Lead-acid battery with exhaust structure and exhaust method

Abstract

This invention relates to the field of lead-acid battery technology, and particularly to a lead-acid battery with a venting structure, comprising a casing, battery assembly, cover plate, and venting assembly. The battery assembly adopts a lean electrolyte separator structure, utilizing the oxygen recombination principle to react oxygen generated at the positive electrode with the lead active material at the negative electrode to generate water, reducing electrolyte loss. The venting assembly includes a safety valve and a safety bursting unit arranged in parallel or series. The safety valve is mechanical or electronically controlled, and the safety bursting unit uses a positively arched aluminum bursting disc with an operating pressure higher than that of the safety valve. A hydrogen sensor, a gas equalization plate, and a controller are also included to monitor the hydrogen concentration in real time and control the electronically controlled venting valve to actively vent. This invention, a lead-acid battery with a venting structure, achieves internal gas recycling through oxygen recombination, and, combined with staged venting and active monitoring and control, significantly improves battery safety, reliability, and maintenance-free performance.

Description

Technical Field

[0001] This invention relates to the field of lead-acid battery technology, and in particular to a lead-acid battery with a venting structure and a venting method. Background Technology

[0002] During the charging and discharging process of lead-acid batteries, especially at the end of charging or in an overcharged state, oxygen will be released from the positive electrode. Hydrogen gas will be released at the negative electrode. If these gases are not released in a timely and safe manner, they will cause the internal pressure of the battery to increase, leading to casing bulging, electrolyte leakage, or even explosion. At the same time, the release of gases will carry away water vapor, causing the electrolyte to lose water and shortening the battery life.

[0003] In existing technologies, valve-regulated sealed lead-acid batteries (VRLA) reduce water loss to some extent through the principle of oxygen recombination, but excessive hydrogen gas can still be generated under abnormal operating conditions (such as overcharging, high temperature, and battery aging). Traditional safety valves are only passive mechanical pressure relief devices and cannot actively monitor hydrogen concentration and vent in time. Moreover, when the safety valve fails, the battery faces a serious risk of deflagration. In addition, existing venting structures lack a graded protection mechanism; once the safety valve fails, the entire battery loses its safety guarantee. Summary of the Invention

[0004] This invention solves the problems in related technologies and proposes a lead-acid battery with an exhaust structure, including a casing, a battery assembly disposed within the casing, and a cover plate connected to the casing;

[0005] The battery assembly includes a positive electrode plate group disposed on one side of the housing, a negative electrode plate group disposed on the other side of the housing, a separator disposed between the positive electrode plate group and the negative electrode plate group, and an electrolyte filled on the separator.

[0006] The positive electrode assembly includes positive electrode plates uniformly disposed within the housing, a positive electrode busbar for connecting the positive electrode plates, a positive electrode post connected to the positive electrode busbar, and a positive electrode terminal disposed on one side of the cover and connected to the positive electrode post.

[0007] The negative electrode plate assembly includes negative electrode plates uniformly disposed within the housing, a negative electrode busbar for connecting the negative electrode plates, a negative electrode post connected to the negative electrode busbar, and a negative electrode terminal disposed on one side of the cover and connected to the negative electrode post.

[0008] The partition is made of ultra-fine glass fiber, which has high porosity and good hydrophilicity, and is used to realize oxygen recombination reaction in a lean solution state.

[0009] By adopting the above technical solution, the oxygen generated by the positive electrode plate reacts chemically with the active material lead in the negative electrode plate to regenerate water, thereby reducing electrolyte loss, improving battery cycle life, and realizing effective circulation and reuse of gas inside the battery assembly. This reduces the risk of casing expansion caused by gas accumulation during battery use. Specifically, firstly, during normal charging and discharging, the oxygen generated by the positive electrode plate diffuses to the negative electrode plate through the pores of the ultra-fine glass fiber separator. Secondly, the oxygen diffused to the negative electrode plate reacts with the active material lead on the negative electrode plate under the action of the electrolyte to generate lead oxide. Then, the generated lead oxide further reacts with sulfuric acid in the electrolyte to generate lead sulfate and water, thus converting the oxygen back into a component of the electrolyte. Finally, any small amount of gas that does not participate in the reaction and accumulates is controlled to be released through an exhaust valve installed on the cover plate, ensuring that the internal pressure of the battery is maintained within a safe range. The above-mentioned venting method not only achieves efficient recombination and recycling of internal gases, reducing electrolyte consumption and extending battery life, but also effectively avoids safety hazards caused by excessive internal pressure through a controllable venting mechanism, thus improving the safety and stability of battery use.

[0010] It also includes an exhaust port disposed on the cover plate and an exhaust assembly connected to the exhaust port;

[0011] The exhaust assembly includes a safety valve and a safety explosion unit;

[0012] The safety valve is configured as either a passive mechanical pressure relief valve or an electrically controlled exhaust valve, and the operating pressure of the rupture unit is greater than the operating pressure of the safety valve.

[0013] The safe blasting unit includes blasting components and mounting components for installing the blasting components;

[0014] The installation blasting device includes a blasting disc body, a fixing plate disposed on the outer circular surface of the blasting disc body, an upper clamp disposed on the upper surface of the fixing plate, a lower clamp disposed on the lower surface of the fixing plate, a connecting plate evenly disposed on the outer circular surfaces of the upper clamp and the lower clamp, and a fixing screw that passes through the connecting plate and connects to the upper clamp and the lower clamp.

[0015] The mounting component includes an exhaust pipe connected to the upper clamp, a first connecting lug plate disposed at one end of the exhaust pipe relative to the upper clamp, an air inlet pipe connected to the lower clamp, a second connecting lug plate disposed at one end of the air inlet pipe relative to the lower clamp, and a connecting screw for connecting the first connecting lug plate and the second connecting lug plate.

[0016] As a preferred embodiment, the exhaust assembly further includes a hydrogen sensor disposed at the top of the inner cavity of the housing, a gas equalization plate fixedly disposed below the hydrogen sensor and disposed on the upper surface of the battery assembly, and a controller electrically connected to the hydrogen sensor.

[0017] By adopting the above technical solution, the hydrogen sensor can monitor the changes in hydrogen concentration inside the battery in real time and transmit the monitoring data to the controller. When the hydrogen concentration reaches a preset safety threshold, the controller will respond quickly, driving the safety valve to open for venting and depressurization, preventing the risk of combustion or explosion caused by excessive hydrogen concentration. The gas equalization plate allows the gas at the top of the inner cavity of the casing to flow smoothly and evenly through the sensing area of ​​the hydrogen sensor, avoiding monitoring errors caused by uneven local gas concentration, and ensuring that the hydrogen sensor can accurately and timely capture the gas state inside the battery. At the same time, the gas equalization plate can also slow down the gas flow speed to a certain extent, providing a stable environment for the hydrogen sensor to detect, further improving the reliability and sensitivity of monitoring, thereby providing strong data support for the precise action of the venting component and ensuring the safe and stable operation of the lead-acid battery.

[0018] As a preferred embodiment, the rupture disc body is configured as a positive arch shape, with the highest point of the convex surface located on the high-pressure side during gas emission, and the rupture disc body is made of aluminum material with a thickness of 0.15-0.3 mm.

[0019] By adopting the above technical solution, it is possible to ensure that the rupture disc reliably ruptures when the internal pressure of the battery reaches the preset safety threshold, releasing excessive pressure in a timely manner, while also guaranteeing good structural stability and fatigue resistance within the normal operating pressure range, avoiding unexpected rupture. The positive arch design ensures that when the rupture disc is subjected to internal pressure, its convex surface first bears the pressure and deforms. When the pressure reaches the burst pressure, the rupture disc ruptures, forming a relatively regular opening, ensuring that gas can be discharged quickly and smoothly. The aluminum material has good ductility and corrosion resistance, enabling it to adapt to the chemical environment inside the battery. At the same time, its relatively low strength also facilitates precise rupture under the set pressure.

[0020] As a preferred embodiment, the upper clamp and the lower clamp are respectively configured as annular structures, and the inner diameter of the upper clamp and the lower clamp is adapted to the outer diameter of the rupture disc.

[0021] By adopting the above technical solution, a tight clamping of the rupture disc body can be achieved. The lower end face of the upper clamp is tightly fitted with the upper end face of the fixed plate, and the upper end face of the lower clamp is tightly fitted with the lower end face of the fixed plate. Through the fastening action of the connecting plate and the fixing screw, the upper clamp, the fixed plate, the lower clamp and the rupture disc body are firmly assembled together to form an integrated safe blasting unit.

[0022] As a preferred embodiment, the upper clamp and the lower clamp are respectively provided with fixing screw holes adapted to the fixing screws, and the connecting plates are evenly distributed along the outer circular surfaces of the upper clamp and the lower clamp.

[0023] By adopting the above technical solution, deformation or damage to the rupture disc body due to uneven stress during installation is prevented. After the fixing screws penetrate the connecting plate, they are threaded into the pre-set fixing screw holes on the upper and lower clamps, respectively. The tightening torque must be strictly controlled to ensure the stability of the connection while avoiding over-tightening that could cause plastic deformation of the rupture disc body or the clamps themselves, affecting the normal function of the safety rupture unit.

[0024] As a preferred embodiment, the first connecting ear plate is arranged circumferentially along the outer surface of the exhaust pipe, and the second connecting ear plate is arranged circumferentially along the outer surface of the intake pipe. The first and second connecting ear plates are provided with connecting holes for connecting screws to pass through, and the inner wall of the connecting hole is set as a smooth arc surface.

[0025] By adopting the above technical solution, the frictional resistance when the connecting screw passes through is reduced, facilitating installation and disassembly. After the two ends of the connecting screw pass through the connecting holes of the first and second connecting lugs respectively, they are tightened with nuts, thereby connecting the exhaust pipe, upper clamp, blasting assembly, lower clamp, and intake pipe into a whole, achieving a sealed connection between the safety blasting unit and the exhaust port.

[0026] As a preferred embodiment, the gas flow equalization plate is uniformly provided with a plurality of gas guide holes, and the diameter of each gas guide hole gradually increases from the side closer to the battery assembly to the side closer to the hydrogen sensor.

[0027] By adopting the above technical solution, the gas guide holes are used to uniformly guide the generated gas to the inlet of the hydrogen sensor and the electronically controlled exhaust valve. The diameter of these gas guide holes gradually increases from the side closer to the battery assembly to the side closer to the hydrogen sensor, forming a gradient structure to promote smooth gas flow and uniform distribution.

[0028] As a preferred embodiment, the safety valve and the safety explosion unit are connected in parallel at the exhaust port, the air inlet of the safety valve is connected to the exhaust port, and the air inlet pipe of the safety explosion unit passes through the cover plate and is connected to the housing.

[0029] By adopting the above technical solution, the outlet of the safety valve and the outlet of the exhaust pipe of the safety burst unit together constitute the final exhaust channel of the battery. This parallel arrangement allows the safety valve to act as the primary protection, initiating exhaust when the normal gas pressure rises, while the safety burst unit acts as the secondary protection, only triggering when the safety valve fails or the internal pressure abnormally rises to its set operating pressure. This forms a dual safety protection mechanism, greatly improving the safety of lead-acid batteries under extreme conditions. There is a clear gradient between the operating pressure settings of the safety valve and the safety burst unit. Typically, the operating pressure setting of the safety burst unit is 1.2-1.5 times higher than that of the safety valve. This ensures that the safety burst unit will not malfunction when the safety valve is functioning normally. The safety burst unit will only activate when the safety valve fails to effectively release pressure, causing the pressure to continuously rise to a dangerous level, thus achieving graded protection for the battery.

[0030] As a preferred embodiment, the safety blasting unit is connected in series on the inlet side of the safety valve;

[0031] The air inlet pipe of the safety blasting unit is connected to the exhaust port, and the exhaust pipe of the safety blasting unit is connected to the air inlet of the safety valve.

[0032] By adopting the above technical solution, the safety rupture unit acts as a physical barrier, isolating the hydrogen gas released from the battery assembly from the safety valve. This prevents the hydrogen gas from directly contacting the metal components inside the safety valve, thus avoiding corrosion or chemical reactions and extending the service life of the safety valve. In the event of system overpressure, the safety rupture unit and the safety valve activate sequentially to release hydrogen gas. Once the system pressure returns to normal, the safety valve automatically closes. Specifically, the rupture disc must be of a fragment-free type to avoid clogging the safety valve. In this series structure, when gas is generated inside the battery and the pressure gradually increases, the rupture pressure threshold of the safety rupture unit must be exceeded first. Once the pressure reaches the set activation pressure of the safety rupture unit, the rupture disc ruptures, and the gas enters the inlet of the safety valve through the inlet pipe, the rupture port of the rupture component, and the exhaust pipe. Subsequently, if the gas pressure continues to rise and reaches the activation pressure of the safety valve, the safety valve opens to release gas and reduce pressure. This series configuration allows the safety rupture unit to not only relieve pressure but also, to a certain extent, perform preliminary filtration or buffering of the gas entering the safety valve, reducing the impact of electrolyte droplets or other contaminants on the sealing performance of the safety valve. Meanwhile, because the burst plate of the safety burst unit cannot self-repair after rupture, if the internal pressure of the battery rises again after the safety valve has finished venting and closed, the ruptured safety burst unit will no longer provide protection. In this case, the safety of the entire venting assembly depends on the normal operation of the safety valve. Therefore, this series connection method is typically suitable for scenarios with extremely high safety requirements and a more prominent need for safety valve protection. It sacrifices the disposable nature of the safety burst unit in exchange for effective protection of the safety valve and an extended service life.

[0033] As a preferred embodiment, the safety blasting unit is connected in series on the outlet side of the safety valve;

[0034] The air inlet of the safety valve is connected to the exhaust port, and the air inlet pipe of the safety explosion unit is connected to the exhaust port of the safety valve.

[0035] By adopting the above technical solution, this design isolates the emission environment from the battery assembly through the rupture disc, effectively preventing dust, moisture, or other corrosive substances from the external environment from flowing back into the battery through the exhaust channel, thus avoiding contamination or damage to the battery assembly. When the internal pressure of the battery rises, the safety valve opens first to exhaust gas. The gas enters the intake pipe of the safety rupture unit through the exhaust end of the safety valve. If the safety valve fails to effectively control the pressure at this time due to a malfunction, causing the gas pressure to continue to rise and reach the activation pressure of the safety rupture unit, the rupture disc ruptures, and the gas is directly discharged to the external environment through the exhaust pipe, forming a secondary protection for the battery. In this series configuration, the safety valve, as the main pressure control device, is responsible for daily gas discharge and pressure regulation, while the safety rupture unit plays a role when the safety valve fails or the exhaust is obstructed, causing an abnormal increase in pressure. It is located on the outlet side of the safety valve, so it does not affect the normal opening and closing of the safety valve, and at the same time, it can further buffer the pressure of the gas discharged from the safety valve and provide safe discharge. Furthermore, since the safety rupture unit is located at the end of the exhaust path, the rupture of its rupture disc will not affect the pressure balance between the battery and the safety valve, ensuring that the gas can be discharged quickly and without obstruction in extreme cases, further improving the reliability and safety of the lead-acid battery exhaust system.

[0036] The invention also provides a method for venting the lead-acid battery described above, comprising the following steps:

[0037] Oxygen recombination cycle steps: During the charging and discharging process of the battery, the oxygen generated by the positive electrode plate diffuses to the negative electrode plate through the pores of the ultra-fine glass fiber separator; the oxygen diffused to the negative electrode plate reacts with the active material lead on the negative electrode plate under the action of the electrolyte to form lead oxide; the generated lead oxide reacts with sulfuric acid in the electrolyte to form lead sulfate and water, thus converting the oxygen back into a component of the electrolyte.

[0038] Active monitoring and controllable exhaust procedure: The hydrogen sensor detects the hydrogen concentration inside the housing in real time, and the gas equalization plate guides the gas evenly to the sensing area of ​​the hydrogen sensor; when the hydrogen concentration reaches the preset safety threshold (e.g., volume concentration 2% to 3%), the controller controls the electronically controlled exhaust valve to open for exhaust; when the hydrogen concentration drops to the safety lower limit (e.g., 1% to 1.5%), the controller controls the electronically controlled exhaust valve to close.

[0039] Staged pressure relief procedure: When the gas pressure inside the housing reaches the safety valve's operating pressure, the safety valve automatically opens to relieve pressure; if the safety valve fails or the venting capacity is insufficient, causing the pressure to continue to rise to the operating pressure of the safety bursting unit, the bursting disc ruptures, and the gas is quickly discharged through the vent pipe; after the pressure relief is completed, if the safety valve is a resettable type, it will automatically close.

[0040] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention has the following advantages:

[0041] 1. Reduced water loss through oxygen recombination cycle: By utilizing the lean electrolyte structure and oxygen diffusion channels of the separator, the oxygen generated at the positive electrode is absorbed by the negative electrode and regenerated into water, reducing the electrolyte loss rate by more than 80% and significantly extending the battery's maintenance-free cycle.

[0042] 2. A hydrogen sensor, in conjunction with a gas equalization plate, enables real-time and uniform monitoring of hydrogen concentration, avoiding localized concentration blind spots. The controller actively opens the electrically controlled exhaust valve based on threshold values, ensuring that the hydrogen concentration remains below the lower explosive limit, fundamentally eliminating the risk of combustion and explosion. The safety valve, as primary protection, activates under normal overpressure conditions; the safety rupture unit, as secondary protection, operates at a higher pressure and employs a positively arched aluminum rupture disc body, ensuring precise rupture pressure, regular opening, and unobstructed venting. Three connection methods (parallel, series inlet, and series outlet) adapt to different application scenarios, providing a flexible redundancy design.

[0043] 3. The full-explosion unit adopts a modular clamping structure, making it easy to replace the rupture discs; the gas flow equalization plate and hydrogen sensor are integrated on the top of the housing, without occupying extra space; the overall solution has good compatibility with existing lead-acid battery production lines. Attached Figure Description

[0044] Figure 1 This is a schematic diagram of the overall structure of a lead-acid battery with an exhaust structure according to the present invention;

[0045] Figure 2 This is a partial half-sectional view of a battery assembly in a lead-acid battery with an exhaust structure according to the present invention.

[0046] Figure 3 This is a schematic diagram of the structure of a lead-acid battery with an exhaust structure in which the safety valve and the safety explosion unit are connected in parallel.

[0047] Figure 4 This is a schematic diagram of the structure of a lead-acid battery with an exhaust structure in which the safety explosion unit is set at the exhaust end of the safety valve (the safety explosion unit is connected in series with the safety valve).

[0048] Figure 5 This is a schematic diagram of the structure of a safety explosion unit of a lead-acid battery with an exhaust structure, which is set at the air inlet end of a safety valve (the safety explosion unit is connected in series with the safety valve).

[0049] Figure 6 This is a schematic diagram of the structure of a safety explosion unit in a lead-acid battery with an exhaust structure according to the present invention;

[0050] Figure 7 This invention relates to a lead-acid battery with an exhaust structure. Figure 6 A schematic diagram of the structure in a partial half-section view;

[0051] Figure 8 This is a schematic diagram of the structure of a lead-acid battery with an exhaust structure according to the present invention, in which the rupture disc is connected to the sealing component.

[0052] Figure 9 This is a schematic diagram of the exploded structure of the rupture disc and the sealing component in a lead-acid battery with an exhaust structure according to the present invention.

[0053] In the picture:

[0054] 100. Housing; 200. Cover plate; 31. Positive electrode plate; 311. Positive electrode busbar; 3111. Positive electrode post; 32. Negative electrode plate; 321. Negative electrode busbar; 3211. Negative electrode post; 33. Separator; 41. Positive terminal; 42. Negative terminal; 5. Exhaust port; 6. Gas equalization plate; 7. Hydrogen sensor; 8. Safety valve; 9. Safety rupture unit; 91. Rupture disc body; 911. Fixing plate; 921. Upper clamp; 922. Lower clamp; 93. Connecting plate; 94. Fixing screw; 941. Fixing screw hole; 951. Exhaust pipe; 9511. First connecting lug; 952. Inlet pipe; 9521. Second connecting lug. Detailed Implementation

[0055] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0056] 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.

[0057] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0058] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms 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, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0059] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0060] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0061] Example 1: Parallel Connection

[0062] Structural description: such as Figure 1 , Figure 2 and Figure 3 As shown, a lead-acid battery with a venting structure includes a casing 100, a battery assembly, and a cover plate 200. The casing 100 is injection molded from ABS plastic and is internally divided into multiple cells by separators 33. The battery assembly adopts a 12V / 100Ah specification and contains 6 cells connected in series.

[0063] like Figure 2 As shown, within each cell, a group of positive electrode plates 31 is disposed on one side of the housing 100, and a group of negative electrode plates 32 is disposed on the other side, with an ultrafine glass fiber separator 33 sandwiched between them. The positive electrode plates 31 are paste-coated grids, with lead dioxide as the active material; the negative electrode plates 32 have spongy lead as the active material. The positive electrode busbar 311 connects the positive electrode plates 31 in parallel and connects them to the positive terminal 41 on the cover plate 200 via the positive electrode post 3111; the same applies to the negative electrode side. The separator 33 is of type EC-90, with a thickness of 2.5 mm, a porosity of 92%, and a pore size of 5 μm to 8 μm. The electrolyte is dilute sulfuric acid with a density of 1.30 g / cm³, and a negative pressure acid injection process is used to saturate the separator 33 to approximately 90%, leaving 10% porosity as an oxygen diffusion channel.

[0064] An exhaust port 5 is provided on the cover plate 200, and the exhaust assembly is connected to the exhaust port 5. In this embodiment, the safety valve 8 and the safety explosion unit 9 are connected in parallel. The safety valve 8 is a passive mechanical pressure relief valve with an opening pressure of 20 kPa and a closing pressure of 15 kPa. The air inlet pipe 952 of the safety explosion unit 9 passes through the cover plate 200 and is directly connected to the inner cavity of the housing 100. Its operating pressure is set to 1.5 times the operating pressure of the 30 kPa safety valve 8.

[0065] like Figure 6 , Figure 7 , Figure 8 and Figure 9 As shown, the specific structure of the safety blasting unit 9 is as follows: The blasting disc body 91 is a positively arched aluminum sheet with a thickness of 0.20 mm and an arch height of 2 mm. The fixing plate 911 is annular and welded to the outer circular surface of the blasting disc body 91. The upper clamp 921 and the lower clamp 922 are both annular stainless steel parts with an inner diameter of Φ25 mm, which is the same as the outer diameter of the blasting disc body 91. There are a total of 4 connecting plates 93. The fixing screws 94 pass through the through holes on the connecting plates 93 and are screwed into the threaded holes on the upper clamp 921 and the lower clamp 922 to clamp the fixing plate 911. In the mounting components, the exhaust pipe 951 is welded to the upper clamp 921, and its end is provided with a first connecting ear plate 9511; the intake pipe 952 is welded to the lower clamp 922, and its end is provided with a second connecting ear plate 9521. The connecting screw passes through the connecting holes of the first connecting ear plate 9511 and the second connecting ear plate 9521, and is locked at both ends with nuts to seal the entire safety blasting unit 9.

[0066] like Figure 2 As shown, the active monitoring and control components include: an electrochemical hydrogen sensor 7 with a range of 0–4% vol and an accuracy of 100 ppm is installed at the top of the inner cavity of the housing 100. A gas equalization plate 6, made of polypropylene and 2 mm thick, is fixed to the upper surface of the battery assembly. The gas equalization plate 6 has 30 evenly distributed gas guide holes, with a lower diameter of 0.8 mm and an upper diameter of 2.0 mm, tapering gradually. The gas equalization plate 6 is fixed to the inner wall of the housing 100 by four clips. The controller is an STM8S003F3 microcontroller, installed in the junction box outside the cover plate 200, and connected to the hydrogen sensor 7 and the electrically controlled exhaust valve. In this embodiment, the safety valve 8 is mechanical, so the electrically controlled exhaust valve is not activated; if an electrically controlled exhaust valve is selected, the controller is electrically connected to it.

[0067] Working principle:

[0068] Normal charge and discharge: During charging, oxygen is evolved at the positive electrode, and the oxygen diffuses to the surface of the negative electrode plate 32 through the pores in the separator 33 that are not occupied by the electrolyte. The negative electrode active material, lead, reacts with oxygen: Oxygen is consumed, and the generated water replenishes the electrolyte; very little hydrogen is released. The pressure inside the casing 100 remains stable at 2–5 kPa, and neither the safety valve 8 nor the safety explosion unit 9 activates.

[0069] Overcharging or Abnormal Hydrogen Evolution: When the charging voltage is too high or the battery is aging, hydrogen evolution begins at the negative electrode. Hydrogen rises to the top of the casing 100, is evenly dispersed through the gas distribution plate 6's vents, and then flows through the hydrogen sensor 7. When the hydrogen concentration reaches a preset threshold of 3%, the controller issues an alarm signal and activates the electronically controlled exhaust valve, which opens if configured. In this embodiment, the safety valve 8 is mechanical and cannot be electronically controlled, but the user can replace it with an electronically controlled exhaust valve as needed. When the pressure reaches 20 kPa, the safety valve 8 opens to exhaust; after exhausting, it closes when the pressure drops below 15 kPa.

[0070] Secondary protection in case of safety valve 8 failure: If safety valve 8 cannot open due to blockage or jamming, and the pressure continues to rise to 30 kPa, the pressure on the rupture disc 91 of the safety rupture unit 9 reaches the limit of its arched structure, causing it to rupture at the arch apex. Due to the positive arch design, the rupture forms a roughly regular circular opening, and gas is rapidly discharged through the inlet pipe 952, the rupture opening, and the exhaust pipe 951, releasing the pressure instantly. After the rupture disc 91 ruptures, the safety rupture unit 9 fails and needs to be replaced with a new rupture assembly.

[0071] Advantages of parallel connection: Safety valve 8 and safety rupture unit 9 work independently without interfering with each other. During normal overpressure, safety valve 8 opens and closes frequently, while safety rupture unit 9 only intervenes in extreme cases, avoiding fatigue damage to the rupture disc 91 due to frequent pressure fluctuations.

[0072] Example 2: Safety blasting unit 9 is connected in series on the inlet side of safety valve 8.

[0073] Structural Description: The difference between this embodiment and Embodiment 1 lies in the connection method of the exhaust assembly. For example... Figure 5 As shown, the air inlet pipe 952 of the safety rupture unit 9 is directly connected to the exhaust port 5 on the cover plate 200, and the exhaust pipe 951 of the safety rupture unit 9 is connected to the air inlet of the safety valve 8. The air outlet of the safety valve 8 is open to the atmosphere. The rupture disc body 91 is made of a non-fragmented type, such as a scored aluminum sheet or a composite diaphragm, to ensure that no small fragments that may block the safety valve 8 are produced when it ruptures.

[0074] Working principle:

[0075] The gas generated inside the battery first enters the air inlet pipe 952 of the safety explosion unit 9 and acts on the convex surface of the explosion disc body 91. Within the normal pressure range of <30kPa, the explosion disc body 91 remains intact, and the gas is sealed at the inlet side of the safety explosion unit 9, unable to reach the safety valve 8.

[0076] When the pressure reaches 30 kPa, the rupture disc 91 ruptures, and gas enters the inlet of the safety valve 8 through the exhaust pipe 951. If the pressure is still higher than the opening pressure of the safety valve 8 (20 kPa), the safety valve 8 will immediately open to release gas; if the pressure has dropped below 20 kPa, for example, when the rupture disc ruptures and the pressure is released instantaneously, the safety valve 8 may not activate.

[0077] The advantages of connecting it in series on the inlet side: The safety burst unit 9 acts as a physical barrier, isolating the hydrogen and acidic gases generated inside the battery from the metal components of the safety valve 8, such as the spring and valve core, preventing corrosion and sulfide deposition, and significantly extending the service life of the safety valve 8. The disadvantage is that it is for single use only; if the burst disc ruptures, the entire safety burst unit 9 must be replaced.

[0078] Applicable scenarios: Long-term float-charged backup power supplies with high requirements for the lifespan of safety valve 8, communication base station batteries, etc.

[0079] Example 3: Safety blasting unit 9 is connected in series on the outlet side of safety valve 8.

[0080] Structural description: In this embodiment, as Figure 4 As shown, the inlet of safety valve 8 is connected to the exhaust port 5, and the outlet of safety valve 8 is connected to the inlet pipe 952 of safety rupture unit 9. The exhaust pipe 951 of safety rupture unit 9 is open to the atmosphere. The rupture disc body 91 is a conventional positive arch aluminum sheet with a thickness of 0.25 mm. The action pressure is set to 25 kPa, slightly higher than the opening pressure of safety valve 8 (20 kPa), as a redundancy.

[0081] Working principle:

[0082] When the internal pressure of the battery increases, safety valve 8 opens first to release gas. After flowing out through safety valve 8, the gas enters the air inlet pipe 952 of the safety burst unit 9. At this time, the pressure direction on the convex surface of the burst disc body 91 is consistent with the gas flow direction, but the pressure peak during normal venting is usually below 25 kPa, and the burst disc will not rupture.

[0083] If safety valve 8 malfunctions, such as the valve core being stuck in the open position but unable to vent, or the opening pressure drifting too high causing the pressure inside housing 100 to continue to rise after venting, or safety valve 81 completely failing and unable to open, the gas pressure will be transmitted to the safety bursting unit 9 through the internal channel of safety valve 8. When the pressure reaches 25 kPa, the bursting disc 91 will rupture, and the gas will be directly discharged into the atmosphere.

[0084] Another important function connected in series on the outlet side is that when the battery is in a negative pressure environment, such as after cooling or when there is moisture or dust in the outside, the bursting disc 91 of the safety bursting unit 9 isolates the external environment from the inside of the battery, preventing contaminants from flowing back into the safety valve 8 and the battery. At the same time, since the bursting disc 91 is located after the safety valve 8, its rupture will not affect the sealing of the safety valve 8, and the safety valve 8 can continue to be used.

[0085] Applicable scenarios: Energy storage systems in outdoor or harsh environments, solar street light batteries, etc.

[0086] The embodiment integrates active electronically controlled exhaust and hydrogen monitoring.

[0087] This embodiment, based on Embodiment 1, replaces the safety valve 8 with a normally closed solenoid valve for electrical exhaust, rated at 12V and 2W, and enables the linkage function between the controller and the hydrogen sensor 7. The gas flow equalization plate 6 has a three-stage gradient for its guide holes: 0.6mm at the bottom, 1.2mm in the middle, and 2.0mm at the top, for a total of 40 holes. The controller is preset with a hydrogen concentration opening threshold of 2.5% and a closing threshold of 1.0%; the pressure opening threshold of 25kPa is measured by an independent pressure sensor, and the closing threshold is 12kPa.

[0088] Work process:

[0089] Normal charging: hydrogen concentration <0.5%, pressure <5kPa, electronically controlled exhaust valve closed.

[0090] When the hydrogen concentration is detected to rise to 2.5%, the controller immediately opens the electronically controlled exhaust valve. After venting for 3-5 seconds, the concentration drops below 1.0%, and the valve closes. If the concentration decreases slowly, the controller uses an intermittent venting strategy, opening for 5 seconds and closing for 10 seconds to avoid excessive venting and water loss.

[0091] If the hydrogen sensor 7 malfunctions or the concentration does not reach the threshold but the pressure rises to 25 kPa (e.g., due to oxygen accumulation), the controller will also open the exhaust valve.

[0092] If the electronically controlled exhaust valve fails, such as if the coil burns out, and the pressure continues to rise to 30 kPa, the safety explosion unit 9 will activate to achieve final protection.

[0093] This embodiment achieves three-level gas management: "oxygen recombination → active electronically controlled venting → safe explosion", keeping the water loss rate at the lowest level. Tests show that the 100Ah battery loses only 3.8mL of water per cell after 168 hours under overcharge conditions, while ensuring that the hydrogen concentration is always below 60% of the lower explosive limit.

[0094] Materials and Process Specifications

[0095] The rupture disc body is made of 1060 aluminum alloy or 3003 aluminum alloy and is annealed.

[0096] The upper clamp 921 and lower clamp 922 are made of 316L stainless steel, and the surface roughness Ra is ≤0.8μm. The tightening torque of the fixing screw 94 is 2~3N·m, which is controlled by a torque wrench.

[0097] The distance between the gas flow equalization plate 6 and the hydrogen sensor 7 is 5mm to 10mm to ensure uniform airflow and a sensor response time of ≤3 seconds.

[0098] The controller adopts a low-power design with a standby current of <0.5mA. It automatically enters sleep mode when the battery voltage is lower than 10.5V and wakes up to check once every minute.

[0099] The lead-acid battery venting structure and method provided by this invention uses mature industrial products for all components, resulting in low manufacturing costs. Taking a 12V / 100Ah battery as an example, the added safety explosion unit 9 costs approximately 8-12 yuan, the hydrogen sensor 7 + controller costs approximately 25-35 yuan, and the electronically controlled venting valve costs approximately 15 yuan, totaling an additional cost of approximately 50 yuan. It is applicable to various types of lead-acid batteries, including starting batteries, energy storage batteries, UPS batteries, and power batteries.

[0100] The above are preferred embodiments of the present invention. Those skilled in the art can make changes and modifications to the above embodiments. Therefore, the present invention is not limited to the specific embodiments described above. Any obvious improvements, substitutions or modifications made by those skilled in the art based on the present invention are within the protection scope of the present invention.

Claims

1. A lead-acid battery with a venting structure and a venting method, comprising a housing (100), a battery assembly disposed within the housing (100), and a cover plate (200) connected to the housing (100), wherein the battery assembly comprises a group of positive electrode plates (31) disposed on one side of the housing (100), a group of negative electrode plates (32) disposed on the other side of the housing (100), a separator (33) disposed between the group of positive electrode plates (31) and the group of negative electrode plates (32), and an electrolyte filled on the separator (33); The positive electrode plate (31) group includes a positive electrode plate (31) uniformly disposed in the housing (100), a positive electrode busbar (311) for connecting the positive electrode plates (31), a positive electrode post (3111) connected to the positive electrode busbar (311), and a positive electrode terminal (41) disposed on one side of the cover and connected to the positive electrode post (3111). The negative electrode plate (32) assembly includes negative electrode plates (32) uniformly disposed within the housing (100), a negative electrode busbar (321) for connecting the negative electrode plates (32), a negative electrode post (3211) connected to the negative electrode busbar (321), and a negative terminal (42) disposed on one side of the cover and connected to the negative electrode post (3211), wherein, The partition (33) is made of ultra-fine glass fiber partition (33), which has high porosity and good hydrophilicity, and is used to realize oxygen recombination reaction in a lean liquid state. The feature is that it also includes an exhaust port (5) provided on the cover plate (200) and an exhaust assembly connected to the exhaust port (5). The exhaust assembly includes a safety valve (8) and a safety explosion unit (9); The safety valve (8) is configured as either a passive mechanical pressure relief valve or an electrically controlled exhaust valve, and the operating pressure of the blasting unit is greater than the operating pressure of the safety valve (8). The safety blasting unit (9) includes a blasting assembly and a mounting component for installing the blasting assembly; The installation blasting device includes a blasting disc body (91), a fixing plate (911) disposed on the outer circular surface of the blasting disc body (91), an upper clamp (921) disposed on the upper end surface of the fixing plate (911), a lower clamp (922) disposed on the lower end surface of the fixing plate (911), a connecting plate (93) evenly disposed on the outer circular surfaces of the upper clamp (921) and the lower clamp (922), and a fixing screw (94) passing through the connecting plate (93) and connecting to the upper clamp (921) and the lower clamp (922). The mounting component includes an exhaust pipe (951) connected to the upper clamp (921), a first connecting ear plate (9511) disposed at one end of the exhaust pipe (951) relative to the upper clamp (921), an air inlet pipe (952) connected to the lower clamp (922), a second connecting ear plate (9521) disposed at one end of the air inlet pipe (952) relative to the lower clamp (922), and a connecting screw for connecting the first connecting ear plate (9511) and the second connecting ear plate (9521). The exhaust assembly also includes a hydrogen sensor (7) disposed at the top of the inner cavity of the housing (100), a gas equalization plate (6) fixedly disposed below the hydrogen sensor (7) and disposed on the upper surface of the battery assembly, and a controller electrically connected to the hydrogen sensor (7).

2. The zipper production equipment according to claim 1, characterized in that: The rupture disc (91) is configured as an arch shape, with the highest point of the convex surface located on the high-pressure side during gas emission, and the rupture disc (91) is made of aluminum material with a thickness of 0.15-0.3 mm.

3. The zipper production equipment according to claim 1, characterized in that: The upper clamp (921) and the lower clamp (922) are respectively configured as annular structures, and the inner diameter of the upper clamp (921) and the lower clamp (922) is adapted to the outer diameter of the rupture disc body (91).

4. The zipper production equipment according to claim 3, characterized in that: The upper clamp (921) and the lower clamp (922) are respectively provided with fixing screw holes (941) that are compatible with the fixing screw (94), and the connecting plate (93) is evenly distributed along the outer surface of the upper clamp (921) and the lower clamp (922).

5. The zipper production equipment according to claim 3, characterized in that: The first connecting ear plate (9511) is arranged circumferentially along the outer surface of the exhaust pipe (951), and the second connecting ear plate (9521) is arranged circumferentially along the outer surface of the intake pipe (952). The first connecting ear plate (9511) and the second connecting ear plate (9521) are provided with connecting holes for the connecting screw (96) to pass through.

6. The zipper production equipment according to claim 2, characterized in that: The gas flow equalization plate (6) is uniformly provided with a number of gas guide holes, and the diameter of each gas guide hole gradually increases from the side closer to the battery assembly to the side closer to the hydrogen sensor (7).

7. The zipper production equipment according to claim 6, characterized in that: The safety valve (8) and the safety blasting unit (9) are connected in parallel at the exhaust port (5). The air inlet of the safety valve (8) is connected to the exhaust port (5). The air inlet pipe (952) of the safety blasting unit (9) passes through the cover plate (200) and is connected to the housing (100).

8. The zipper production equipment according to claim 7, characterized in that: The safety blasting unit (9) is connected in series on the inlet side of the safety valve (8); The air inlet pipe (952) of the safety blasting unit (9) is connected to the exhaust port (5), and the exhaust pipe (951) of the safety blasting unit (9) is connected to the air inlet end of the safety valve (8).

9. The zipper production equipment according to claim 8, characterized in that: The safety blasting unit (9) is connected in series on the outlet side of the safety valve (8); The air inlet of the safety valve (8) is connected to the exhaust port (5), and the air inlet pipe (952) of the safety explosion unit (9) is connected to the exhaust port of the safety valve (8).

10. A method for venting the lead-acid battery according to any one of claims 1 to 9, characterized in that, Includes the following steps: Oxygen recombination cycle steps: During the charging and discharging process of the battery, the oxygen generated by the positive electrode plate diffuses to the negative electrode plate through the pores of the ultra-fine glass fiber separator; the oxygen diffused to the negative electrode plate reacts with the active material lead on the negative electrode plate under the action of the electrolyte to form lead oxide; the generated lead oxide reacts with sulfuric acid in the electrolyte to form lead sulfate and water, thus converting the oxygen back into a component of the electrolyte. Active monitoring and controllable exhaust steps: The hydrogen sensor detects the hydrogen concentration inside the housing in real time, and the gas equalization plate guides the gas evenly to the sensing area of ​​the hydrogen sensor; when the hydrogen concentration reaches the preset safety threshold, the controller controls the electronically controlled exhaust valve to open for exhaust; when the hydrogen concentration drops to the lower safety limit, the controller controls the electronically controlled exhaust valve to close. Staged pressure relief procedure: When the gas pressure inside the housing reaches the safety valve's operating pressure, the safety valve automatically opens to relieve pressure; if the safety valve fails or the venting capacity is insufficient, causing the pressure to continue rising to the operating pressure of the safety bursting unit, the bursting disc ruptures, and the gas is quickly discharged through the vent pipe; after pressure relief is completed, if the safety valve is a resettable type, it will automatically close; the safety bursting unit is for single use and needs to be replaced.

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