High power battery with radio structure integrated with multielement corrosion resistant alloy

Abstract

This invention discloses a high-power battery integrating a radioactive structure and a multi-element corrosion-resistant alloy, belonging to the field of lead-acid battery technology. It constructs a core component integrating a radioactive grid structure and a multi-element corrosion-resistant alloy. The radioactive grid adopts a centrally radiating structure, with 8-12 variable cross-section radial grid bars and 3-4 rings of progressively spaced annular grid bars forming a closed conductive network. The multi-element alloy is composed of Pb 98.5%-99.2%, Sn 0.3%-0.8%, Ag 0.05%-0.1%, Ca 0.06%-0.12%, and Al 0.03%-0.05%, with precise matching between composition and structure. The battery is manufactured through medium-frequency induction melting, controlled-cooling grid forming, stepped heat treatment, and optimized assembly processes. The battery has a C10 capacity of not less than 100Ah, a P15min discharge time of not less than 15min, a cycle life of not less than 780 cycles, a grid corrosion rate of not more than 0.023mm / a, and an energy utilization rate of not less than 87%. This design overcomes the performance bottleneck of traditional grid-alloy separation designs, combining high power, long lifespan, and high stability.

Description

Technical Field

[0001] This invention belongs to the field of lead-acid battery technology, and particularly relates to a high-power storage battery that integrates a radioactive structure with a multi-element corrosion-resistant alloy. Background Technology

[0002] Lead-acid batteries, with their advantages of low cost, high reliability, stable charge and discharge performance, and solid high-current output capability, occupy an important position in fields such as UPS power supplies, communication base station backup power supplies, emergency start-up equipment, and new energy storage systems. In recent years, as high-power UPS products have gradually become the mainstream in the market and backup power time has continued to shorten, while the demand for high-rate discharge and long cycle life of batteries in the new energy storage field has become increasingly urgent, the market has placed higher requirements on the comprehensive performance of batteries.

[0003] In existing technologies, grid structure and alloy composition are mostly designed independently, lacking synergistic optimization logic, leading to performance bottlenecks. On the one hand, traditional linear grids have inherent defects such as uneven current distribution and high internal resistance, resulting in severe energy loss during high-current discharge and failing to meet high-power output requirements. On the other hand, traditional grid alloys are mostly single lead-antimony alloys or binary lead-calcium alloy systems, with limited corrosion resistance. Long-term use is prone to corrosion flaking and structural deformation, and the alloy properties are not well-suited to the grid structure, making it difficult to fully realize the potential for structural optimization. This separate design prevents the battery's high-rate discharge capability and cycle life from being simultaneously improved, failing to meet the long-term stable operation requirements of high-power devices and energy storage systems. Summary of the Invention

[0004] To address the problems in the prior art, the present invention proposes the following technical solution: A high-power battery integrating a radial structure and a multi-element corrosion-resistant alloy includes a centrally radial grid structure. The grid has 8-12 radial grid bars evenly arranged around a central node, connected by 3-4 rings of annular grid bars. The multi-element corrosion-resistant grid alloy is composed of the following components by mass percentage: Pb 98.5%-99.2%, Sn 0.3%-0.8%, Ag 0.05%-0.1%, Ca 0.06%-0.12%, and Al 0.03%-0.05%. The parameters of the radial grid structure are precisely matched with the compositional characteristics of the multi-element corrosion-resistant alloy, forming an integrated and synergistic structure.

[0005] As a preferred embodiment of the above technical solution, the width of the radial grid gradually decreases from the center node to the edge, with a center width of 2.5-3.0 mm, an edge width of 1.2-1.5 mm, and a grid thickness of 1.0-1.2 mm; the diameter of the center node is 5-8 mm, the width of the annular grid is 1.0-1.2 mm, and the spacing between adjacent annular grids increases sequentially from the inside to the outside, with a spacing range of 8-15 mm.

[0006] As a preferred embodiment of the above technical solution, the manufacturing process of the integrated core component is as follows: after melting the multi-element corrosion-resistant alloy, it is formed into a radial grid structure by punching. During the forming process, the cooling rate is controlled at 5-8℃ / min, and then heat treatment is carried out at 350-380℃ for 2-3 hours. After the heat treatment, a stepped cooling method is adopted, with a stepped cooling rate of 50℃ per hour.

[0007] As a preferred embodiment of the above technical solution, the battery assembly compression ratio is controlled at 1.4-1.6, and the electrolyte density used during assembly is 1.28-1.30 g / cm³. 3 .

[0008] As a preferred embodiment of the above technical solution, the smelting process of the multi-element corrosion-resistant alloy is as follows: the raw materials are put into a medium-frequency induction furnace and melted at 480-520℃, the stirring rate is controlled at 30-50 r / min, and after stirring evenly, the mixture is kept at the temperature for 30-35 min to remove impurities.

[0009] As a preferred embodiment of the above technical solution, the alloy grain size of the radial grid after being formed by punching is 50-80μm.

[0010] Based on the above-mentioned high-power battery integrating a radioactive structure and a multi-element corrosion-resistant alloy, the battery C10 capacity is not less than 100Ah, the P15min high-rate discharge time is not less than 15min, the cycle life is not less than 780 cycles, the grid structure deformation rate is not higher than 1.0%, and the grid corrosion rate is not higher than 0.023mm / a.

[0011] Based on the aforementioned high-power battery integrating a radioactive structure with a multi-element corrosion-resistant alloy, the battery energy utilization rate is no less than 87%, making it suitable for high-power UPS, emergency power supplies, communication base stations, or new energy storage scenarios.

[0012] The beneficial effects of this invention are as follows: This invention utilizes a centrally radiating variable cross-section design of a radial grid, combined with an increasing spacing of annular grid bars, to achieve uniform current distribution, reduced internal resistance, and suitability for the conductivity characteristics of multi-element alloys. In these multi-element alloys, Sn enhances conductivity and formability, Ag strengthens corrosion resistance and mechanical strength, Ca reduces self-discharge rate, and Al inhibits intergranular corrosion, precisely supporting the stress distribution and conduction requirements of the radial structure. Combined with controlled cooling forming, stepped heat treatment, and optimized assembly processes, this invention collectively improves the battery's high-rate discharge performance, cycle life, and structural stability. Detailed Implementation

[0013] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments.

[0014] This invention relates to a high-power battery integrating a radioactive structure with a multi-element corrosion-resistant alloy. It constructs a core component integrating a radioactive grid structure and a multi-element corrosion-resistant alloy. The two components achieve synergistic effects through deep adaptation of composition design and structural parameters. The specific technical solution is as follows: Integrated core component design principle: The current conduction path and stress distribution characteristics of the radial grid structure are deeply adapted to the conductivity, mechanical strength, corrosion resistance, and formability of the multi-element corrosion-resistant alloy. The alloy composition is improved to address the centrally converging current conduction characteristics and stress distribution patterns of the radial grid. The structural parameters are precisely adjusted based on the alloy's mechanical strength, formability, and conductivity. The process parameters are further enhanced to ensure the compatibility between the structure and composition, maximizing current conduction efficiency, structural stability, and material durability simultaneously.

[0015] Radial Grid Structure: Utilizing a centrally radiating integrated structure, the grid's central node serves as the current-converging core, with 8-12 radiating grid strips evenly distributed outwards. These strips are interconnected by 3-4 rings of annular grid strips, forming a closed conductive network to ensure uniform current diffusion. Taking advantage of the conductivity of the multi-element alloy, the radiating grid strips employ a variable cross-section design, with the width gradually decreasing from the central node to the edge (2.5-3.0 mm at the center, 1.2-1.5 mm at the edge). This design ensures sufficient current convergence at the center while reducing energy loss at the edges, thus minimizing material usage. The grid strip thickness is set at 1.0-1.2 mm to match the alloy's mechanical strength, preventing structural deformation during long-term charging and discharging. The central node diameter is 5-8 mm, the annular grid strip width is 1.0-1.2 mm, and the spacing between adjacent annular grid strips increases progressively from the inside out (8-15 mm), aligning with the alloy's corrosion resistance, reducing localized corrosion concentration, and improving structural durability.

[0016] Multi-component corrosion-resistant alloy formulation: The alloy is composed of the following components by mass percentage: Pb 98.5%-99.2%, Sn 0.3%-0.8%, Ag 0.05%-0.1%, Ca 0.06%-0.12%, Al 0.03%-0.05%. The components work synergistically to precisely match the requirements of the radial grid structure: Sn enhances the alloy's conductivity and formability, ensuring uniform conduction efficiency in the radial structure; Ag strengthens the alloy's corrosion resistance and mechanical strength, supporting the structural stability of the variable cross-section design of the radial grid and preventing grid breakage; Ca reduces the battery's self-discharge rate and, in conjunction with structural optimization, improves energy utilization; Al inhibits intergranular corrosion, adapts to the spacing design of the annular grid, avoids crevice corrosion, and ensures that structural and material properties are fully utilized.

[0017] Integrated manufacturing process: Alloy melting: Weigh each raw material precisely according to the formula, put them into a medium frequency induction furnace, melt them at 480-520℃, control the stirring rate at 30-50r / min, and after stirring evenly, keep them at the temperature for 30-35min to remove impurities, ensure the uniformity of alloy composition, and provide a stable material basis for structural forming. Integrated molding: High-precision punching and molding process is adopted to directly process the molten alloy into a radial grid structure. During the molding process, the cooling rate is controlled at 5-8℃ / min. The controlled cooling process refines the alloy grains to 50-80μm, enhancing the tightness of the bond between the structure and the material. Heat treatment strengthening: After molding, hold at 350-380℃ for 2-3 hours, and use step cooling (50℃ per hour) to eliminate internal stress during molding and further improve the structural stability and corrosion resistance of the integrated component. Battery assembly: An optimized assembly compression ratio (1.4-1.6) is adopted to assemble the integrated grid, plates, and separators into an electrode group, which enhances the contact tightness between the plates and separators, reduces the contact internal resistance, and forms a performance synergy with the integrated core components. Subsequent processes: formation (current density 15mA / cm²) 2 (Conversion time 24h), electrolyte injection (electrolyte density 1.28-1.30g / cm³) 3 The finished battery is manufactured using conventional processes such as sealing.

[0018] Example 1 Multi-component corrosion-resistant alloy smelting: Weigh Pb 98.8%, Sn 0.5%, Ag 0.07%, Ca 0.09%, and Al 0.04% by mass percentage, put them into a medium-frequency induction furnace, melt them at 490℃, stir them evenly at a rate of 40r / min, and hold them at the temperature for 30min to remove impurities; Integrated radial grid forming: High-precision punching and forming equipment is used to process the molten alloy into a radial grid. The center node diameter is 6mm, there are 10 radial grid bars with a center width of 2.8mm, an edge width of 1.3mm, and a grid bar thickness of 1.1mm. There are 3 ring grid bars with a width of 1.1mm. The spacing between adjacent ring grid bars is 10mm, 12mm, and 14mm respectively. The cooling rate is controlled at 6℃ / min during forming. After forming, it is held at 360℃ for 2.5h and a stepped cooling method is used. Battery assembly: The assembly compression ratio is controlled at 1.5. The integrated grid is assembled with the plates and separators, and then formed (current density 15mA / cm). 2 (Formation time 24h), electrolyte injection (electrolyte density 1.28g / cm³) 3 Through processes such as sealing, lead-acid batteries of model LCP12-430C are manufactured. Performance testing: The battery has a C10 capacity of 105Ah, a P15min discharge time of 16.2min, a cycle life (100% deep discharge) of 800 cycles, a grid corrosion rate of 0.021mm / a, a structural deformation rate of only 0.8%, and an energy utilization rate of 89%.

[0019] Example 2 Multi-component corrosion-resistant alloy smelting: Weigh Pb 99.0%, Sn 0.3%, Ag 0.05%, Ca 0.06%, and Al 0.03% by mass percentage, put them into a medium-frequency induction furnace, melt them at 500℃, stir them evenly at a rate of 30r / min, and hold them at the temperature for 25min to remove impurities; Integrated radial grid forming: High-precision punching and forming equipment is used to process the molten alloy into a radial grid. The center node diameter is 5mm, there are 8 radial grid bars with a center width of 2.5mm, an edge width of 1.2mm, and a grid bar thickness of 1.0mm. There are 3 ring grid bars with a width of 1.0mm. The spacing between adjacent ring grid bars is 8mm, 10mm, and 12mm. The cooling rate is controlled at 5℃ / min during forming. After forming, the grid is held at 350℃ for 3 hours, and a stepped cooling method is used. Battery assembly: The compression ratio is controlled at 1.4. The integrated grid is assembled with the plates and separators, followed by formation and electrolyte injection (electrolyte density 1.29 g / cm³). 3 Through processes such as sealing, lead-acid batteries of model LCP12-430C are manufactured. Performance testing: The battery has a C10 capacity of 102Ah, a P15min discharge time of 15.5min, a cycle life (100% deep discharge) of 780 cycles, a grid corrosion rate of 0.023mm / a, a structural deformation rate of 1.0%, and an energy utilization rate of 87%.

[0020] Example 3 Multi-component corrosion-resistant alloy smelting: Weigh out Pb 98.5%, Sn 0.8%, Ag 0.1%, Ca 0.12%, and Al 0.05% by mass percentage, put them into a medium-frequency induction furnace, melt them at 480℃, stir them evenly at a rate of 50 r / min, and hold them at the temperature for 35 min to remove impurities; Integrated radial grid forming: High-precision punching and forming equipment is used to process the molten alloy into a radial grid. The center node diameter is 8mm, there are 12 radial grid bars with a center width of 3.0mm, an edge width of 1.5mm, and a grid bar thickness of 1.2mm. There are 4 ring grid bars with a width of 1.2mm. The spacing between adjacent ring grid bars is 10mm, 12mm, 14mm, and 15mm. The cooling rate is controlled at 8℃ / min during forming. After forming, the grid is held at 380℃ for 2 hours, and a stepped cooling method is used. Battery assembly: The assembly compression ratio is controlled at 1.6. The integrated grid is assembled with the plates and separators, followed by formation and electrolyte injection (electrolyte density 1.30 g / cm³). 3 Through processes such as sealing, lead-acid batteries of model LCP12-430C are manufactured. Performance testing: The battery has a C10 capacity of 108Ah, a P15min discharge time of 16.8min, a cycle life (100% deep discharge) of 820 cycles, a grid corrosion rate of 0.018mm / a, a structural deformation rate of 0.6%, and an energy utilization rate of 91%.

[0021] Example 4 Multi-component corrosion-resistant alloy smelting: Weigh out Pb 98.7%, Sn 0.6%, Ag 0.08%, Ca 0.10%, and Al 0.04% by mass percentage, put them into a medium-frequency induction furnace, melt them at 495℃, stir them evenly at a rate of 45r / min, and hold them at the temperature for 32min to remove impurities; Integrated radial grid forming: High-precision punching and forming equipment is used to process the molten alloy into a radial grid. The center node diameter is 7mm, there are 11 radial grid bars with a center width of 2.9mm, an edge width of 1.4mm, a grid bar thickness of 1.1mm, and 3 ring grid bars with a width of 1.1mm. The spacing between adjacent ring grid bars is 9mm, 11mm, and 13mm. The cooling rate is controlled at 7℃ / min during forming. After forming, it is held at 370℃ for 2.2h, and a stepped cooling method is used. Battery assembly: The compression ratio is controlled at 1.55. The integrated grid is assembled with the plates and separators, followed by formation and electrolyte injection (electrolyte density 1.28 g / cm³). 3 Through processes such as sealing, lead-acid batteries of model LCP12-430C are manufactured. Performance testing: The battery has a C10 capacity of 106Ah, a P15min discharge time of 16.5min, a cycle life (100% deep discharge) of 810 cycles, a grid corrosion rate of 0.019mm / a, a structural deformation rate of 0.7%, and an energy utilization rate of 90%.

[0022] Example 5 Multi-component corrosion-resistant alloy smelting: Weigh Pb 99.1%, Sn 0.4%, Ag 0.06%, Ca 0.07%, and Al 0.03% by mass percentage, put them into a medium-frequency induction furnace, melt them at 510℃, stir them evenly at a rate of 35r / min, and hold them at the temperature for 28min to remove impurities; Integrated radial grid forming: High-precision punching and forming equipment is used to process the molten alloy into a radial grid. The center node diameter is 6mm, there are 9 radial grid bars with a center width of 2.7mm, an edge width of 1.3mm, a grid bar thickness of 1.05mm, and 3 ring grid bars with a width of 1.05mm. The spacing between adjacent ring grid bars is 8mm, 11mm, and 13mm. The cooling rate is controlled at 5.5℃ / min during forming. After forming, it is held at 355℃ for 2.8h, and a stepped cooling method is used. Battery assembly: The compression ratio is controlled at 1.45. The integrated grid is assembled with the plates and separators, followed by formation and electrolyte injection (electrolyte density 1.29 g / cm³). 3 Through processes such as sealing, lead-acid batteries of model LCP12-430C are manufactured. Performance testing: The battery has a C10 capacity of 103Ah, a P15min discharge time of 15.8min, a cycle life (100% deep discharge) of 790 cycles, a grid corrosion rate of 0.022mm / a, a structural deformation rate of 0.9%, and an energy utilization rate of 88%.

[0023] Comparative Example 1 (Traditional linear grid + binary lead-calcium alloy) Grid alloy: A traditional binary lead-calcium alloy with a mass percentage of 99.7% Pb and 0.3% Ca; Plate grid structure: Traditional straight plate grid, with all grid bars being 2.0mm wide and 1.1mm thick, and orthogonally distributed; Manufacturing process: conventional melting and casting, mesh forming, no specific heat treatment, assembly compression ratio 1.2, electrolyte density 1.28 g / cm³. 3 ; Performance testing: A lead-acid battery with model number LCP12-430C was manufactured, with a C10 capacity of 95Ah, a P15min discharge time of 12.3min, a cycle life (100% deep discharge) of 520 cycles, a grid corrosion rate of 0.035mm / a, a structural deformation rate of 2.5%, and an energy utilization rate of 78%.

[0024] Comparative Example 2 (Radioactive grid + conventional binary lead-calcium alloy) Grid alloy: A traditional binary lead-calcium alloy with a mass percentage of 99.7% Pb and 0.3% Ca; Grid structure: The same radial grid structure as in Example 1; Manufacturing process: conventional melting and casting, mesh forming, no specific heat treatment, assembly compression ratio 1.5, electrolyte density 1.28 g / cm³. 3 ; Performance testing: A lead-acid battery with model number LCP12-430C was manufactured with a C10 capacity of 98Ah, a P15min discharge time of 13.8min, a cycle life (100% deep discharge) of 610 cycles, a grid corrosion rate of 0.032mm / a, a structural deformation rate of 1.8%, and an energy utilization rate of 82%.

[0025] Comparative Example 3 (Straight-line grid + Multi-component corrosion-resistant alloy of this invention) Grid alloy: The multi-element corrosion-resistant alloy formula of Example 1 of this invention is adopted; Plate grid structure: Traditional straight plate grid, with all grid bars being 2.0mm wide and 1.1mm thick, and orthogonally distributed; Manufacturing process: conventional melting and casting, mesh forming, no specific heat treatment, assembly compression ratio 1.2, electrolyte density 1.28 g / cm³. 3 ; Performance testing: A lead-acid battery with model number LCP12-430C was manufactured with a C10 capacity of 97Ah, a P15min discharge time of 13.2min, a cycle life (100% deep discharge) of 630 cycles, a grid corrosion rate of 0.025mm / a, a structural deformation rate of 2.2%, and an energy utilization rate of 81%.

[0026] The above performance comparison shows that: The batteries in Examples 1-5 are significantly better than the three comparative examples in key performance indicators such as C10 capacity, P15min discharge time, cycle life, and energy utilization rate. Furthermore, the grid corrosion rate and structural deformation rate are greatly reduced, proving the effectiveness and stability of the integrated design of the radioactive grid structure-multi-element corrosion-resistant alloy of the present invention. Although the performance of Comparative Example 2 (radioactive grid + conventional alloy) and Comparative Example 3 (linear grid + multi-element alloy) is better than that of Comparative Example 1, it is far inferior to that of the Example. This shows that simply optimizing the structure or alloy composition alone cannot achieve a comprehensive breakthrough in performance. Only by integrating and synergistically designing both can the synergistic effect be fully realized. Example 3 exhibits the best performance, with the best compatibility of its multi-element alloy composition ratio, radial grid structure parameters, and process parameters. This further verifies the scientific validity of the synergistic design logic of the present invention, which includes structural compatibility, compositional support structure, and process enhancement.

[0027] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it.

Claims

1. A high-power storage battery integrating a radioactive structure with a multi-component corrosion-resistant alloy, characterized in that, The plate grid includes a centrally radial structure, wherein 8-12 radial grid bars are evenly arranged around the central node as the origin, and the radial grid bars are connected by 3-4 ring grid bars. The multi-component corrosion-resistant grid alloy is composed of the following components by mass percentage: Pb 98.5%-99.2%, Sn 0.3%-0.8%, Ag 0.05%-0.1%, Ca 0.06%-0.12%, and Al 0.03%-0.05%. The parameters of the radial grid structure are precisely matched with the compositional characteristics of the multi-component corrosion-resistant alloy to form an integrated and synergistic structure.

2. The high-power storage battery integrating a radioactive structure with a multi-element corrosion-resistant alloy as described in claim 1, characterized in that, The width of the radial grid gradually decreases from the center node to the edge, with a center width of 2.5-3.0 mm and an edge width of 1.2-1.5 mm. The grid thickness is 1.0-1.2 mm. The diameter of the center node is 5-8 mm. The width of the annular grid is 1.0-1.2 mm. The spacing between adjacent annular grids increases sequentially from the inside to the outside, with a spacing range of 8-15 mm.

3. The high-power storage battery integrating a radioactive structure and a multi-element corrosion-resistant alloy as described in claim 1, characterized in that, The manufacturing process of the integrated core component is as follows: after melting the multi-element corrosion-resistant alloy, it is formed into a radial grid structure by punching. During the forming process, the cooling rate is controlled at 5-8℃ / min, and then heat treatment is carried out at 350-380℃ for 2-3 hours. After heat treatment, a stepped cooling method is adopted, with a stepped cooling rate of 50℃ per hour.

4. The high-power storage battery integrating a radioactive structure and a multi-element corrosion-resistant alloy as described in claim 1, characterized in that, The battery assembly compression ratio is controlled between 1.4 and 1.6, and the electrolyte density used during assembly is 1.28-1.30 g / cm³. 3 .

5. The high-power storage battery integrating a radioactive structure with a multi-element corrosion-resistant alloy as described in claim 1, characterized in that, The smelting process of the multi-element corrosion-resistant alloy is as follows: the raw materials are put into a medium-frequency induction furnace and melted at 480-520℃. The stirring rate is controlled at 30-50 r / min. After stirring evenly, the mixture is kept at the temperature for 30-35 min to remove impurities.

6. The high-power storage battery integrating a radioactive structure with a multi-component corrosion-resistant alloy as described in claim 1, characterized in that, After the radioactive grid is formed by punching, the alloy grain size is 50-80μm.

7. The high-power storage battery integrating a radioactive structure with a multi-component corrosion-resistant alloy as described in any one of claims 1-6, characterized in that, The battery C10 capacity is not less than 100Ah, the high-rate discharge time of P15min is not less than 15min, the cycle life is not less than 780 cycles, the grid structure deformation rate is not higher than 1.0%, and the grid corrosion rate is not higher than 0.023mm / a.

8. The high-power storage battery integrating a radioactive structure with a multi-component corrosion-resistant alloy according to any one of claims 1-6, characterized in that, The battery energy utilization rate is no less than 87%, making it suitable for high-power UPS, emergency power supplies, communication base stations, or new energy storage scenarios.