Aluminum-based mixed material prefabricated punched plate grid and storage battery prepared from aluminum-based mixed material prefabricated punched plate grid

Abstract

The invention relates to the field of storage batteries, in particular to an aluminum-based mixed material prefabricated punched grid and a storage battery prepared thereof.The aluminum-based mixed material prefabricated punched grid comprises an aluminum plate base body, a plurality of punched holes are prefabricated in the aluminum plate base body, and lead-tin alloy plating layers are arranged on the surfaces of the aluminum plate base body and the punched holes of the aluminum plate base body; the surface of the aluminum plate base body provided with the plating layer is provided with a concave-convex structure formed through crease concave-convex treatment, the thickness of the aluminum plate base body ranges from 0.4 mm to 1.5 mm, the thickness of the lead-tin alloy plating layer ranges from 5 micrometers to 10 micrometers, and in the lead-tin alloy, the mass percent of lead ranges from 50% to 60%, and the mass percent of tin ranges from 40% to 50%. According to the aluminum-based mixed material prefabricated punched plate grid and the storage battery prepared from the aluminum-based mixed material prefabricated punched plate grid, the mode that the lead-tin alloy is electroplated on the aluminum plate base body is adopted, the light weight and high conductivity of aluminum and the acid resistance of the lead alloy are achieved, and therefore the weight and cost of the storage battery are greatly reduced, the specific energy of the storage battery is improved, and the cycle life of the storage battery is prolonged.

Description

Technical Field

[0001] This invention relates to the field of storage batteries, and particularly to a pre-fabricated perforated grid plate made of aluminum-based hybrid material and the storage battery prepared therefrom. Background Technology

[0002] Lead-acid batteries are widely used due to their mature technology, high reliability, and high recyclability. However, their core component—the grid—is mainly made of lead-based alloys (such as lead-calcium-tin-aluminum alloy), with a density as high as approximately 11.3 g / cm³ and a lead content exceeding 98%. This results in heavy batteries, low specific energy (typically 38-45 Wh / kg), and material costs significantly affected by lead prices. Taking the common electric bicycle battery 6-DZF-20Ah as an example, a single cell weighs 6.1-6.2 kg, with the grid material accounting for approximately 15% of the total battery weight, making it a key factor limiting its specific energy and cost.

[0003] With the maturation of lithium-ion and sodium-ion battery technologies, the disadvantages of traditional lead-acid batteries in terms of specific energy and weight have become increasingly apparent, leading to a decline in their market competitiveness. Therefore, developing a new type of grid material and battery structure that can significantly reduce weight, increase specific energy, and lower costs is urgently needed. Aluminum has a much lower density (approximately 2.7 g / cm³) than lead, and a lower electrical conductivity (approximately 37.7 × 10⁻⁶). 6 S / m) is for lead (approximately 4.8 × 10⁻⁶). 6 Aluminum has a surface area (S / m) 7-8 times that of sulfuric acid electrolytes, making it an ideal alternative material. However, aluminum is easily corroded in sulfuric acid electrolytes, and how to apply it to acidic battery environments is a major technical challenge. Summary of the Invention

[0004] The main objective of this invention is to provide a pre-fabricated perforated grid plate made of aluminum-based hybrid material and the battery prepared therefrom. By electroplating a lead-tin alloy onto the aluminum plate substrate, the battery combines the lightweight and high conductivity of aluminum with the acid resistance of lead alloy, thereby significantly reducing the weight and cost of the battery and improving its specific energy and cycle life.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A prefabricated perforated grid made of aluminum-based hybrid material, comprising, An aluminum plate substrate, wherein the aluminum plate substrate is pre-formed with multiple punches, and the aluminum plate substrate and the surface of the punches are provided with a lead-tin alloy plating layer, and the surface of the aluminum plate substrate after the plating layer is provided has an uneven structure formed by crease concavity and convexity treatment.

[0006] Furthermore, the thickness of the aluminum plate substrate is 0.4-1.5 mm.

[0007] Furthermore, the thickness of the lead-tin alloy plating is 5-10 μm, and the lead-tin alloy contains 50%-60% lead and 40%-50% tin by mass.

[0008] Furthermore, the crease treatment is wavy or W-shaped, and the overall thickness of the plate grid increases by 0.1-0.3 mm after treatment.

[0009] Furthermore, the shape of the punch is square, trapezoidal, rhomboid, circular, or elliptical.

[0010] Furthermore, the aluminum plate substrate undergoes one of the following surface anti-oxidation treatments before electroplating: zinc immersion, anodizing, or electroless nickel plating.

[0011] A storage battery includes a pre-fabricated perforated grid made of aluminum-based composite material. The busbar and tabs of the storage battery are made of aluminum and are connected by laser spot welding or casting welding. The upper part of the busbar and the tabs is wrapped with epoxy resin.

[0012] Furthermore, the thickness of the positive electrode of the battery is 0.6-1.8 mm, and the thickness of the negative electrode is 0.5-1.5 mm.

[0013] A method for preparing a battery comprising an aluminum substrate grid includes the following steps: Step 1: Aluminum plate substrate rolling and aluminum plate substrate punching; Step 2: Anti-oxidation treatment of the surface of the punched aluminum plate substrate; Step 3: Electroplating lead-tin alloy onto the surface-treated aluminum plate substrate to form a grid. Step 4: Perform crease and relief treatment on the electroplated grid. Step 5: Apply lead paste to the grid. Step 6: Apply a film to the surface of the grid after applying the paste and then roll it. Step 7: Cut, dry, and cure the grid. Step 8: Electrode assembly, housing installation, and welding of electrode tabs and busbars; Step nine: sealing the battery cap, filling with electrolyte, formation, capacity testing, grouping, and packaging.

[0014] Compared with the prior art, the present invention has the following beneficial effects: This invention significantly reduces weight and increases specific energy. The grid density of the aluminum substrate is much lower than that of the traditional lead substrate grid, which greatly reduces the total weight of the battery. The high conductivity of aluminum reduces the internal resistance of the battery and reduces heat accumulation, making it suitable for high current discharge and modular design. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0016] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0017] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0018] A prefabricated perforated grid made of aluminum-based hybrid material, comprising, An aluminum plate substrate, wherein the aluminum plate substrate is pre-formed with multiple punches, and the aluminum plate substrate and the surface of the punches are provided with a lead-tin alloy plating layer, and the surface of the aluminum plate substrate after the plating layer is provided has an uneven structure formed by crease concavity and convexity treatment.

[0019] Furthermore, the thickness of the aluminum plate substrate is 0.4-1.5 mm.

[0020] Furthermore, the thickness of the lead-tin alloy plating is 5-10 μm, and the lead-tin alloy contains 50%-60% lead and 40%-50% tin by mass.

[0021] Furthermore, the crease treatment is wavy or W-shaped, and the overall thickness of the plate grid increases by 0.1-0.3 mm after treatment.

[0022] Furthermore, the shape of the punch is square, trapezoidal, rhomboid, circular, or elliptical.

[0023] Furthermore, the aluminum plate substrate undergoes one of the following surface anti-oxidation treatments before electroplating: zinc immersion, anodizing, or electroless nickel plating.

[0024] A storage battery includes a pre-fabricated perforated grid made of aluminum-based composite material. The busbar and tabs of the storage battery are made of aluminum and are connected by laser spot welding or casting welding. The upper part of the busbar and the tabs is wrapped with epoxy resin.

[0025] Furthermore, the thickness of the positive electrode of the battery is 0.6-1.8 mm, and the thickness of the negative electrode is 0.5-1.5 mm.

[0026] A method for preparing a battery comprising an aluminum substrate grid includes the following steps: Step 1: Aluminum plate substrate rolling and aluminum plate substrate punching; Step 2: Anti-oxidation treatment of the surface of the punched aluminum plate substrate; Step 3: Electroplating lead-tin alloy onto the surface-treated aluminum plate substrate to form a grid. Step 4: Perform crease and relief treatment on the electroplated grid. Step 5: Apply lead paste to the grid. Step 6: Apply a film to the surface of the grid after applying the paste and then roll it. Step 7: Cut, dry, and cure the grid. Step 8: Electrode assembly, housing installation, and welding of electrode tabs and busbars; Step nine: sealing the battery cap, filling with electrolyte, formation, capacity testing, grouping, and packaging.

[0027] Example 1: Fabrication of an aluminum substrate grid and battery for a 12V / 20Ah storage battery Grid fabrication: Substrate selection: Industrial pure aluminum plates with a thickness of 0.8mm were selected.

[0028] Punching: A precision die is used to continuously punch aluminum plates to form diamond-shaped holes.

[0029] Surface treatment: The punched aluminum plate is immersed in zinc to enhance the adhesion of subsequent coatings.

[0030] Electroplating: The treated aluminum plate is electroplated with lead-tin alloy to achieve a uniform coating thickness of 7μm.

[0031] Surface embossing: The plated grid is embossed with a wave pattern using rollers, which increases its total thickness by about 0.2 mm.

[0032] Lead paste preparation: Lead blocks are granulated and ball-milled into powder. After aging, the powder is mixed with sulfuric acid, deionized water and additives in a paste mixing machine, and the apparent density of the lead paste is controlled at about 4.0 g / cm³.

[0033] Electrode manufacturing: Lead paste is applied to the prepared grid, followed by surface coating (such as covering with tracing paper), rolling to a fixed weight, and slitting into electrode sheets of specified sizes, then curing and drying. After slitting, the sheets are horizontally collected and transported by machine to prevent deformation.

[0034] Battery assembly: The positive and negative electrodes are encased together with the AGM separator to form an electrode group.

[0035] The electrode group is installed into the battery casing.

[0036] Thin aluminum sheets are used as tabs and busbars, and they are reliably connected using a laser spot welding machine.

[0037] Epoxy resin is applied to the upper part of the busbar and the electrode tab welding point, and a protective layer is formed after curing.

[0038] Sealing, welding terminals, and liquid injection.

[0039] Battery formation: After injecting sulfuric acid electrolyte, charge and discharge formation is carried out, and finally capacity testing is performed.

[0040] Comparative example: Batteries of the same specifications (12V / 20Ah) were manufactured using traditional gravity casting of lead-calcium-tin-aluminum alloy grids.

[0041] Performance Comparison: Tests showed that the battery prepared in Example 1 of this invention has a specific energy of 50Wh / Kg, while the conventional comparative battery only has 40Wh / Kg.

[0042]

[0043] Aluminum 18 yuan / kg, lead 17 yuan / kg Material cost analysis shows significant cost savings per battery. Deep cycle life testing demonstrates a significant improvement in the cycle life of the battery of this invention. In summary, this invention effectively overcomes the shortcomings of existing technologies and provides a novel high-performance, low-cost, and lightweight battery solution. The above description is only a preferred embodiment of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0044] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A prefabricated perforated grid made of aluminum-based composite material, characterized in that, include, An aluminum plate substrate, wherein the aluminum plate substrate is pre-formed with multiple punches, and the aluminum plate substrate and the surface of the punches are provided with a lead-tin alloy plating layer, and the surface of the aluminum plate substrate after the plating layer is provided has an uneven structure formed by crease concavity and convexity treatment.

2. The aluminum-based hybrid material pre-fabricated perforated grid and the resulting battery according to claim 1, characterized in that: The thickness of the aluminum plate substrate is 0.4-1.5 mm.

3. The aluminum-based hybrid material prefabricated perforated grid and the battery prepared therefrom according to claim 1, characterized in that: The thickness of the lead-tin alloy coating is 5-10 μm, and the lead-tin alloy contains 50%-60% lead and 40%-50% tin by mass.

4. The aluminum-based hybrid material pre-perforated grid and the battery prepared therefrom according to claim 1, characterized in that: The crease treatment is wavy or W-shaped, and the overall thickness of the grating increases by 0.1-0.3 mm after treatment.

5. The aluminum-based hybrid material pre-fabricated perforated grid and the battery prepared therefrom according to claim 1, characterized in that: The shape of the punch can be square, trapezoidal, rhomboid, circular, or elliptical.

6. The aluminum-based hybrid material prefabricated perforated grid and the battery prepared therefrom according to claim 1, characterized in that: The aluminum plate substrate undergoes one of the following surface anti-oxidation treatments before electroplating: zinc immersion, anodizing, or electroless nickel plating.

7. A storage battery, characterized in that, The battery comprises a prefabricated perforated grid of aluminum-based composite material as described in any one of claims 1 to 6, wherein the busbar and the tabs of the battery are made of aluminum and are connected by laser spot welding or casting welding, and the upper part of the busbar and the tabs is wrapped with epoxy resin.

8. The storage battery according to claim 7, characterized in that, The thickness of the positive electrode plate of the battery is 0.6-1.8 mm, and the thickness of the negative electrode plate is 0.5-1.5 mm.

9. A method for preparing a storage battery as described in any one of claims 7-8, characterized in that, Includes the following steps, Step 1: Aluminum plate substrate rolling and aluminum plate substrate punching; Step 2: Anti-oxidation treatment of the surface of the punched aluminum plate substrate; Step 3: Electroplating lead-tin alloy onto the surface-treated aluminum plate substrate to form a grid. Step 4: Perform crease and relief treatment on the electroplated grid. Step 5: Apply lead paste to the grid. Step 6: Apply a film to the surface of the grid after applying the paste and then roll it. Step 7: Cut, dry, and cure the grid. Step 8: Electrode assembly, housing installation, and welding of electrode tabs and busbars; Step nine: sealing the battery cap, filling with electrolyte, formation, capacity testing, grouping, and packaging.

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