Busbar, cast-weld mold and lead-acid battery for a lead-acid battery

Abstract

A kind of busbar for lead-acid battery, cast-weld mould and lead-acid battery belong to the structural technical field of lead-acid battery.The structure includes polar column and straight pole, which contains polar column busbar and polar lead structure, and C corner structure transition in the middle of polar column busbar and polar lead structure.The straight pole contains busbar and conical structure.The busbar head of two products has wedge-shaped groove, which facilitates the lug of the plate to smoothly enter the cast-weld mould.The busbar reduces lead consumption, optimizes cost, improves product competitiveness and product performance through optimized structure.

Description

Technical Field

[0001] This utility model relates to the field of lead-acid battery structure technology, specifically to a busbar, a casting and welding mold, and a lead-acid battery. Background Technology

[0002] With the development of science and technology, the manufacturing level of lead-acid batteries has gradually matured. However, the main raw material of lead-acid batteries is lead, a heavy metal that poses serious hazards to the environment and human health (especially the nervous system). Lead mining, smelting, and battery recycling processes easily cause soil, water, and air pollution. Although the recycling rate of lead-acid batteries is relatively high (approximately 90% in China), informal recycling channels still pose risks of lead acid leakage and worker exposure. Lead accounts for 40-50% of the cost of batteries. Reducing lead consumption can directly reduce raw material costs and reduce pollution throughout the entire battery lifecycle. The electrification of automobiles increases the energy density requirements of batteries, requiring lead-acid batteries to compete with lithium batteries in niche markets through lead reduction (such as AGM batteries). Reducing lead consumption is an inevitable choice for the battery industry to address environmental constraints, resource bottlenecks, and economic efficiency, requiring coordinated advancement through technological innovation and a circular economy. In the short term, the focus is on optimizing lead usage. Within the lead-acid battery industry, the busbar is a crucial component, serving as a vital connector between the internal electrode group and the external conductors. Summary of the Invention

[0003] The purpose of this invention is to provide a busbar and casting mold for lead-acid batteries, which reduces lead consumption and enhances product competitiveness by optimizing the structure.

[0004] Another objective of this invention is to provide a lead-acid battery.

[0005] The technical solution of this utility model is: a busbar for lead-acid batteries, comprising a horizontally arranged busbar body, with the side and bottom surfaces of the busbar body inclined together, the bottom of the busbar body being a lug connecting part for connecting the lugs of a group of electrodes, and the side surface of the busbar body having a wedge-shaped groove, the wedge-shaped groove near the top surface being wider and the wedge-shaped groove near the bottom surface being narrower; it also includes a vertical connector, the vertical connector being a lead-biased component or a conical structure; when the vertical connector is a lead-biased component, the busbar body and the lead-biased component are connected to form a biased electrode post; when the vertical connector is a conical structure, the busbar body and the conical structure are connected to form a straight electrode post.

[0006] The lead-biased component is a vertical plate, including a connecting plate portion connected to the busbar body and a side plate portion placed on one side of the busbar body. The heads of the connecting plate portion and the side plate portion protrude from the top surface of the busbar body. The side plate portion forms a welding surface. There is a chamfer structure at the corner between the top surface of the busbar body and the connecting plate portion near the side plate portion. There is a gap between the upper end of the chamfer structure and the head of the lead-biased component.

[0007] The head of the lead-biased component on the side closer to the busbar body has a chamfered corner C (D), while the head of the lead-biased component on the side farther from the busbar body has a rounded chamfered corner E.

[0008] The busbar body in the bias pole has at least one wedge-shaped groove on one side, and the busbar body in the straight pole has at least one wedge-shaped groove on each of the two opposite sides.

[0009] The side of the busbar body opposite to the wedge-shaped groove is integrally formed with the lead-biased component to form the bias pole; the busbar body is integrally formed with the conical structure to form the straight pole.

[0010] The busbar body is a truncated pyramid structure. The three sides of the busbar body are inclined to the bottom surface. The three sides are side A, side B, and side C. Side B has a wedge-shaped groove.

[0011] The lead-biased component is a vertical plate. The bottom surface of the plate is flush with the bottom surface of the busbar body. The top surface of the plate protrudes from the top surface of the busbar body. The front end of the plate does not protrude from the side surface 3C of the busbar body. The side surface 4D of the busbar body, which is opposite to the wedge groove, is in contact with one side of the plate. The other side of the plate protrudes from the side surface 4D of the busbar body.

[0012] The top surface of the bus body has a distinguishing groove for distinguishing positive and negative electrodes. The number of distinguishing grooves is one or two. If the number of distinguishing grooves is one, it represents the negative electrode. If the number of distinguishing grooves is two, it represents the positive electrode.

[0013] The three sides are inclined with the bottom to form a demolding angle.

[0014] A lead-acid battery, characterized in that it includes a busbar for a lead-acid battery as described above.

[0015] A busbar casting mold is used to cast busbars for lead-acid batteries as described above. The mold cavity has wedge-shaped protrusions for forming wedge-shaped grooves. During operation, the wedge-shaped protrusions guide the lugs of the electrode group entering the mold cavity.

[0016] This invention optimizes the chamfered structure of the lead-biased component of the bias pole and adds a groove structure (i.e., a wedge-shaped groove) to the busbar head, thereby reducing lead consumption and saving production costs. It also facilitates the entry of the electrode plate lugs into the casting mold, reducing the risk of exposed lugs during casting and improving production yield. By optimizing the C-angle structure of the busbar and lead-biased component of the bias pole, the current distribution is more uniform during welding, and the lead parts generate less heat, thus improving product performance. Attached Figure Description

[0017] Figure 1 This is a top view of the lead-acid battery of this utility model;

[0018] Figure 2 This is a perspective view of the lead-acid battery of this utility model;

[0019] Figure 3 This is a schematic diagram of the off-center column structure;

[0020] Figure 4 for Figure 3 Side view;

[0021] Figure 5 This is a schematic diagram of the structure of a straight pole.

[0022] Figure 6 This is a schematic diagram of the existing eccentric pole structure;

[0023] In the diagram: 1. Offset post, 1-1. Groove structure, 1-2. Busbar 1, 1-3. Lead-acid component, 1-4. Chamfered C-angle structure, 1-5. Groove structure 1 at the head of the busbar; 2. Straight post, 2-1. Groove structure, 2-2. Busbar 2, 2-3. Conical structure, 2-4. Groove structure 2 at the head of the busbar; 3. Lead-acid battery. Detailed Implementation

[0024] To more clearly illustrate the design schemes in the embodiments of this utility model, the utility model will be further described in detail below through specific embodiments. The following embodiments are only descriptive and not limiting. Obviously, the drawings in the following description are only some embodiments of this utility model. For those skilled in the art, all other embodiments obtained without creative effort are within the protection scope of this utility model.

[0025] The present invention will be further described in detail below with reference to the busbar connecting the six cells of a lead-acid battery 3, in conjunction with the accompanying drawings.

[0026] Figure 1-5 The present invention relates to a busbar for lead-acid batteries, comprising:

[0027] The bias post 1 is made of lead-tin alloy, with a length of 27.5mm, a width of 17mm, and a thickness of 5mm. It includes busbar 1-2 (i.e., busbar body) connected to the plate lugs of the grid and biased lead component 1-3 for welding positive and negative electrodes. The biased lead component 1-3 and busbar 1 are vertically connected. Busbar 1-2 has a C-corner chamfer structure 1-4 on its surface.

[0028] 1) Busbar 1-2 is the channel through which the battery's charging / discharging current is collected. During assembly, the upper parts of the positive or negative electrode tabs are fused together using a casting and welding mold with molten welding alloy. This process simultaneously forms the busbar, which essentially connects the positive or negative electrode plates in parallel. To distinguish between positive and negative polarities and prevent reverse polarity during insertion, the upper surface of busbar 1-2 is designed with a groove structure 1-1 (i.e., a distinguishing groove). One or two groove structures are used to differentiate between the positive and negative electrodes. Three sides (sides A, B, and C) of busbar 1-2 have a 5° demolding angle for easy product demolding. The positive and negative electrode tabs are inserted into the busbar before it solidifies and fuse together after cooling.

[0029] 2) Compared with existing polarizing posts, the busbar 1-2 of the polarizing post 1 of this utility model has a head groove structure (i.e., a wedge-shaped groove), which reduces the amount of lead used. The protruding structure on the mold forms a wedge-shaped groove on the polarizing post 1 or the straight post 2, and the angle between the bottom of the wedge-shaped groove and the bottom surface of the busbar 1-2 is 74°. During casting, the protruding structure on the mold guides the lugs of the positive or negative electrode plate, facilitating the forming of the casting mold. On the other hand, it pinches the lugs inward, reducing the risk of the lugs being exposed during the casting process.

[0030] 3) The lead-biased component is the welding surface. A chamfered C-angle structure 1-4 (i.e., a chamfered structure) is added to the welding surface. The position of the chamfered C-angle structure 1-4 is between the upper surface of the busbar and the middle of the lead-biased component (i.e., there is a gap between the chamfered C-angle structure 1-4 and the top of the lead-biased component in this invention). This reduces lead consumption while meeting performance requirements. Simulation analysis shows a significant delay in the heat distribution generated during the current flow path, indicating a better effect. The structure of the welded lead component is mainly considered from two aspects: first, whether the cross-sectional area through which the large current flows meets the product requirements; and second, whether the heat generated by the large current flowing through the path within a certain time is lower than the melting temperature of the welded lead component.

[0031] 4) The head of the lead-biased component has a large C-corner chamfer D on the side near the busbar and a large rounded corner E on the other side, which can reduce lead consumption while meeting performance requirements.

[0032] Direct terminal 2: Made of lead-tin alloy, 27.5mm long, 17mm wide, and 5mm thick, it includes busbar 2-2 connected to the plate lugs of the grid and a tapered structure 2-3 for welding to the tapered terminal of the cover. The tapered structure matches the inner diameter of the cover lead ring (i.e., the tapered terminal). After heat sealing, the terminal is flush with the lead ring for connection to automotive parts. Busbar 2-2 has a busbar head groove structure 2-4 at both ends, and the tapered structure 2-3 is connected to the front side of busbar 2-2.

[0033] Figure 6In the existing structure of the bias pole, there are a busbar and a biasing component. The busbar head does not have a groove structure. The starting position M of the C-angle between the busbar and the biasing component is the upper surface of the busbar and the upper surface of the biasing component.

Claims

1. A busbar for lead-acid batteries, characterized in that: It includes a horizontally arranged bus body, which is inclined between the side and bottom surfaces of the bus body. The bottom of the bus body is a plate lug connection part for connecting the plates of a pole group. The side of the bus body has a wedge-shaped groove, with the wedge-shaped groove opening wider near the top surface and narrower near the bottom surface. It also includes a vertical connector, which is a lead-biased component or a conical structure; when the vertical connector is a lead-biased component, the bus body is connected to the lead-biased component to form a biased pole; when the vertical connector is a conical structure, the bus body is connected to the conical structure to form a straight pole.

2. The busbar for lead-acid batteries according to claim 1, characterized in that: The lead-biased component is a vertical plate, including a connecting plate portion connected to the busbar body and a side plate portion placed on one side of the busbar body. The heads of the connecting plate portion and the side plate portion protrude from the top surface of the busbar body. The side plate portion forms a welding surface. There is a chamfer structure at the corner between the top surface of the busbar body and the connecting plate portion near the side plate portion. There is a gap between the upper end of the chamfer structure and the head of the lead-biased component.

3. The busbar for lead-acid batteries according to claim 1, characterized in that: The head of the lead-biased component on the side closer to the busbar body has a chamfered corner C (D), while the head of the lead-biased component on the side farther from the busbar body has a rounded chamfered corner E.

4. The busbar for lead-acid batteries according to claim 1, characterized in that: The busbar body in the bias pole has at least one wedge-shaped groove on one side, and the busbar body in the straight pole has at least one wedge-shaped groove on each of the two opposite sides.

5. The busbar for lead-acid batteries according to claim 1, characterized in that: The side of the busbar body opposite to the wedge-shaped groove is integrally formed with the lead-biased component to form the bias pole; the busbar body is integrally formed with the conical structure to form the straight pole.

6. The busbar for lead-acid batteries according to claim 1, characterized in that: The busbar body is a truncated pyramid structure. The three sides of the busbar body are inclined to the bottom surface. The three sides are side A, side B, and side C. Side B has a wedge-shaped groove. The lead-biased component is a vertical plate. The bottom surface of the plate is flush with the bottom surface of the busbar body. The top surface of the plate protrudes from the top surface of the busbar body. The front end of the plate does not protrude from the side surface 3C of the busbar body. The side surface 4D of the busbar body, which is opposite to the wedge groove, is in contact with one side of the plate. The other side of the plate protrudes from the side surface 4D of the busbar body.

7. The busbar for lead-acid batteries according to claim 1, characterized in that: The top surface of the bus body has a distinguishing groove for distinguishing positive and negative electrodes. The number of distinguishing grooves is one or two. If the number of distinguishing grooves is one, it represents the negative electrode. If the number of distinguishing grooves is two, it represents the positive electrode.

8. The busbar for lead-acid batteries according to claim 1, characterized in that: The three sides are inclined with the bottom to form a demolding angle.

9. A lead-acid battery, characterized in that: Includes the busbar for lead-acid batteries as described in any one of claims 1-8.

10. A casting mold for casting a busbar for a lead-acid battery as described in any one of claims 1-8, characterized in that: The mold cavity has wedge-shaped protrusions for forming wedge-shaped grooves; during operation, the wedge-shaped protrusions guide the lugs of the pole group entering the mold cavity.

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