminal battery structure. Furthermore, based on actual battery performance test results, the original copper positive and negative terminals can be directly optimized into aluminum positive and negative terminals, thereby reducing the material cost of lead-acid batteries, avoiding lead pollution, simplifying the lead-acid battery manufacturing process, and directly leading to the upgrading of lead-acid manufacturing technology and the reduction of costs. At the same time, since the conductivity of tin-plated aluminum strips is better than that of lead, the internal resistance of lead-acid batteries is reduced, and the performance is improved.

[0087] like Figure 7 As shown, the present invention also discloses a storage battery manufactured using the above-described storage battery manufacturing method.

[0088] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0089] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A battery busbar forming process, characterized in that, Includes the following steps: S1. Provide an electrode assembly, a lead-free metal strip, and a battery slot; install the electrode assembly in the battery slot to form a battery, and form a tab cluster on the electrode assembly; the surface of the lead-free metal strip is provided with brazing filler metal; position the lead-free metal strip and the tab cluster. S2. Use a resistance heating element to approach or contact the lead-free metal strip to heat up the lead-free metal strip, or use a high-frequency induction heating element to heat up the lead-free metal strip and melt the brazing filler metal on the surface of the lead-free metal strip. Then, bring the tab cluster into contact with the lead-free metal strip, and part of the tab cluster is fused with the brazing filler metal. After cooling, the tab cluster is welded to the lead-free metal strip. S3. Cut the non-lead metal strips that were welded to the tab clusters in step S2 according to the series and parallel connection requirements of the battery, and the cut-off part forms the final busbar of the storage battery. In step S1, the positioning process of the non-lead metal strip and the tab cluster is as follows: Place the battery upside down on the workbench or conveyor belt with the tab clusters facing down; the workbench or conveyor belt has through holes to accommodate the tab clusters; place non-lead metal strips on the welding station so that each row of tab clusters of each battery is directly opposite a non-lead metal strip. In step S2, the welding method between the non-lead metal strip and the tab cluster is as follows: A non-lead metal strip is placed on a welding station, which includes a lifting platform for raising and lowering the non-lead metal strip. A liftable heating element is also provided on the lifting platform below the non-lead metal strip. The heating element is controlled to rise and approach or contact the non-lead metal strip. The non-lead metal strip is heated evenly through heat conduction or heat convection. At the same time, the entire lifting platform rises and contacts the heated non-lead metal strip with the tab cluster. After the brazing filler layer on the outer surface of the non-lead metal strip and the tab cluster are fused together, the heating element is lowered and removed. The non-lead metal strip and the tab cluster remain fused together. After the welding is completed by cooling, the lifting platform is lowered. Alternatively, in step S2, the welding method between the lead-free metal strip and the tab cluster is as follows: The lead-free metal strip is placed on a welding station, which includes a lifting platform for raising and lowering the lead-free metal strip. A high-frequency induction heating component is also provided around the lead-free metal strip on the lifting platform. The high-frequency induction heating component heats the lead-free metal strip evenly through thermal radiation. At the same time, the entire lifting platform rises, bringing the heated lead-free metal strip into contact with the tab cluster. After the brazing filler layer on the outer surface of the lead-free metal strip and the tab cluster are fused together, the high-frequency induction heating component stops heating. The lead-free metal strip and the tab cluster remain in a fused state. After the welding is completed by cooling, the lifting platform descends. During the process of the heated non-lead metal strip coming into contact with the tab cluster, the lifting platform always maintains a slow upward movement, and stops rising when the heating element descends.

2. The battery busbar forming process according to claim 1, characterized in that, The lead-free metal strip is flat and elongated with a smooth surface. Its width is greater than or equal to the cross-sectional width of the battery tab cluster, and its thickness is 1mm to 3mm.

3. The battery busbar forming process according to claim 1, characterized in that, The non-lead metal strip is made of a metal with a higher electrical conductivity than lead.

4. The battery busbar forming process according to claim 1, characterized in that, The brazing filler metal is silver or tin and is attached to the surface of a non-lead metal strip by electroplating.

5. The battery busbar forming process according to claim 1, characterized in that, In step S1, before positioning the non-lead metal strip with the tab cluster, the method further includes: applying flux to the surface of the non-lead metal strip to degrease and remove the oxide film.

6. The battery busbar forming process according to claim 1, characterized in that, In step S1, before positioning the non-lead metal strip with the tab cluster, the method further includes: cutting and polishing the tab cluster to remove surface oxidation.

7. The battery busbar forming process according to claim 6, characterized in that, After the tab clusters are cut flat and the surface oxidation is removed by grinding, the flux is applied.

8. A method for manufacturing a storage battery, characterized in that, Includes the following steps: The battery busbar forming process described in any one of claims 1 to 7 is adopted.

9. A method for manufacturing a storage battery according to claim 8, characterized in that, After step S3, step S4 is further included, which involves welding the positive and negative terminals onto the non-lead metal strip. The specific process is as follows: the bus and / or the positive and negative terminals are heated, and then the positive and negative terminals are pressed to both ends of the bus, so that the positive and negative terminals are welded together with the bus.

10. A method for manufacturing a storage battery according to claim 9, characterized in that, In step S4, a clamping device is used to grip the positive and negative terminals, and the contact point between the clamping device and the positive and negative terminals is a heating electrode. The heating electrode wraps around the positive and negative terminals. When the heating electrode is energized, the positive and negative terminals are heated. After heating, the positive and negative terminals are pressed into the busbar. After the solder layer on the outer surface of the busbar and the positive and negative terminals are fused together, the heating electrode is de-energized, maintaining the fused state between the busbar and the positive and negative terminals. After cooling and solidification, the clamping device is removed from the positive and negative terminals.

11. A method for manufacturing a storage battery according to claim 9, characterized in that, During the welding process between the positive and negative terminals and the busbar, solder wire is simultaneously fed to the welding joint.

12. A method for manufacturing a storage battery according to claim 9, characterized in that, Before welding the positive and negative terminals, apply flux to the surfaces of the busbar where the positive and negative terminals are to be welded.

13. A method for manufacturing a storage battery according to claim 9, characterized in that, Following step S4, the following steps are also included: S5. Seal the battery obtained in step S4 with glue and then cover it. S6. After sealing the battery cover, cut the corresponding position on the top of the battery cover to expose the positive and negative terminals of the battery.

14. A storage battery, characterized in that, It is manufactured using the battery manufacturing method described in any one of claims 8 to 13.

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