Battery cover with fail-safe ionic conductivity isolation for flooded lead-acid batteries

Abstract

The present invention discloses a battery cover (100) with fail-safe ionic conductivity isolation for flooded lead-acid batteries, comprising a bottom plate (110) with a plurality of through holes (112) and channels (116) facilitating electrolyte refilling and gas egress A main channel (114) on the bottom plate (110) receives replenished electrolyte, distributed via the plurality of channels (116). The top plate (120) mates with the bottom plate (110) to conceal the channels and through holes. A flow regulator assembly (130) selectively controls electrolyte flow, including options for manual or electric operation. Float-cum-level indicators (140) in the through holes provide real-time electrolyte level indication. The vent (150) includes a flame arrestor to ensure safety. This design offers advantages such as precise electrolyte distribution, enhanced safety through gas egress management, and real-time electrolyte level monitoring, ensuring optimal battery performance and longevity.

Description

BATTERY COVER WITH FAIL-SAFE IONIC CONDUCTIVITY ISOLATION FORFLOODED LEAD-ACID BATTERIESFIELD OF THE INVENTION

[0001] The present invention relates generally to the field of batteries, and more particularly to a cover assembly for multi -cell flooded lead-acid batteries which is fail safe. Specifically, the invention pertains to a battery cover design that isolates the inter-cell spaces and prevents ionic conductivity between adjacent cells, especially during electrolyte refilling or topping operations in flooded lead-acid batteries.BACKGROUND OF THE INVENTION

[0002] In the field of electrochemical energy storage, flooded lead-acid batteries have long been a paragon of reliability and cost-effectiveness. However, the idiosyncratic nature of their construction and operation gives rise to a plethora of quandaries that, if left unresolved, can precipitate a deleterious impact on the battery's performance, longevity, and overall safety profile.

[0003] One such predicament arises from the intrinsic process of electrolyte maintenance, which is an indispensable requirement for the optimal functioning of these batteries. The aqueous electrolyte solution, a crucial component in facilitating the electrochemical reactions within each cell, undergoes gradual depletion due to the inexorable process of electrolysis. This depletion culminates in an escalation of the electrolyte's specific gravity, necessitating periodic replenishment through a process colloquially termed "topping" or "refilling."

[0004] However, the act of introducing supplemental electrolyte or distilled water into the cells is fraught with perils, particularly in multi -cell configurations that are ubiquitous inindustrial and large-scale applications. One such quandary is the propensity for electrolyte spillage or dispersal between adjacent cells, engendering undesirable ionic conductivity pathways. This aberrant conductivity can precipitate a cascade of deleterious consequences, including but not limited to short-circuiting, voltage imbalances, accelerated degradation of internal components, and even thermal runaways, which can culminate in catastrophic failures and pose grave safety hazards.

[0005] Another problem encountered in this domain is the potential for shortcircuiting to transpire if the errant electrolyte establishes a conductive bridge between the positive and negative terminals of neighboring cells. Such an occurrence can engender excessive current flow, enervating the battery's capacity and potentially inflicting irreparable damage to its internal components.

[0006] Moreover, the introduction of ionic conductivity between cells can catalyze a disruption in the voltage equilibrium within the battery, inducing a state of imbalance wherein certain cells discharge at an accelerated rate relative to others. This disparity in discharge rates can precipitate a precipitous diminution in the battery's overall capacity and performance, rendering it an inefficacious energy storage solution.

[0007] Furthermore, the ingress of electrolyte into adjacent cells can initiate a sequence of deleterious reactions that can accelerate the degradation of the electrodes and ancillary internal components. This premature degradation can curtail the battery's service life, necessitate more frequent replacements and augment the operational expenditures associated with its deployment and maintenance.

[0008] In the most egregious scenarios, electrolyte spillage and the ensuing shortcircuiting can engender an exothermic reaction, generating copious quantities of heat that can precipitate a phenomenon colloquially known as "thermal runaway." This phenomenon can culminate in the rupture of the battery casing, potentially leading to the dissemination ofcorrosive electrolyte and the ignition of adjacent combustible materials, posing a grave risk to personnel and property alike.

[0009] While a multitude of techniques and designs have been proposed to mitigate these issues and isolate the cells during the topping process, many of these solutions are either excessively convoluted, prohibitively expensive, or inefficacious in completely precluding inter-cell ionic conductivity. Some designs rely on intricate sealing mechanisms or specialized electrolyte delivery systems, which can augment manufacturing costs and maintenance requirements to an untenable degree. Others employ rudimentary partitions or barriers that may not provide adequate isolation, leaving room for electrolyte spillage and cross-contamination.

[0010] In light of these multifarious challenges, there is an acute and pressing need for a simple, effective, and cost-efficient mechanism that can reliably isolate the inter-cell spaces, preventing ionic conductivity between adjacent cells during electrolyte refilling or topping operations. Such a mechanism would not only enhance the safety and performance of flooded lead-acid batteries but also reduce maintenance costs and extend their overall service life, rendering them more competitive and sustainable in an increasingly energy-conscious world.OBJECTS OF THE INVENTION

[0011] Several objects of the currently disclosed invention, with at least one being satisfied by one or more disclosed embodiments, are outlined as follows:

[0012] An object of the present invention is to present an alternative that surpasses at least one hindering limitation encountered in existing prior art

[0013] Another object of the present invention is to provide a battery cover design that effectively isolates the inter-cell spaces in multi -cell flooded lead-acid batteries, therebypreventing ionic conductivity between adjacent cells during electrolyte refilling or topping operations and which is fail safe.

[0014] Still another object of the present invention is to provide a battery cover assembly that incorporates a multi-level safety mechanism, wherein ionic conductivity between adjacent cells is precluded at multiple levels, thereby ensuring redundancy and failsafe operation.

[0015] Yet another object of the present invention is to provide a battery cover design that mitigates the deleterious consequences of inter-cell ionic conductivity, such as shortcircuiting, voltage imbalances, and accelerated degradation, even in the event of a failure at one or more safety levels due to an accident or oversight.

[0016] Another object of the present invention is to provide a battery cover assembly that offers a robust and reliable multi-tiered approach to preventing inter-cell ionic conductivity, underscoring the invention's commitment to enhanced safety and performance in flooded lead-acid battery systems.

[0017] Another object of the present invention is to provide a battery cover design that incorporates innovative multi-level isolation mechanisms, ensuring that the problems encountered in the prior art related to inter-cell ionic conductivity are effectively avoided or eliminated, even under adverse or unforeseen circumstances.

[0018] Still another object of the present invention is to provide a battery cover assembly that mitigates the risk of short-circuiting due to electrolyte spillage or dispersal between neighboring cells, thereby enhancing the safety and reliability of the battery system.

[0019] Yet another object of the present invention is to provide a battery cover design that maintains the voltage equilibrium within the battery by precluding the introduction of ionic conductivity pathways between cells, thus ensuring optimal performance and capacity utilization.

[0020] Another object of the present invention is to provide a battery cover assembly that prevents the ingress of electrolyte into adjacent cells, thereby mitigating the accelerated degradation of internal components and extending the overall service life of the battery.

[0021] Another object of the present invention is to provide a battery cover design that reduces the likelihood of thermal runaways and catastrophic failures resulting from excessive heat generation due to short-circuiting, thus enhancing the overall safety profile of the battery system.

[0022] Another object of the present invention is to provide a battery cover assembly that is simple in its design and construction, thereby facilitating cost-effective manufacturing and ease of installation and maintenance.

[0023] Another object of the present invention is to provide a battery cover design that requires minimal modification to existing battery configurations, enabling seamless integration and retrofitting in various applications.

[0024] Another object of the present invention is to provide a battery cover assembly that is compatible with a wide range of multi -cell flooded lead-acid battery configurations, ensuring versatility and broad applicability across different industries and use cases.

[0025] Another object of the present invention is to provide a battery cover design that is resilient and durable, capable of withstanding the harsh operating conditions and environmental factors encountered in various application scenarios.

[0026] Another object of the present invention is to provide a battery cover assembly that is easy to inspect and maintain, thereby minimizing downtime and reducing the overall operational costs associated with battery maintenance.

[0027] Still another object of the present invention is to provide a battery cover design that is environmentally friendly and compliant with relevant safety and regulatory standards, promoting sustainability and responsible energy storage practices.

[0028] Yet another object of the present invention is to provide a battery cover assembly that incorporates innovative materials and design features, leveraging advanced manufacturing techniques and technologies to enhance its performance and functionality.

[0029] Another object of the present invention is to provide a battery cover design that offers a modular and scalable solution, allowing for customization and adaptation to specific battery configurations and application requirements.

[0030] Another object of the present invention is to provide a battery cover assembly that minimizes the risk of electrolyte spillage and cross-contamination during the topping process, thereby enhancing the overall cleanliness and tidiness of the battery maintenance operations.

[0031] Still another object of the present invention is to provide a battery cover design that contributes to the overall cost-effectiveness and economic viability of flooded lead-acid batteries, reinforcing their competitiveness in the energy storage market.

[0032] Further objects and advantages of the present invention will become apparent from the subsequent description, which does not intend to limit the scope of the present invention.SUMMARY OF THE INVENTION

[0033] The present invention relates to a battery cover design that isolates the intercell spaces and prevents ionic conductivity between adjacent cells, especially during electrolyte refilling or topping operations in flooded lead-acid batteries.

[0034] The battery cover includes a bottom plate received on and sealably fitted to the top open end of a battery case, which holds multiple electrochemical cells. The bottom plate has several through holes, each corresponding to a compartment, facilitating the topping or refilling of electrolyte and the egress of gases formed within the compartments. It alsofeatures a main channel on its upper surface for receiving replenished electrolyte and multiple channels that facilitate fluid communication from the main channel to the through holes. The top plate comprises a substantially planar body designed to mate with the bottom plate, concealing the through holes, main channel, and multiple channels. Additionally, a flow regulator assembly selectively allows electrolyte flow from the source to the through holes, and multiple float-cum-level indicators are attached to the through holes.

[0035] The battery cover has a main channel deeper than the multiple channels, each of which is sloped at an angle of 0 to 10 degrees with respect to the bottom plate, with the end connecting to the main channel being higher than the end connecting to the through holes.

[0036] Both the bottom plate and top plate are made of a polymeric material or a chemically resistant polymeric material, such as polypropylene, polyethylene, or polyvinyl chloride. They are also non-conductive.

[0037] The flow regulator assembly includes a valve that can be either manually or electrically operated. It is designed to control the flow rate of the electrolyte to the through holes.

[0038] The flow regulator assembly can also include a pump, which may be manually operated or electrically powered, and a flow meter to measure the electrolyte flow rate.

[0039] The float-cum-level indicators consist of a float element and a level indicating portion. The top plate has holes for the level indicating portions and an inlet aperture for receiving the electrolyte. The float element is buoyant, and the level indicating portion provides a visual indication of electrolyte levels in each compartment, with a colored portion visible through the through holes.

[0040] The battery cover includes a vent to allow gas egress from the battery case, featuring a fluid permeable membrane to prevent contaminants' ingress and a flame arrestor.The multiple channels taper in depth towards the through holes, and the main channel spans a substantial portion of the bottom plate's upper surface.

[0041] A handle attached to the top plate facilitates its removal and placement. The top plate also has a transparent portion for viewing the main channel and multiple channels. The through holes are threaded to receive the float-cum-level indicators in a threaded engagement.

[0042] The bottom plate includes a peripheral seal to engage with the battery case's top open end, and a locking mechanism with multiple clamps selectively secures the top plate to the bottom plate. The electrolyte is a sulfuric acid solution, and the cells are lead-acid types.

[0043] The difference in length of the multiple channels is 2% to 8% of their length, which ranges from 5 cm to 30 cm. The channels can have circular, rectangular, or triangular cross-sections, optimized for fluid flow, and may feature a hydrophobic coating to improve fluid flow.

[0044] A drain in the battery cover allows for the removal of electrolyte from the main and multiple channels. The flow regulator assembly features a sliding gate mechanism for controlling electrolyte flow, and the main channel is broader than the multiple channels. The bottom plate also has a sealing gasket along its perimeter for a leak-proof fit with the battery case.

[0045] The top plate is removably attached to the bottom plate using fastening mechanisms and includes a manual control knob for the flow regulator assembly. The channels are configured radially around the main channel, and the float-cum-level indicators are color-coded to indicate different electrolyte levels.

[0046] The flow regulator assembly can be automated and controlled by a microprocessor. The top plate integrates a pressure relief valve and has molded guides toensure proper alignment with the battery case. The through holes include fine mesh filters to prevent contamination, and the main channel has volume markings for the electrolyte.

[0047] The flow regulator assembly also includes a one-way valve to prevent backflow of electrolyte. The float-cum-level indicators feature an electrical contact for signaling low electrolyte levels and magnets to activate external sensors. The main channel is centrally located on the bottom plate.

[0048] The flow regulator assembly controls electrolyte flow within the battery, featuring a shutter base with serrations and a horizontally extending tab. A shutter rubber with corresponding serrations acts as a gasket, and a buoyant with a slit part and buoyant part filled with air or gas facilitates sliding movement within the main channel. The top plate conceals the flow regulator assembly and includes a slit or hole for the tab's displacement, allowing for electrolyte flow regulation by aligning or misaligning the serrations.

[0049] The method of regulating electrolyte flow involves providing the flow regulator assembly within the main channel, securing the shutter rubber, positioning the shutter base to slide along the shutter rubber, placing the buoyant in contact with the shutter base, and covering the assembly with the top plate. Electrolyte flow is regulated by moving the tab to align or misalign the serrations.

[0050] A battery cover assembly with integrated flow regulation and electrolyte level indication includes the flow regulator assembly, secured shutter rubber, and a top plate with a slit or hole for the tab's displacement. The assembly interacts with the buoyant for flow regulation and features float-cum-level indicators for real-time electrolyte level feedback, with each indicator resilient to the battery's internal environment.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0051] The present discourse shall expound upon the inventive subject matter in conjunction with the accompanying schematic, tendered herewith as an elucidatory framework. This schematic serves as an exemplar to facilitate a deeper apprehension of the intricate constituents and nuanced functionalities inherent in the invention. It is incumbent upon the reader to acknowledge that the schematic, while provided for elucidative purposes, does not adhere to precise scaling and thus is not intended to circumscribe the breadth of the invention.

[0052] Furthermore, it is imperative to underscore that the depictions of embodiments within the schematic are merely illustrative and should not be misconstrued as imposing limitations upon the scope of the invention in any capacity. The adaptability and modifiability of the disclosed embodiments remain uninhibited, and variations thereof may be effectuated without departing from the fundamental essence and coverage of the invention, as defined by the appended claims. The linguistic expressions utilized herein are formulated for descriptive explication and are not intended to impose constraints upon the scope of the invention.

[0053] Through meticulous scrutiny of this visual aid, the reader is afforded a comprehensive and exhaustive comprehension of the operational mechanics and structural composition of the invention. The schematic, serving as a pictorial complement to the ensuing detailed narrative, accentuates the salient facets and distinctive attributes of the invention. It is paramount to recognize that the ensuing narrative discourse aims to provide elucidation regarding various manifestations of the invention and does not purport to encompass every conceivable permutation thereof. The construal of the invention's ambit is to be guided by the appended claims and their attendant legal equivalents, ensuring a robust and encompassing interpretation thereof.

[0054] FIG. 1 A illustrates a schematic isometric view of a battery cover in accordance with an embodiment of the present invention.

[0055] FIG. IB illustrates an exploded view of the battery cover of FIG. 1A.

[0056] FIG. 1C illustrates a schematic side view of the battery cover of FIG. 1 A.

[0057] FIG. ID illustrates another schematic side view of the battery cover of FIG. 1A.

[0058] FIG. IE illustrates pipes or conduits as alternative to the channels (116) configured on the bottom plate of the battery cover of FIG. 1 A.

[0059] FIG. 2A-1 and FIG. 2A-2 illustrate a schematic isometric view and side view, respectively, of a vent cap of the battery cover of FIG. 1 A.

[0060] FIG. 2B and FIG. 2C illustrate schematic isometric views of a rubber gasket and buffer cap, respectively.

[0061] FIG. 2D-1, and FIG. 2D-2 illustrate a side view and isometric view of a float element in accordance with the embodiments of the present invention.

[0062] FIG. 2E illustrates an isometric view of a float guide for guiding the float element of FIG. 2D-1, and FIG. 2D-2.

[0063] FIG. 2F-1 and FIG. 2F-2 illustrate a side view and isometric view of a level indicating portion of the float element.

[0064] FIG. 2G-1 and FIG. 2G-2 illustrate a side view and isometric view of a buoyant holder.

[0065] FIG. 2H illustrates a side view of a float-cum-level indicator.

[0066] FIG. 21 illustrates a schematic cross-sectional side view a battery along with the battery cover of FIG. 1 A.

[0067] FIG. 2J-1 illustrates a schematic isometric view of a battery along with the battery cover of FIG. 1A.

[0068] FIG. 2J-2 illustrates a schematic isometric view of the battery of FIG. 2J-1 along with the battery bottom plate and the top plate removed.

[0069] FIG. 3A-1 and FIG. 3A-2 illustrate an isometric and a side view, respectively, of a shutter base which forms part of a flow regulator assembly.

[0070] FIG. 3B-1 and FIG. 3B-2 illustrate an isometric and a side view, respectively, of a shutter base which forms part of a flow regulator assembly in accordance with another embodiment.

[0071] FIG. 3C and FIG. 3D illustrate an isometric and a side view, respectively, of a shutter rubber which forms part of a flow regulator assembly.

[0072] FIG. 3E and FIG. 3F illustrate a side view and an isometric view of a buoyant which forms part of a flow regulator assembly.

[0073] FIG. 4 A and FIG. 4B illustrate a flow regulator assembly in accordance with the embodiments of the present invention.LIST OF NUMERALS

[0074] The following enumeration delineates the reference numerals utilized throughout the figures and detailed description, serving as precise identifiers for various components and elements disclosed herein.Numeral Component / Feature100 - Battery cover110 - Bottom plate112 - Through holes114 - Main channel116 - Channels118 - Drain120 - Top plate122 - Planar body124 - Holes126 - Handle128 - Locking mechanism129 - Inlet aperture / Orifice130 - Flow regulator assembly132 - Shutter base134 - Shutter rubber136 - Buoyant138 - Tab140 - Float-cum-level indicators142 - Float element142- A - Top portion142-B - Bottom portion142-C - Float guide144 - Level indicating portion146 - Vent cap147 - Buoyant holder148 - Rubber gasket149 - Buffer cap150 - Vent200 - Battery container210 - Battery compartmentDETAILED DESCRIPTION

[0075] The present invention relates to a battery cover and a battery employing the same.

[0076] Within the ensuing description and appended claims, a meticulous adherence to specialized lexicon and technical terminology is mandated, with interpretations thereof aligning with their conventional meanings ascribed within the pertinent field, unless explicitly redefined within this context.

[0077] Throughout the exposition and associated claims, it is crucial to underscore that the use of singular forms such as "a," "an," and "the" is intended to encompass plural references, thereby embracing diverse instances unless the context unequivocally necessitates a singular interpretation. Similarly, the inclusion of terms like "one," "a," "an," or "the" is deemed inclusive of both singular and plural manifestations, unless the context decidedly dictates otherwise.

[0078] Sequential designations, denoted by terms such as "first," "second," "third," and the like, serve exclusively to differentiate between various elements or components and do not imply any inherent sequence or hierarchical structure, unless explicitly stipulated or inferred from the context.

[0079] The term "may" conveys a sense of possibility or alternative rather than obligation, unless expressly mandated by the contextual milieu.

[0080] References to specific materials, compositions, or substances inherently encompass their functional equivalents unless explicitly specified otherwise by the context.

[0081] Expressions delineating spatial orientation such as "upper," "lower," "top," "bottom," "front," "rear," "side," and the like, serve solely to describe the relative positioning or orientation of elements or components within the disclosed embodiments and should not be construed as confining the invention to any particular spatial configuration unless explicitly declared or inferred from the context.

[0082] Terms such as "coupled," "connected," and "attached," including their variations, are utilized interchangeably and do not impose limitations on the nature of connection or attachment, unless explicitly necessitated by the context.

[0083] Numeric values specified within this discourse are inherently inclusive of a range extending approximately 10% below and above the stated value, unless an alternate range is expressly delineated.

[0084] Phrases such as "in one embodiment" are not indicative of identical embodiments but rather denote distinct instances that may represent different facets or aspects of the invention.

[0085] The terms "optional" or "optionally" signify that subsequent elements, steps, or features may or may not be encompassed within the scope of the invention, contingent upon specific embodiments or implementations.

[0086] When qualifiers like "substantially" or "essentially" are employed to characterize a characteristic or property, they encompass variations recognized by one skilled in the relevant field as not significantly altering the intended outcome or performance of the described embodiment.

[0087] The term "comprising," utilized herein, signifies inclusivity and openness, allowing for the incorporation of additional elements, features, components, process steps, sub-steps, and / or aspects as deemed suitable, unless explicitly stated otherwise.

[0088] Measurements and values disclosed herein are considered subject to modification by the term "about," intended to encompass deviations within a range extending approximately ±10% of the stated value, unless a different range is explicitly specified.

[0089] By enhancing operational efficiency and reliability, the battery cover presented herein offers a solution that rectifies various deficiencies observed in prior art. Especially crucial during electrolyte replenishment or augmentation procedures in flooded lead-acid batteries, this design prevents ionic conductivity between adjacent cells by isolating interstitial cell spaces. This battery cover design is meticulously crafted, as disclosed in the present disclosure.

[0090] The present invention is now described with reference to the accompanying drawings.

[0091] Referring to FIG. 1 A which illustrates a schematic isometric view of a battery cover (100) in accordance with an embodiment of the present invention, and FIG. IB which illustrates an exploded view of the battery cover (100) of FIG. 1A, the battery cover (100) being designed to isolate ionic conductivity in flooded lead-acid batteries, comprising a bottom plate (110) with through holes (112) for electrolyte management and gas egress, a main channel (114) for receiving electrolyte, and a network of channels (116) to distribute it. Atop plate (120) conceals these components, while a flow regulator assembly (130) controls electrolyte flow, and float-cum-level indicators (140) monitor electrolyte levels.

[0092] More specifically, the battery cover (100) with fail-safe ionic conductivity isolation for flooded lead-acid batteries comprises a bottom plate (110) configured to be received on and sealably fitted to the top open end of a battery case containing a plurality of compartments, each accommodating an electrochemical cell. The bottom plate (110) includes a plurality of through holes (112), each corresponding to one of the compartments, facilitating the topping or refilling of electrolyte into the compartments, and allowing for the egress of gases formed within the compartments. It further comprises a main channel (114) configured on the upper surface, designed to receive electrolyte from an electrolyte source, and a plurality of channels (116) also on the upper surface, which establish electrolytic fluid communication from the main channel (114) to the through holes (112), with the length of the channels (116) being L and having a length variation within a range of 0% to 10% of L. Additionally, a top plate (120) comprising a substantially planar body (122) is designed to be received on and mate with the bottom plate (110), thereby concealing the through holes (112), main channel (114), and plurality of channels (116). The battery cover also includes a flow regulator assembly (130) designed to selectively permit the flow of electrolyte from the source to the through holes (112), and a plurality of float-cum-level indicators (140) received in and attached to the through holes (112).

[0093] The main channel (114) and plurality of channels (116) facilitate the transfer of electrolytic fluid from the main channel to the plurality of holes (112) the channels (114, 116) being configured on an upper surface of the bottom plate (110). The electrolyte is allowed to flow from the main channel (114) into the cellular compartments of the battery via this plurality of channels (116) and the aforementioned plurality of through holes (112). The depth or vertical extent of the main channel (114) surpasses that of the plurality of channels (116). Upon the completion of the electrolyte flow, the fluidic connection between the main channel and the plurality of channels is severed, an outcome achieved through the employment of a buoyant (136) strategically positioned within the main channel (114). This buoyant (136) undergoes an upward displacement, consequently lowering the electrolyte level within the main channel and arresting the flow of electrolyte from the main channel to the plurality of channels. This feature effectively mitigates the potential for ionic conductivity, thereby enhancing the overall safety and performance of the battery system.

[0094] The above feature of having the depth or vertical extent of the main channel (114) greater than that of the plurality of channels (116) in conjunction with the buoyant (136) provides the following functionality and / or advantages:

[0095] By severing the fluidic connection between the main channel (114) and the plurality of channels (116), the design ensures that the electrolyte remains confined within the individual cellular compartments of the battery, preventing any inadvertent leakage or crosscontamination. This containment measure enhances the overall reliability and longevity of the battery by mitigating the risk of internal short circuits or chemical degradation caused by uncontrolled electrolyte migration.

[0096] Further, the cessation of electrolyte flow between the main channel (114) and the plurality of channels (116) effectively eliminates ionic conductivity pathways that could potentially bridge separate electrochemical cells or components within the battery. Thiselectrical isolation measure contributes to the overall safety of the battery system by reducing the likelihood of internal short circuits, thermal runaway, or other hazardous events that could compromise the integrity of the battery or pose a risk to the end-user.

[0097] In addition to the previously elucidated architectural elements, this battery cover design incorporates another feature wherein each of the plurality of channels (116) is oriented at an oblique angle relative to the horizontal plane of the upper surface of the bottom plate (110). Specifically, the plurality of channels (116) exhibit an angular deviation ranging from 0 to 10 degrees with respect to the aforementioned horizontal plane.

[0098] This angular configuration is implemented in a manner such that the terminus of each subsidiary channel (116) that interfaces with the main channel (114) is positioned at a more elevated altitude than the terminus that facilitates the egress of the electrolytic fluid into the multiplicity of apertures (112) on the bottom plate.

[0099] This deliberate inclination of the plurality of channels (116) serves to optimize the fluidic dynamics and facilitate the expeditious and uniform distribution of the electrolyte from the main channel (114) into the cellular compartments of the battery. Furthermore, this angular orientation aids in mitigating the potential for residual electrolyte accumulation within the subsidiary channels after the cessation of the infusion process, thereby enhancing the overall efficiency and reliability of the electrolyte management system.

[0100] To further augment the fluidic dynamics within the intricate network of conduits, the main channel (114) and the plurality of subsidiary channels (116) have been subjected to a specialized surface treatment designed to facilitate and optimize the flow of the electrolytic fluid. Specifically, this surface treatment entails the application of a hydrophobic coating, a stratum possessing an inherent aversion to the adhesion or retention of aqueous substances.

[0101] This judicious incorporation of a hydrophobic coating serves to mitigate the potential for electrolyte adherence to the internal surfaces of the main channel and the plurality of channels, thereby reducing the impediments to fluid flow that could arise from surface tension phenomena or intermolecular attractive forces. Consequently, this surface treatment promotes a more seamless and unimpeded transit of the electrolytic solution through the intricate channel network, ensuring an efficient and uniform distribution to the cellular compartments of the battery.

[0102] Moreover, the hydrophobic nature of the coating confers an additional layer of protection against potential electrolyte seepage or leakage, as the inherent repellency of the coated surfaces discourages the retention or accumulation of residual electrolyte within the channels. This attribute further contributes to the overall reliability and longevity of the battery system by mitigating the risk of internal short circuits, chemical degradation, or other deleterious effects that could arise from uncontrolled electrolyte migration or exposure.

[0103] The implementation of this supplementary design feature, in conjunction with the previously delineated architectural elements, constitutes a comprehensive and meticulously engineered solution that optimizes the electrolyte distribution process, electrical isolation, and safety considerations within the battery enclosure. This synthesis of design principles exemplifies a holistic approach to addressing the multifaceted challenges associated with the production and operation of high-performance electrochemical energy storage systems.

[0104] The bottom plate (110) is engineered to be sealably fitted to the top open end of a battery case, which contains multiple compartments, each housing an electrochemical cell. This plate is essential for ensuring a secure and airtight connection to the battery case. The bottom plate (110) is equipped with a plurality of through holes (112), each aligning with one of the compartments. These through holes (112) facilitate the topping or refilling ofelectrolyte into the compartments and provide a pathway for the egress of gases produced within the compartments. The structure and geometry of the bottom plate (110) are designed for optimal fit and functionality, typically made from a durable, acid-resistant material such as polypropylene to withstand the harsh conditions within the battery.

[0105] On the upper surface of the bottom plate (110), a main channel (114) is configured to receive electrolyte from an external source. This channel is meticulously designed to ensure efficient distribution of the electrolyte across the battery compartments. The main channel (114) connects to a plurality of subsidiary channels (116), which are also located on the upper surface of the bottom plate (110). These channels (116) provide electrolytic fluid communication from the main channel (114) to the through holes (112). The length of the channels (116) is denoted as L, with a permissible variation range of 0% to 10% of L, ensuring uniform distribution of the electrolyte. The channels are designed to optimize fluid flow, reduce turbulence, and prevent blockages, typically constructed from the same material as the bottom plate (110) for consistency and durability.

[0106] The length of the plurality of channels (116), which fluidly connect the main channel (114) to the plurality of through holes (112), is meticulously calibrated to ensure that the electrolyte concurrently reaches all through holes (112), or, stated otherwise, the lengths of the plurality of channels (116) are substantially uniform. This deliberate design choice is implemented for several critical reasons.

[0107] Firstly, ensuring the electrolyte reaches all through holes (112) simultaneously guarantees uniform electrolyte distribution across all compartments. This uniformity is crucial for maintaining consistent electrochemical conditions within each cell, thereby optimizing the overall performance and efficiency of the battery. Disparities in electrolyte levels can lead to imbalances in cell voltage and capacity, potentially reducing the battery's operational lifespan and reliability.

[0108] Secondly, the uniform length of the channels (116) mitigates the risk of localized overfilling or underfilling. Such inconsistencies can result in electrolyte spillage, leading to corrosive damage to the battery components and surrounding equipment. Furthermore, underfilled compartments may expose the cell plates to air, causing sulfation and irreversible damage to the battery. By ensuring equal channel lengths, the design promotes precise and controlled electrolyte distribution, thereby safeguarding the structural and functional integrity of the battery.

[0109] In some alternative designs, the difference in length of the plurality of channels (116) is in the range of 2% to 8% of the length L. In a specific example the difference in length of the plurality of channels (116) is in the range of 0.1 mm to 100 mm. In some specific examples, the length L of the plurality of channels is in the range of 5 cm to 30 cm.

[0110] In the expounded discourse, it is discerned that the plurality of channels, designated by the numerical label 116, embody a rich tapestry of conduit configurations. These configurations transcend the conventional geometries of circular, rectangular, and triangular cross-sections, encompassing a diverse array of pertinent shapes. Notably, within this comprehensive repertoire, one may discern profiles such as elliptical, trapezoidal, hexagonal, semi-circular, pentagonal, as well as configurations reminiscent of the letters "V" or "U", and even the more intricate "W" shaped channels. Furthermore, attention is drawn to the inclusion of channels distinguished by smooth contours, eschewing sharp comers for a more streamlined architectural integrity. This amalgamation of geometrical variations serves to enhance the versatility and functionality of the delineated conduits.

[0111] In some embodiments, the channels (116) may be in form of conduits or pipes. More specifically, FIG. IE illustrates pipes or conduits as alternative to the channels (116) configured on the bottom plate of the battery cover of FIG. 1A. The rest of details ofpipes or conduits may be similar to that of the channels discussed herein above and is not repeated for sake of brevity.

[0112] The top plate (120) features a substantially planar body (122), designed to be received on and securely mate with the bottom plate (110). This top plate conceals the through holes (112), main channel (114), and the plurality of subsidiary channels (116) underneath, providing a clean and protected surface. The top plate (120) is crucial for maintaining the integrity of the internal components and preventing contaminants from entering the battery. It is generally made from the same robust, acid-resistant material as the bottom plate to ensure compatibility and longevity.

[0113] In the specified scenario, the adaptation of comers through cutting or incorporating nearby openings in the bottom and top plates is particularly aimed at accommodating the ends of battery electrodes, both positive and negative. This strategic modification allows for the convenient fitting of these electrode ends into the designated corners of the battery structure. By ensuring that these crucial components are readily accommodated, the design optimizes the assembly process and promotes efficient utilization of space within the battery enclosure.

[0114] The material selection for both the bottom plate (110) and the top plate (120) is guided not only by their non-corrosive or corrosion-resistant properties but also by various other factors such as manufacturability, cost-effectiveness, and environmental considerations. These plates are meticulously chosen to ensure resilience and prolonged functionality within the demanding battery environment while also adhering to sustainable manufacturing practices.

[0115] Specifically, the preference for a non-conductive polymeric substance, such as polypropylene, polyethylene, or polyvinyl chloride, stems from their ability to withstand the corrosive effects of electrolyte exposure. Furthermore, these materials offer advantages interms of manufacturability, as they can be easily molded into complex shapes, facilitating efficient production processes and reducing manufacturing costs.

[0116] In addition to manufacturability and cost considerations, environmental impact is also taken into account. The selected materials are chosen for their compatibility with recycling processes, ensuring that end-of-life disposal is conducted in an environmentally responsible manner. Moreover, by utilizing materials that are inherently durable and long-lasting, the need for frequent replacements is minimized, contributing to resource conservation and waste reduction.

[0117] Furthermore, while polymeric materials are favored for their corrosion resistance and manufacturability, alternative materials with similar properties, such as composite materials or specially formulated coatings, may also be considered within the scope of the present invention. These materials are evaluated based on their ability to meet the stringent performance requirements of battery covers while balancing considerations of cost, manufacturability, and environmental impact.

[0118] Ultimately, the material selection process encompasses a comprehensive evaluation of multiple criteria, including corrosion resistance, manufacturability, cost- effectiveness, and environmental sustainability, to ensure that the chosen materials not only meet functional requirements but also align with broader considerations of efficiency, affordability, and environmental stewardship.

[0119] Incorporated within this assembly is a flow regulator (130), a critical component designed to selectively control the flow of electrolyte from the source to the through holes (112). This assembly includes various sub -components such as valves or adjustable apertures, precisely engineered to manage the electrolyte flow rate. The flow regulator assembly (130) is constructed from materials resistant to corrosion and chemical degradation, ensuring reliable performance over the battery's lifespan.

[0120] More specifically, in certain embodiments of the present invention, the flow regulator assembly (130) is designed to efficiently manage electrolyte flow dynamics. This assembly incorporates a valve mechanism at its core, serving as the primary means of regulating electrolyte flow. Operators can adjust easily, with options for both manual operation and electrical control.

[0121] In some embodiments, the flow regulator assembly (130) offers adaptability through the inclusion of a pump, providing an alternative mechanism for controlling electrolyte flow. This feature caters to diverse operational scenarios, with options for manual and electrically powered pumps.

[0122] In some embodiments, a flow meter is integrated within the flow regulator assembly (130) which enables precise measurement and monitoring of electrolyte flow rates. This capability enhances operational efficiency and facilitates proactive maintenance by providing real-time insights into electrolyte circulation within the battery system.

[0123] Overall, the flow regulator assembly (130) plays a crucial role in optimizing battery performance and ensuring operational reliability across various applications and environments.

[0124] In the specific implementation currently disclosed, the flow regulator assembly (130) (referenced in FIG. 1 A, FIG. IB, FIG. 1C, FIG. ID, FIG. IE, and FIG. 3A through FIG. 4B) comprises a shutter base (132), a shutter rubber (134), and a buoyant (136). This assembly is situated within the main channel (114), precisely aligned with the inner edge where the main channel (114) intersects or connects with the plurality of channels (116). Its primary function, as previously articulated, is to govern the flow of electrolyte from the main channel (114) into the plurality of channels (116).

[0125] The shutter base (132) in this exemplar implementation features a longitudinal strip-like structure (depicted in FIG. 3A-1, FIG. 3A-2, FIG. 3B-1 and FIG. 3B-2). This strip-like form possesses a substantially rectangular outline, distinguished by first and second lengthy edges, as well as first and second short edges. While the first lengthy edge remains unadorned, devoid of additional embellishments, the second lengthy edge exhibits a series of serrations, each corresponding to the terminus of one of the plurality of channels (116). These serrations may assume various shapes, ideally resembling the crosssection of the plurality of channels (116). Furthermore, the second lengthy edge incorporates a tab-like structure, extending predominantly horizontally from its surface, featuring a perforation situated at its extremity. Preferably centered along the second lengthy edge, this tab-like structure ensures an equitable distribution of serrations on either side. Additionally, certain embodiments may incorporate another tab-like structure protruding upwardly from the second lengthy edge, positioned preferably in proximity to the midpoint.

[0126] Similarly, the shutter rubber (134) mirrors the structural configuration of the shutter base, characterized by first and second lengthy edges, as well as first and second short edges, delineating a rectangular shape. Its second lengthy edge, akin to that of the shutter base, is adorned with a series of serrations, mirroring the count observed on the shutter base (132). Functioning as a type of gasket, the shutter rubber (134) is preferably composed of rubber or analogous materials.

[0127] Integral to the flow regulator assembly is the buoyant (136), comprising a body featuring a slit segment and a buoyant segment, with the former exhibiting a greater length than the latter. The buoyant segment embodies a hollow structure, preferably infused with air or a gaseous substance.

[0128] Secured to the inner periphery of the main channel (114), the shutter rubber (134) may employ various securing mechanisms, including fasteners, adhesives, or integration into the channel's structure through molding. Notably, the serrations along thesecond lengthy edge of the shutter rubber (134) are strategically positioned to align with the termini of the plurality of channels (116).

[0129] The placement of the shutter base (132) adjacent to the shutter rubber (134) ensures flush alignment with the latter's inner surface. In certain embodiments, the shutter base (132) is designed to slide along the inner surface of the shutter rubber (134) with a degree of friction, facilitating longitudinal movement within the main channel (114) while maintaining consistent contact with the shutter rubber (134).

[0130] Additionally, the buoyant (136) is positioned to interface with the inner surface of the shutter base (132), with its buoyant segment positioned within the main channel. Concurrently, its slit segment engages with a pin (136 A), designed to facilitate sliding movement along its length.

[0131] Moreover, a tab (138) is incorporated onto the surface of the main channel (114), serving as an additional element within the flow regulation mechanism.

[0132] Concealed beneath the top plate (120), the flow regulator assembly (130) remains obscured from view, save for an upwardly extending tab affixed to the second lengthy edge of the shutter base. The top plate (120) is outfitted with a slit or orifice (125), accommodating the upwardly extending tab and facilitating its movement.

[0133] Upon displacement, the upwardly extending tab initiates a transition of the shutter base (132) from its initial open position, wherein the serrations of the shutter base (132) and the shutter rubber (134) remain misaligned. Simultaneously, the hole on the horizontal tab fails to align with the orifice (129) on the top plate (120). Consequently, electrolyte flow from the source to the orifice (129) and subsequently into the main channel (114) is impeded, thereby precluding electrolyte entry into the battery enclosure. Notably, the buoyant (136) undergoes elevation due to the presence of the tab (138), resulting in a reduction of electrolyte levels within the main channel (114).

[0134] In an alternative electrolyte flow configuration, displacement of the tab on the second lengthy edge of the shutter base (132) shifts the shutter base (132) to a secondary position. This realignment brings about a synchronization of the serrations between the shutter rubber (134) and the shutter base (132). Furthermore, the horizontal tab on the second lengthy edge of the shutter base (132) aligns with the orifice (129) on the top plate (120). Consequently, electrolyte from the source gains ingress through the orifice (129), flowing into the main channel (114). Correspondingly, the buoyant (136) adjusts its position within the main channel (114), elevating electrolyte levels to accommodate the plurality of channels (116). Collectively, these adjustments establish an electrolyte flow pathway from the source, through the plurality of channels, and up to the plurality of through holes (112), enabling the unimpeded flow of electrolyte into the battery compartments.

[0135] Lastly, the battery cover includes a plurality of float-cum-level indicators (140). These indicators are received in and attached to the through holes (112). Each float- cum-level indicator (140) provides real-time feedback on the electrolyte level within each compartment, ensuring that the electrolyte levels are maintained within optimal ranges. These indicators typically consist of a buoyant float attached to a visible marker or electronic sensor, made from materials that can withstand exposure to the battery's internal environment.

[0136] The float-cum-level indicators (140) are now described herein below with reference to FIG. 2H, wherein FIG. 2H illustrates a side view of a float-cum-level indicator, and further with reference to FIG. 2A-1 and FIG. 2A-2 which illustrate a schematic isometric view and side view, respectively, of a vent cap of the battery cover of FIG. 1 A, FIG. 2B and FIG. 2C which illustrate schematic isometric views of a rubber gasket and buffer cap respectively, FIG. 2D-1, and FIG. 2D-2 which illustrate a side view and isometric view of a float element in accordance with the embodiments of the present invention, FIG. 2E whichillustrates an isometric view of a float guide for guiding the float element of FIG. 2D-1, and FIG. 2D-2, FIG. 2F-1 and FIG. 2F-2 which illustrate a side view and isometric view of a level indicating portion of the float element, and FIG. 2G-1 and FIG. 2G-2 which illustrate a side view and isometric view of a buoyant holder.

[0137] Further, FIG. 21 illustrates a schematic cross-sectional side view a battery along with the battery cover of FIG. 1 A, FIG. 2J-1 illustrates a schematic isometric view of a battery along with the battery cover of FIG. 1 A, and FIG. 2J-2 illustrates a schematic isometric view of the battery of FIG. 2J-1 along with the battery bottom plate and the top plate removed.

[0138] More specifically, each of the plurality of float-cum-level indicators (140) (FIG. 2H) comprises a buoyant holder (147), a buoyant or float element (142), a buoyant guide (142-C), a buoyant indicator or level indicating portion (144), a vent cap (146), a rubber gasket (148), a buffer cap (149), a vent (150) configured on the vent cap (146), and a fluid permeable membrane.

[0139] In particular, the each of the plurality of float-cum-level indicators (140) comprises a buoyant holder (147), which in the present case (FIG. 2G-1, and FIG-2G-2) comprises a frustoconical cylindrical basket like structure, having an open upper end, and a closed lower end. The basket is perforated. The basket can be made of any suitable material selected from the group consisting of a polymer, copolymer and combinations thereof. The material of the basket is so selected that the material is corrosion resistant under the corrosive environment of the battery cells, as the buoyant holder (147) is received in and secured to the plurality of holes (112) such that the lower end is suspended within the battery cells and the upper end is received on the periphery of vent caps (146), and the vent caps being received on and secured to the plurality of holes (112).

[0140] The float-cum -level indicators (140) further includes buoyant or float element (142). The buoyant or float element (142) comprises a dumbbell shaped body having a top portion (142-A), and a bottom portion (142-B) connected to each other. The float element (142) is substantially hollow body and may be filled with air or any suitable gas or fluid. The float element (142) is configured to float on the electrolyte with each of the battery compartments or cells. Specifically, the float element (142) is received in the basket of the buoyant holder (147) and is held therein in freely movable manner. Since the basket is perforated, wherein the electrolyte level increases, the float element (142) floats on the electrolyte surface, which is received in the basket. The float element (142) is received in upright manner such that the lower portion (142-B) is received on the closed end of the basket and the upper portion (142-A) points upward towards the open end of the basket.

[0141] The float element (142) has a buoyant guide (142-C) secured to the upper portion (142-A) (see FIG. 2H). The buoyant guide (142-C) is a longitudinal element and is provided with few markings or gradings configured thereon. When the float element (142) is raised or lowered due to rising or lower of the electrolyte level in the cells, the buoyant guide (142-C) is also raised or lowered. The markings or gradings, which may be calibrated suitably facilitates measurement of electrolyte level within each of the cells of the battery. In some embodiments, the float-cum -level indicators (140) may be provided for each cell of the battery. In some other embodiments, the float-cum-level indicators (140) are provided only for the centermost cells wherein the electrolyte level is relatively rapidly reduced due to heat generated within the battery as there is no other way to radiate the heat. The float element (142) is received through and clearly visible above the holes (124) in the top plate (120) and is termed as a buoyant indicator or level indicating portion (144).

[0142] Further a vent cap (146) is received in each of the through holes (112) wherein the vent cap (146) sits above the buoyant holder (147). A rubber gasket (148) isprovided between the upper end of the vent cap (146) and the periphery or edges of the through holes (112) which acts as a seal for preventing ingress of foreign material into the cells and egress of electrolyte. The vent cap (146) is hollow and has engaging formations on an outer surface thereof to engage with the periphery of the through holes (112).

[0143] Abuffer cap (149) is provided which is disposed just below the lower end of the vent cap (146). The buffer cap (149) has a central hole which allows the buoyant guide (142-C) to pass there through into the vent cap and then through the vent (150). The central hole has a dimension such that the upper portion (142-A) does not pass there through, i.e., the upper portion has higher dimensions than the central hole. This allows complete closure of the through holes (112) when the electrolyte level is up to the mark.

[0144] In some embodiments, a fluid permeable membrane (not shown in the figures) may be provided which permits breathing of the cells allowing the vapors formed to move out of the cell and air to come in when the electrolyte level falls.

[0145] In the disclosed embodiment, the battery cover (100) features a float element (142) constructed from buoyant material. Additionally, the level indicating portion (144) is designed to provide a visual indication of the electrolyte level in each compartment, including a colored portion visible through the plurality of through holes (112).

[0146] This detailed embodiment describes the incorporation of a float element (142) within the battery cover (100). The float element (142) is fabricated from a material with inherent buoyancy properties, enabling it to float on the surface of the electrolyte within the battery. The level indicating portion (144), which is integrally associated with the float element (142), is meticulously engineered to offer a clear, visual indication of the electrolyte level present in each individual compartment of the battery. This level indicating portion (144) includes a distinct colored section that is purposefully designed to be visible throughthe plurality of through holes (112) that penetrate the battery cover (100), thereby facilitating easy monitoring and maintenance of optimal electrolyte levels.

[0147] The vent (150) within the battery cover (100) incorporates a flame arrestor. The plurality of channels (116) are designed with a depth that tapers towards the plurality of through holes (112). The main channel (114) extends across a significant portion of the upper surface of the bottom plate (110).

[0148] The vent (150) integrated into the battery cover (100) is equipped with a flame arrestor, a critical safety feature that mitigates the risk of igniting flammable gases that may be emitted from the battery's electrolyte. This flame arrestor is designed to allow gases to escape while preventing external flames from entering the battery interior. Additionally, the plurality of channels (116) feature a tapered depth design, strategically narrowing as they approach the through holes (112). This design ensures efficient flow and distribution of the electrolyte. The main channel (114), a primary conduit for electrolyte flow, spans a substantial portion of the bottom plate's upper surface, ensuring thorough and uniform distribution across all battery compartments.

[0149] A handle (126) is affixed to the top plate (120) to facilitate its removal and placement. The top plate (120) also includes a transparent portion allowing for the observation of the main channel (114) and the plurality of channels (116). The through holes (112) are threaded to accommodate the plurality of float-cum-level indicators (140) in a threaded engagement.

[0150] To enhance user convenience, a handle (126) is securely attached to the top plate (120), simplifying the removal and placement of the top plate during maintenance or inspection procedures. Furthermore, the top plate (120) features a transparent section, providing an unobstructed view of the main channel (114) and the plurality of channels (116). This transparency allows for real-time monitoring of the electrolyte flow and levels. Thethrough holes (112) are meticulously designed with threading to enable the secure engagement of the float-cum -level indicators (140), ensuring they remain firmly in place during battery operation.

[0151] The bottom plate (110) is equipped with a peripheral seal to engage sealably with the top open end of the battery case. A locking mechanism (128), consisting of multiple clamps, selectively secures the top plate (120) to the bottom plate (110).

[0152] The bottom plate (110) of the battery cover (100) includes a peripheral seal, a critical feature designed to establish a secure and leak-proof engagement with the open top end of the battery case. This seal prevents electrolyte leakage and contamination, ensuring the integrity and longevity of the battery. Additionally, a locking mechanism (128) is incorporated, comprising multiple clamps that can be selectively engaged to secure the top plate (120) to the bottom plate (110). This locking mechanism ensures a firm and reliable connection between the two plates, enhancing the overall structural stability of the battery cover (100).

[0153] The electrolyte within the battery cover (100) is a sulfuric acid solution, and the electrochemical cells are of the lead-acid type. The assembly includes a drain (118) to facilitate the removal of the electrolyte from the main channel (114) and the plurality of channels (116).

[0154] The battery cover (100) is designed to house an electrolyte composed of a sulfuric acid solution, which is the standard electrolyte used in lead-acid type electrochemical cells. These cells are widely recognized for their reliability and efficiency in energy storage and delivery. To facilitate maintenance, the assembly includes a drain (118), strategically positioned to allow for the efficient removal of the electrolyte from both the main channel (114) and the plurality of channels (116). This feature is particularly useful during servicing or replacement of the electrolyte, ensuring that the battery can be easily and safely emptied.

[0155] The flow regulator assembly (130) incorporates a sliding gate mechanism to control the flow of electrolyte. The main channel (114) is broader in width than the plurality of channels (116). Additionally, the bottom plate (110) features a sealing gasket along its perimeter to ensure a leak-proof fit with the battery case.

[0156] The flow regulator assembly (130) within the battery cover (100) is equipped with a sliding gate mechanism. This mechanism is designed to precisely control the flow of the electrolyte, allowing it to be directed as needed through the battery's internal channels. The main channel (114) is intentionally designed to be broader in width compared to the plurality of channels (116), facilitating a higher volume of electrolyte flow through the main channel. The bottom plate (110) also includes a sealing gasket along its perimeter, which is essential for ensuring a leak-proof fit with the battery case. This gasket enhances the overall durability and reliability of the battery cover (100) by preventing any potential leaks.

[0157] The top plate (120) is detachably secured to the bottom plate (110) using fastening mechanisms. The flow regulator assembly (130) is also equipped with a manual control knob. The plurality of channels (116) are arranged radially around the main channel (114).

[0158] The top plate (120) of the battery cover (100) is designed to be detachably secured to the bottom plate (110) through the use of various fastening mechanisms. This detachable design allows for easy access to the internal components of the battery for maintenance or inspection purposes. The flow regulator assembly (130) features a manual control knob, providing users with the ability to manually adjust the flow of electrolyte as required. The plurality of channels (116) are systematically arranged in a radial pattern around the main channel (114), optimizing the distribution and flow of the electrolyte throughout the battery compartments.

[0159] The float-cum-level indicators (140) are color-coded to indicate varying levels of electrolyte. The flow regulator assembly (130) can be automated and regulated by a microprocessor. The top plate (120) incorporates an integrated pressure relief valve.

[0160] To facilitate easy monitoring of electrolyte levels, the float-cum-level indicators (140) are color-coded. This color-coding allows for quick visual identification of the electrolyte levels in each compartment. Additionally, the flow regulator assembly (130) has the capability to be automated and controlled by a microprocessor, allowing for precise regulation of electrolyte flow. The top plate (120) includes an integrated pressure relief valve, a crucial safety feature that helps to prevent excessive pressure buildup within the battery cover (100), thereby enhancing the overall safety and reliability of the battery.

[0161] Guides molded integrally into the bottom plate (110) ensure proper alignment with the battery case. The through holes (112) contain fine mesh filters to prevent contamination. The main channel (114) includes markings to denote the volume of electrolyte.

[0162] The bottom plate (110) features integrally molded guides, which play a vital role in ensuring the proper alignment of the battery cover (100) with the battery case. This alignment is essential for maintaining the structural integrity and sealing capabilities of the battery cover. The through holes (112) are equipped with fine mesh filters, designed to prevent any contaminants from entering the battery's electrolyte system. Additionally, the main channel (114) includes precise markings that indicate the volume of electrolyte, aiding in accurate monitoring and maintenance of the electrolyte levels.

[0163] The flow regulator assembly (130) features a one-way valve to prevent electrolyte backflow. The plurality of channels (116) are optimized in cross-sectional shape for fluid flow. The float-cum-level indicators (140) include an electrical contact for signalinglow electrolyte levels and are equipped with magnets to activate external sensors. Finally, the main channel (114) is centrally located on the bottom plate (110).

[0164] The flow regulator assembly (130) incorporates a one-way valve, a critical feature that prevents the backflow of electrolyte, ensuring unidirectional flow and maintaining the efficiency of the battery's electrolyte distribution system. The plurality of channels (116) are specifically optimized in their cross-sectional shape to enhance fluid flow, thereby improving the overall performance of the battery. The float-cum-level indicators (140) are designed with an electrical contact, which signals low electrolyte levels, providing an additional layer of monitoring and safety. These indicators also feature magnets that can activate external sensors, further enhancing the monitoring capabilities. The main channel (114) is centrally located on the bottom plate (110), ensuring optimal distribution of electrolyte throughout the battery. In summary, the battery cover (100) for flooded lead-acid batteries is a sophisticated assembly of components, each designed with precision to ensure fail-safe ionic conductivity isolation, efficient electrolyte management, and reliable operation under challenging conditions.

[0165] In various embodiments presented herein, the battery cover is ingeniously crafted to function as a retrofitting solution, enabling seamless adaptation to existing conventional batteries through carefully tailored modifications. This innovative design embodies the principle of "fit and forget," thereby obviating the need for specialized tools or intricate fitting procedures traditionally associated with such installations. This streamlined approach ensures that individuals, irrespective of their technical proficiency or prior experience, can effortlessly install the battery cover.

[0166] The retrofit capability of the battery cover is designed to accommodate diverse configurations of conventional batteries, enhancing versatility and usability across different applications. By incorporating user-friendly features and intuitive design elements,the patent exemplifies a significant advancement in the field, promising enhanced accessibility and operational efficiency in retrofitting conventional battery systems. This embodiment underscores the patent's commitment to innovation by addressing practical challenges and simplifying the adoption of advanced battery technologies in various industrial and consumer sectors.TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE OF THE PRESENT INVENTIONTECHNICAL ADVANTAGES:

[0167] The present invention proffers a panoply of technical advantages that elevate the safety, performance, and longevity of multi-cell flooded lead-acid batteries to unprecedented heights. Paramount among these advantages is the unparalleled ability of the inventive battery cover design to effectuate a hermetic isolation of the inter-cell spaces, thereby precluding the establishment of ionic conductivity pathways between adjacent cells during electrolyte refilling or topping operations. This ingenious feature mitigates the risk of short-circuiting due to electrolyte spillage or dispersal, a quandary that has long been a bane to the battery industry, engendering catastrophic failures and posing grave safety hazards.

[0168] Moreover, by maintaining the voltage equilibrium within the battery and preventing the ingress of electrolyte into adjacent cells, the present invention forestalls the deleterious effects of imbalanced discharge rates and accelerated degradation of internal components, respectively. Consequently, the battery's performance and capacity utilization are optimized, while its service life is extended, rendering it a more robust and durable energy storage solution.

[0169] The inventive battery cover assembly also serves as a bulwark against the pernicious phenomenon of thermal runaways, which can arise from the exothermic reactionsprecipitated by short-circuiting. By mitigating the risk of such events, the present invention enhances the overall safety profile of the battery system, safeguarding personnel and property from the potential hazards of battery rupture and subsequent dissemination of corrosive electrolyte and ignition of adjacent combustible materials.

[0170] Furthermore, the ingenious design of the battery cover assembly is distinguished by its simplicity and elegance, eschewing the need for intricate sealing mechanisms or specialized electrolyte delivery systems. This salient feature not only facilitates cost-effective manufacturing but also ensures ease of installation and maintenance, thereby minimizing downtime and reducing the operational costs associated with battery maintenance.

[0171] Notably, the present invention proffers a multi-level safety mechanism, wherein ionic conductivity between adjacent cells is precluded at multiple levels. This redundant safeguard ensures that even in the event of a failure at one or more levels, due to an accident or oversight, the deleterious consequences of inter-cell ionic conductivity, such as short-circuiting, voltage imbalances, and accelerated degradation, are effectively mitigated or eliminated. This multi-tiered approach to safety underscores the invention's commitment to robust and reliable battery performance, further cementing its technical superiority over conventional designs.ECONOMIC ADVANTAGES:

[0172] In addition to its technical tour de force, the present invention proffers a cornucopia of economic advantages that render it a paragon of cost-effectiveness and economic viability. By virtue of its simplicity and compatibility with existing battery configurations, the inventive battery cover design requires minimal modification to the latter, thereby enabling seamless integration and retrofitting in various applications. This attributenot only mitigates the costs associated with wholesale replacement or overhaul but also fosters versatility and broad applicability across diverse industries and use cases.

[0173] Furthermore, the resilience and durability of the battery cover assembly, coupled with its capacity to withstand the vicissitudes of harsh operating conditions and environmental factors, contribute to the longevity of the battery system. This translates into tangible cost savings by reducing the frequency of battery replacements and minimizing the associated expenditures.

[0174] Moreover, the ease of inspection and maintenance afforded by the present invention serves to curtail downtime and its concomitant economic repercussions, further augmenting the cost-effectiveness of the battery system. Additionally, the invention's adherence to relevant safety and regulatory standards, as well as its environmental friendliness, promotes sustainability and responsible energy storage practices, thereby mitigating the potential for costly legal liabilities and reinforcing the battery's competitiveness in an increasingly eco-conscious market.

[0175] In summation, the present invention represents a paradigm shift in the field of battery design and construction, offering an unparalleled synergy of technical and economic advantages that elevate the performance, safety, and cost-effectiveness of multi-cell flooded lead-acid batteries to unprecedented heights, thereby positioning them as a preeminent energy storage solution for the modem era.

Claims

We claim:

1. A battery cover (100) with fail-safe ionic conductivity isolation for flooded lead-acid batteries, the battery cover (100) comprising: a. A bottom plate (110): i. received on and sealably fitted to a top open end of a battery case having a plurality of compartments each holding an electrochemical cell therewithin; ii. having a plurality of through holes (112): b. one each corresponding to the plurality of compartments; i. for facilitating topping or refiling of electrolyte into the plurality of compartments therethrough; ii. for facilitating egress of gases formed within the plurality of compartments; iii. having a main channel (114) configured on an upper surface thereof, the main channel (114) for receiving the electrolyte to be replenished from a source of electrolyte; iv. having a plurality of channels (116) configured on the upper surface thereof, the plurality of channels (116) configuring an electrolytic fluid communication from the main channel (114) to the plurality of through holes (112), wherein the length of the plurality of channels (116) being L with a difference in the range of 0 % to 10 % of L;c. Atop plate (120): i. comprising a substantially planar body (122); ii. being configured to be received on and mate with the bottom plate (110) concealing the plurality of through holes (112), main channel (114), and plurality of channels (116) thereunder; d. A flow regulator assembly (130) configured to selectively allow the flow of the electrolyte from the source to the plurality of through holes (112); and e. A plurality of float-cum-level indicators (140) being received in and attached to the plurality of through holes (112).

2. The battery cover as claimed in claim 1, a. wherein the depth of the main channel (114) is greater than the depth of the plurality of channels (116); b. wherein each of the plurality of channels (116) are sloped at an angle in the range 0 to 10 degrees with respect to the surface of the bottom plate (110), the end connecting the main channel (114) being at a higher elevation than the end connecting the plurality of holes (112); c. wherein the bottom plate (110) and the top plate (120) are made of a polymeric material or chemically resistant polymeric material, and the polymeric material is one selected from the group consisting of polypropylene, polyethylene, and polyvinyl chloride;d. wherein the bottom plate (110) and the top plate (120) are made of a non- conductive polymeric material; e. wherein the flow regulator assembly (130) comprises a valve, wherein the valve is a manually operable valve, and wherein the valve is an electrically operable valve; f. wherein the flow regulator assembly (130) is configured to control flow rate of the electrolyte to the plurality of through holes (112).

3. The battery cover (100) as claimed in claim 1, wherein the flow regulator assembly (130) comprises a pump, wherein the pump is a manual pump, and wherein the pump is an electrically powered pump.

4. The battery cover (100) as claimed in claim 1, a. wherein the flow regulator assembly (130) comprises a flow meter to measure the flow rate of the electrolyte; b. wherein the plurality of float-cum-level indicators (140) comprise a float element (142) and a level indicating portion (144); c. wherein the top plate (120) having: i. a plurality of holes (124) receiving the level indicating portion (144) therethrough and there above; and ii. an inlet aperture (129) for receiving the electrolyte therethrough; d. wherein the float element (142) is made of a buoyant material;e. wherein the level indicating portion (144) is configured to provide a visual indication of electrolyte level in each of the plurality of compartments; f. wherein the level indicating portion (144) comprises a colored portion that is visible through the plurality of through holes (112).

5. The battery cover (100) as claimed in claim 1, includes a. a vent (150) configured to allow egress of gases from the battery case; b. wherein the vent (150) comprises a fluid permeable membrane that prevents ingress of contaminants; and c. wherein the vent (150) comprises a flame arrestor.

6. The battery cover (100) as claimed in claim 1, a. wherein the plurality of channels (116) have a depth that tapers toward the plurality of through holes (112); b. wherein the main channel (114) extends across a substantial portion of the upper surface of the bottom plate (110); includes a handle (126) attached to the top plate (120) to facilitate removal and placement of the top plate (120).

7. The battery cover (100) as claimed in claim 1, a. wherein the top plate (120) comprises a transparent portion to allow viewing of the main channel (114) and the plurality of channels (116); b. wherein the plurality of through holes (112) are threaded to receive the plurality of float-cum-level indicators (140) in a threaded engagement;wherein the bottom plate (110) comprises a peripheral seal configured to sealably engage with the top open end of the battery case; c. includes a locking mechanism (128) to selectively lock the top plate (120) to the bottom plate (110), wherein the locking mechanism (128) comprises a plurality of clamps; d. wherein the difference in length of the plurality of channels (116) is in the range of 2% to 8% of the length L; and e. wherein the length L of the plurality of channels is in the range of 5 cm to 30 cm.

8. The battery cover (100) as claimed in claim 1, a. wherein the plurality of channels (116) having a cross-sectional shape selected from circular, rectangular, and triangular; b. wherein the main channel (114) and the plurality of channels (116) have a surface treatment to improve fluid flow; and c. wherein the surface treatment comprises a hydrophobic coating.

9. The battery cover (100) as claimed in claim 1, a. includes a drain (118) configured to allow removal of the electrolyte from the main channel (114) and the plurality of channels (116); and b. wherein the main channel (114) has a width greater than that of the plurality of channels (116);c. wherein the flow regulator assembly (130) comprises a sliding gate mechanism to selectively allow or stop the flow of electrolyte.

10. The battery cover (100) as claimed in claim 1, a. wherein the bottom plate (110) further comprises a sealing gasket along its perimeter to ensure a leak-proof fit with the battery case; b. wherein the top plate (120) is removably attached to the bottom plate (110) using fastening means; wherein the flow regulator assembly (130) includes a manual control knob; c. wherein the plurality of channels (116) are configured in a radial pattern around the main channel (114); d. wherein the float-cum-level indicators (140) are color-coded to indicate different levels of electrolyte; e. wherein the flow regulator assembly (130) is automated and controlled by a microprocessor; and f. wherein the top plate (120) includes an integrated pressure relief valve.

11. The battery cover (100) as claimed in claim 1, a. wherein the bottom plate (110) includes integrally molded guides to ensure proper alignment with the battery case; b. wherein the plurality of through holes (112) include fine mesh filters to prevent contamination;c. wherein the main channel (114) includes markings to indicate the volume of electrolyte; d. wherein the flow regulator assembly (130) includes a one-way valve to prevent backflow of electrolyte; e. wherein the plurality of channels (116) have a cross-sectional shape optimized for fluid flow; wherein the float-cum-level indicators (140) include an electrical contact for signaling low electrolyte levels; f. wherein the plurality of float-cum-level indicators (140) are equipped with magnets to trigger external sensors; g. wherein the main channel (114) is centrally located on the bottom plate (110); wherein the flow regulator assembly for controlling the flow of electrolyte within a battery, comprising: i. A shutter base (132) configured with a longitudinal strip-like body having a substantially rectangular shape, the body defined by first and second long edges, and first and second short edges, wherein:

1. The first long edge is plain;2. The second long edge comprises a series of serrations, each serration corresponding to the end of one of a plurality of channels (116), and a tab-like structure extending substantially horizontally from the second long edge, said tab-like structure featuring a hole at its end;ii. A shutter rubber (134) having a structure substantially identical to that of the shutter base, defined by first and second long edges, and first and second short edges, the second long edge of the shutter rubber comprising a series of serrations that register with the serrations of the shutter base, wherein the shutter rubber acts as a gasket; iii. A buoyant (136) comprising a slit part and a buoyant part, the slit part having a length greater than the buoyant part, wherein the buoyant part comprises a hollow body filled with air or gas; iv. A main channel (114) configured to house the flow regulator assembly, wherein: v. The shutter rubber (134) is secured to the inner edge of the main channel (114) using fasteners, adhesives, or by molding, vi. The shutter base (132) is positioned adjacent to the shutter rubber (134) and is capable of sliding along its inner surface with friction, vii. The buoyant (136) is positioned in contact with the shutter base (132) such that the buoyant part is disposed within the main channel (114) and the slit part engages with a pin (136A) to facilitate sliding movement; h. A top plate (120) that conceals the flow regulator assembly, wherein the top plate (120) comprises a slit or hole (125) to accommodate the upwardly extending tab from the second long edge of the shutter base, allowing for displacement and movement of the shutter base (132).

12. A method of regulating electrolyte flow in a battery employing the flow regulator assembly (130) as claimed in claim 11, comprising: a. Providing a flow regulator assembly (130) within a main channel (114), wherein the assembly includes: i. A shutter base (132) with a series of serrations and a horizontally extending tab featuring a hole, ii. A shutter rubber (134) with serrations registering with those on the shutter base (132), iii. A buoyant (136) with a slit part and a buoyant part; b. Securing the shutter rubber (134) to the inner edge of the main channel (114); c. Positioning the shutter base (132) adjacent to the shutter rubber (134) such that it slides along the shutter rubber's inner surface with friction; d. Placing the buoyant (136) in contact with the shutter base (132) so that the buoyant part is disposed within the main channel (114) and the slit part engages with a pin (136A); e. Covering the flow regulator assembly with a top plate (120) that includes a slit or hole (125) to allow movement of the upwardly extending tab from the shutter base (132); f. Regulating the electrolyte flow by displacing the upwardly extending tab to: i. An open position where the serrations of the shutter base (132) and shutter rubber (134) are mismatched, preventing electrolyte flow,ii. A second position where the serrations align, allowing electrolyte to flow from the source through the main channel (114) and into the plurality of channels (116).

13. A battery cover assembly with integrated flow regulation and electrolyte level indication as claimed in claim 11, comprising: a. A flow regulator assembly (130) positioned within a main channel (114), including: i. A shutter base (132) with a longitudinal strip-like body featuring first and second long edges, where the second long edge includes serrations and a horizontally extending tab with a hole; ii. A shutter rubber (134) having a similar structure to the shutter base with corresponding serrations, iii. A buoyant (136) comprising a slit part and a buoyant part filled with air or gas; b. Means for securing the shutter rubber (134) to the inner edge of the main channel (114); c. A top plate (120) with a slit or hole (125) to accommodate an upwardly extending tab from the shutter base (132), enabling its displacement; d. A tab (138) placed on the surface of the main channel (114) to interact with the buoyant (136);e. A plurality of float-cum-level indicators (140) attached to through holes (112) in the battery cover, each indicator providing real-time feedback on electrolyte levels within the battery compartments, wherein each float-cum-level indicator (140) includes a buoyant float and a visible marker or electronic sensor resilient to the battery's internal environment.

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