Battery grid for use with a lead-acid battery, battery plate including the battery grid, lead-acid battery having the battery plate, and method of manufacturing the same

Abstract

An example battery grid described herein includes a first grid wire and a second grid wire. The second grid wire intersects the first grid wire at a node and, together, the first and second grid wire form a plane. A battery grid window is formed by at least the first grid wire. The battery grid window is configured to absorb growth stress of the second grid wire in the plane. The first grid wire is configured to bend at the node to absorb growth stress of the second grid wire in the plane.

Description

BATTERY GRID FOR USE WITH A LEAD-ACID BATTERY, BATTERY PLATE INCLUDING THE BATTERY GRID, LEAD-ACID BATTERY HAVING THE BATTERY PLATE, AND METHOD OF MANUFACTURING THE SAMEFIELD OF THE DISCLOSURE

[0001] The disclosure relates to the field of lead-acid batteries. The disclosure more specifically relates to battery grid and battery plate designs. The disclosure also relates to methods of making battery grids, battery plates, and lead-acid batteries.BACKGROUND

[0002] A secondary battery, rechargeable battery, storage battery, or accumulator (collectively referred to herein as a battery) are part of a group of batteries having one or more electrochemical cells in which the electrochemical reactions are electrically reversible. One type of battery is a lead-acid battery.

[0003] Lead-acid batteries include plates of lead and plates of lead dioxide. The plates are submerged into an electrolyte solution. The lead, lead dioxide, and electrolyte cause a chemical reaction that releases electrons, allowing them to flow through conductors to produce electricity. When the battery is charged, the chemical reaction is reversed. As the battery discharges, the acid of the electrolyte reacts with the materials of the plates. Lead-acid batteries generally have a long life, or lifecycle, resulting in a large number of charge and discharge cycles.

[0004] The battery plates include battery grids. The battery grids, and in particular positive battery grids, have been known to grow over time as the grid goes through its lifecycle. One known failure mode of a lead-acid battery occurs naturally through the positive grid growth. Moreover, excessive cycling of the battery, excessive temperature, and over-charging can accelerate the rate of grid growth.

[0005] Grid wire layouts for lead-acid battery grids have traditionally been optimized for current flow resistance per weight. Lead-acid battery design over time has included expanded metal grids for positive electrodes utilizing wrought strip. The wrought strip introduced a new corrosion behavior to the battery grid. More specifically, cast grids generally crumble while wrought strip metal significantly expands and grow as compared to cast grids. More recentDocket No. 57501-3120 manufacturing techniques include combining a wrought strip with known cast / bookmold type wire layouts. The improved techniques improved current flow per unit weight over what was obtained with older designs. Designers have retarded but not eliminated grid growth through the use of thick exterior frames. However, grid growth still remains the primary corrosion failure mode for wrought strip metal battery plates. Accordingly, a different solution is desired.SUMMARY

[0006] When utilizing wrought metals for positive grids, the corrosion mechanism typically results in elongation stress. This stress typically results in either growth or buckling of the plates. This growth or buckling, in turn, typically leads to the development of short circuits and ultimately battery failure.

[0007] Grid wire layout has traditionally followed two primary paths. First, it optimizes for current flow and high power, which is not the most critical design consideration for this disclosure. Second, it is designed for rigid strength to handle physical movement through the process. As a tertiary consideration, prior layout designs went into wire layout improvements for life expectancy but focused on increasing strength / rigidity as the method for delivering life improvement.

[0008] This disclosure proposes an additive, or even optimal, approach to life expectancy. Instead of discouraging grid growth, this disclosure aims to accept and direct grid growth. Instead of symmetrical wire layouts, which concentrate and build elongation stress, this disclosure proposes asymmetrical layouts where wire growth direction has a “buckle zone” on the grid wire. The absorption of stress can be accomplished through the use of discontinuous wire segments (e.g., either through repeated patterns or discretely implemented discontinuations). Additionally or alternatively, the absorption of stress can be accomplished through the employment of curved wires, achieving a similar effect.

[0009] In embodiments, the disclosure provides a battery grid for use in a lead-acid battery. The battery grid comprises a first grid wire and a second grid wire intersecting or coupling with the first grid wire at a node. The first grid wire and the second grid wire define a plane. The battery grid further comprises a battery grid window formed by at least the first grid wire. TheDocket No. 57501-3120 battery grid window absorbs growth stress of the second grid wire in the plane. In additional or alternative embodiments, the first grid wire bends at the node to absorb growth stress of the second grid wire in the plane.

[0010] In embodiments, the first grid wire and the second grid wire comprise a linear grid wire arrangement. In alternative embodiments, the first grid wire and the second grid wire comprise a nonlinear grid wire arrangement. In alternative embodiments, the first grid wire and the second grid wire comprise a combined segmented and nonlinear grid wire arrangement. In alternative embodiments, the first grid wire and the second grid wire comprise at least a portion of a tessellated grid pattern.

[0011] In embodiments, the second grid wire segments the first grid wire at the node, and the growth stress of the second grid wire moves the node toward the battery grid window. In additional or alternative embodiments, the second grid wire includes a nonlinear grid wire portion, and the growth stress of the second grid wire moves the nonlinear grid wire portion toward the battery grid window. In additional or alternative embodiments, the second grid wire includes a nonlinear grid wire portion which segments the first grid wire at the node, and the growth stress of the second grid wire moves the node and the nonlinear grid portion toward the battery grid window.

[0012] In embodiments, the disclosure provides a battery plate comprising the battery grid.

[0013] In embodiments, the disclosure provides a lead-acid battery comprising the battery plate.

[0014] These and other features, advantages, and embodiments of apparatus and methods according to the invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.BRIEF DESCRIPTION OF DRAWINGS

[0015] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render otherDocket No. 57501-3120 details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

[0016] FIG. l is a perspective view of an example lead-acid battery capable of including a battery grid of the disclosure herein.

[0017] FIG. 2 is a top plan view of the lead-acid battery shown in FIG. 1, with the battery cover removed.

[0018] FIG. 3 is a cross-sectional elevation view of the lead-acid battery shown in FIG. 1.

[0019] FIG. 4 is a cut-away perspective view of the lead-acid battery including a prior battery grid, showing the grid and an absorbent glass mat.

[0020] FIG. 5 is a side plan view of a prior positive battery grid capable of being used with the lead-acid battery shown in FIG. 1.

[0021] FIG. 6 is a side plan view of the grid arrangement shown in FIG. 5 provided with an active mass, a portion of which is removed.

[0022] FIG. 7 is a partially exploded perspective view of the encasing of a grid arrangement provided with an active mass within a separator.

[0023] FIG. 8 is a side view of a faulted plate of the prior art.

[0024] FIG. 9 is a reverse perspective view of the faulted plate of FIG. 8.

[0025] FIG. 10 is a side plan view showing expansion forces on a frame of the grid of FIG.5.

[0026] FIG. 11 is a side plan view of a prior positive battery grid capable of being used with the lead-acid battery shown in FIG. 1.

[0027] FIGS. 12-14 are side plan views of battery grid arrangements capable of being used with the lead-acid battery shown in FIG. 1.

[0028] FIG. 15 represents an expansion of a grid wire at a node.Docket No. 57501-3120

[0029] FIG. 16 represents an expansion of a grid-wire pattern having nonlinear grid wires.

[0030] FIG. 17 is a side plan view of a battery grid capable of being used in the lead-acid battery shown in FIG. 1.

[0031] FIG. 18 is a side plan view of a battery grid capable being used in the lead-acid battery shown in FIG. 1.

[0032] FIG. 19-22 are side plan views of battery grid arrangements capable of being used with a battery grid for the lead-acid battery shown in FIG. 1.

[0033] FIG. 23 is a side plan view of a battery grid capable being used in the lead-acid battery shown in FIG. 1.

[0034] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, the following description, the claims, and / or the drawings, and in particular the individual features thereof, may be taken independently or in combination. That is, all embodiments and all features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.DETAILED DESCRIPTION

[0035] A battery 100 is disclosed in FIG. 1. The shown battery is a lead-acid rechargeable storage battery. Various embodiments of lead-acid storage batteries may be either sealed (e.g., non-maintenance) or unsealed (e.g., wet). The shown lead acid storage battery is a sealed absorbent glass mat (AGM) lead-acid battery. While specific examples are described and illustrated, the battery may be any lead-acid battery suitable for the purposes provided.

[0036] Referring to FIGS. 1-4, the lead-acid battery includes several electrochemical cells 105 (may also be referred to as cell elements) that are provided in separate compartments of a container or housing 110 containing electrolyte. A cover 115 or lid is provided for the housing. In various embodiments, the cover includes battery terminals 120 (e.g., a positive terminal and aDocket No. 57501-3120 negative terminal). The cover can be sealed to the housing. The battery housing or cover may also include one or more filler hole caps 125 and / or vent assemblies 130.

[0037] The illustration provided herein for purposes of example include groups of electrode plates 135, 140 in each of six stacks or plate sets or blocks 145. One skilled in the art after reading this specification will realize that the size and number of plates in any particular stack (including the size and number of the individual grids), and the number of stacks used to construct the battery may vary depending upon the desired end use. Each electrochemical cell may include one or more positive plates and one or more negative plates, and preferably includes a plurality of positive plates and a plurality of negative plates.

[0038] Each plate is formed of a grid 150, 155 pasted with an active material 160, 165. It should be understood the disclosed grids of FIGs. 4-11 are example grids used to help explain the environment of a lead-acid battery. However, other grid arrangements are provided in FIGS. 12-23 and further described below.

[0039] As set forth in greater detail below, known techniques of lead-acid battery grid making include: batch processes such as book mold gravity casting; and continuous processes such as strip expansion, strip stamping, continuous casting, and continuous casting followed by rolling. Grids made from these processes have unique features characteristic of the particular process and behave differently in lead-acid batteries. It should be appreciated that grids formed from any conventional or later-developed grid manufacturing process may be utilized with the disclosure herein.

[0040] A battery grid 170 is shown in FIGS. 5 and 6. For the grid shown in FIGS. 5 and 6, the grid 170 is a stamped grid and is a positive grid provided for use in association with a positive plate. In the particular example provided, the positive battery grid is a flat plate or planar plate. The grid shown in FIGS. 5 and 6 is a prior art positive battery grid and is used to help identify particular elements of a grid.

[0041] The grid includes an exterior frame 175. The frame has a top frame element 180, first and second side frame elements 185 and 190, and a bottom frame element 195. A current collection lug 200 is integral with the top frame element. The lug may be offset from the centerDocket No. 57501-3120 of the top frame element, or alternatively may be centered or positioned closer to either the first or second side frame elements.

[0042] The battery grid also includes grid wires 205. The grid wires may be provided in a grid network formed by a plurality of grid wires arranged in a grid pattern 210. The grid network includes one or more grid wires joined to the top frame element, one or more grid wires joined to the first side frame element, one or more grid wires joined to the second side frame element, and one or more grid wires joined to the bottom frame element.

[0043] The plurality of grid wires defines a grid pattern (i.e., one or more patterns) including open areas 215 in the grid network and within the frame. The plurality of grid wires is interconnected within each of the frames to create interstices 217. The open areas help hold active material or paste 220. One or more of the grid wires may increase in cross-sectional area along their length. For example, the grid wires may have a tapered shape to optimize the current carrying capacity of the wires to help carry away increasing current being generated from the distance furthest from the lug to the distance closest to the lug on the grid.

[0044] Referring to FIG. 7, separator material 225 may be provided between each positive plate and negative plate. The separator may be an absorbent glass mat (AGM), and in one or more examples of embodiments may be wrapped around a portion of or interleaved with / between one (or both) of the positive and negative plates. Accordingly, the battery or electrochemical cells in FIG. 2 includes a plurality of positive plates each comprising a positive grid and a positive paste thereon, a plurality of negative plates each comprising a negative grid and a negative paste thereon, an absorbent glass mat interleaved between each positive plate and each negative plate, and an electrolyte retained by the absorbent glass mat and / or otherwise provided in the battery container.

[0045] The plurality of electrochemical cells may be electrically connected, e.g., electrically coupled in series or another configuration according to the capacity of the lead storage battery. One or more cast on straps (or intercell connectors) 230 (FIG. 2) are provided which electrically couple the lugs in a plate set and other respective plate sets in the battery. One or more positive and one or more negative terminals 235 and 240 (FIG. 1) may also be provided. Such terminals typically include portions which may extend through the cover and / or housing, depending uponDocket No. 57501-3120 the battery design. It will be recognized that a variety of terminal arrangements are possible, including top, side, or corner configurations known in the art.

[0046] Referring again to FIG. 5, the intersection or joining of a radially extending grid wire 250 and a grid cross 255 wire may occur at a node, generally. A plurality of such intersections or coupled grid wires and grid cross wires form a plurality of nodes. The combination of radially grid wires and / or nodes form the one or more open spaces or windows in the grid wire network carried by the frame. As a result, the plurality of grid wires may define a grid pattern or arrangement including open areas or windows in the grid network and within the frame. In other words, a plurality of grid wires may be interconnected within each of the frames to create interstices. The open areas may help hold the active material or paste, which may be held in the form of “pellets” as is known in the art.

[0047] Both the positive grid and the negative grid may be formed in the same or a similar grid pattern. It is contemplated, however, that the pattern may also vary between the positive grid and negative grid.

[0048] The thickness of each grid may vary based upon desired manufacturing and performance parameters. For instance, thickness may be determined based upon minimum manufacturing requirements or minimum requirements for paste adhesion, or other suitable parameters. It is understood by one of skill in the art that a variety of grid forming methods exist and it is contemplated that any one or more of such methods may be adapted to form a grid accomplishing the objectives provided herein. Likewise, the weight of the grid, and ultimately the weight of the resulting battery, may also be varied. For example, by reducing an amount of lead in the grid, the overall weight of the grid, and thus the battery including one or more such grids, is reduced. In one example of embodiments, the positive and negative grids may be formed of different thickness. However, it is contemplated that the grids may be of the same thickness.

[0049] The batteries herein may be used in vehicular contexts as well as other energy storage and expending applications (e.g., an energy storage for an electrical grid). That is, the batteries described herein may be used to provide power to various types of vehicles. However, it is envisioned that the battery modules may be used in other energy storage and expending applications. As an example, batteries in accordance with herein may be incorporated with orDocket No. 57501-3120 provide power to stationary power systems. Other example applications or environments include: starting, cycling, and powernet support applications; deep cycle primary power and motive power applications; and high rate and long duration reserve power applications. Example starting, cycling, and powernet support applications include: automotive; van and light duty commercial; heavy duty truck; bus and utility; agriculture; construction; marine; residential vehicle (RV); power sports including motorcycle, all-terrain vehicle (ATV), snowmobile, electric bicycle; genset; lawn and garden; rail; military, aerospace, and defense; etc. Example deep cycle primary power and motive power applications include: heavy duty load and lift gates; marine cycling; golf vehicles; motive such as forklift and guided vehicles; industrial such as scissor lift, scrubber, and pallet jack; wheelchairs; etc. Example high rate and long duration reserve power applications include: uninterruptable power source such as for a data center, critical power system, and emergency lighting; telecommunications such as wireline, wireless, broadband, and microwave; power generation and distribution, renewable energy; grid support including smart and distributed; safety, security, and traffic; etc. Such battery systems may include one or more batteries, each battery having a housing and a number of battery cells arranged within the housing, to provide particular voltages, currents, and / or power to the associated application.

[0050] As mentioned earlier, prior attempts to improve resistance to grid growth have been primarily focused on improving strength and rigidity. Improving strength and rigidity is a relatively obvious path to consider since the rigid side frames slow the growth seen under expanded metal technology. As such, a typical prior solution has been to further improve frame rigidity to further slow growth. However, growth forces transverse to the grid are not effectively controlled with this solution. Growth in the transverse direction to the grid tends to cause the frame to bend in the transverse direction or the plate to buckle out of the primary plane of the grid. This is shown in FIGs. 8 and 9. Any growth of the grid in the X-Y direction tends to grow the most away from constrained points / areas 265 of the grid (see FIG. 10). The growth stress transverse to the grid comes from the elongation of the grid wires (e.g., wires 270 and 275 (FIG. 11) within the grid frame. A different solution is desired.

[0051] Generally, the solution proposed comprises a grid (e.g., a grid wire arrangement) that absorbs grid wire growth stress before it is experienced by the grid frame. The solution discussedDocket No. 57501-3120 herein applies to all lead-acid battery technologies. Three examples are shown in FIGS. 12, 13, and 14. FIG. 12 shows a linear grid wire arrangement 280 configured to absorb grid wire growth stress before it is experienced by the grid frame. Grid wires of arrangement 280 segment one another. FIG. 13 uses a nonlinear (e.g., arcuate or curvilinear) grid wire arrangement 290 to absorb grid wire growth stress before it is experienced by the grid frame. FIG. 14 shows a combined segmented and non-linear grid wire arrangement 295 to absorb grid wire growth stress before it is experienced by the grid frame. A combined segmented and linear grid wire arrangement to absorb grid wire growth stress before it is experienced by the grid frame is also contemplated.

[0052] Referring to FIG. 15, a first grid wire 300 is connected to a second grid wire 305 at a node 310 (the node is exaggerated). The second grid wire is a segmented wire at the node. The segmented wire allows for the segmented wire to bend and absorb the growth in the plane of the grid.

[0053] Referring to FIG. 16, a first grid wire 315 is connected to a second grid wire 320 and a third grid wire 325 at a first node 330 and a second node 335, respectively. In addition to any movement at the nodes 330 and 335, the arcuate segments (e.g., segments 340, 345, and 350) allow for wires to bend and absorb the growth in the plane of the grid network. It should be noted that the bending and growth of wires is into open areas or windows of the grid network.

[0054] There are many options to develop grid wire layouts that rely upon segmented (or discontinuous) wires and / or non-linear wires to allow for strategic growth. One such example that uses both segmented and curved wires is shown in FIG. 14. The segmented wires and / or non-linear wires provide ability to absorb growth stress and will typically have an inverse impact on conductivity / weight ratio.

[0055] FIGS. 17 and 18 disclose two grids 355 and 360, each grid having a respective tessellated grid pattern 365 and 370. As will be clear below, the tessellated grid patterns 365 and 370 are two examples of many possible tessellated grid patterns. For the patterns 365 and 370, the substantially vertical grid lines, which may also be referred to as radial grid wires, are angled (e.g., at fifteen degrees) with respect to the Y-axis. This allows for more charge / current to flow in the direction of the lugs at the top of the grid frames. For grid pattern 365, horizontal gridDocket No. 57501-3120 wires (e.g., grid wire 375 and 380) are connected to substantially vertical grid wires (e.g., grid wire 385 and 390) at nodes (e.g. nodes 395 and 400) creating segmented wires similar to the segmented wires shown in FIG. 15. For grid pattern 370, horizontal grid wires (e.g., grid wire 405 and 410) are connected to substantially vertical grid wires (e.g., grid wire 415 and 420) at nodes (e.g. nodes 425 and 430) creating segmented wires similar to the segmented wires shown in FIG. 15. Similar to FIG. 15, the segmented wires allow for wires to bend and absorb the growth in the plane (i.e., the X-Y plane) of the grid.

[0056] With reference to FIG. 17, the nodes segment grid wires to create two sized windows (e.g., small window 435 and large window 440). Small windows 435 have no segmented grid wires, while each large window 440 is segmented at the midpoint of each side. Each window 435 and 440 can receive a paste pellet as discussed earlier. However, the amount of area for the smaller window (e.g., window 435) is approximately a quarter of the area for the larger windows (e.g., window 440).

[0057] With reference to FIG. 18, the nodes segment grid wires to create two sized windows (e.g., small window 445 and large window 450). Unlike FIG. 17, Both the small windows 445 and the large windows 450 are segmented on each side. For the example shown, each grid wire is segmented at a 1 / 3 versus 2 / 3 location. This also allows for pellets for the smaller windows to be more similar in size to the pellets for the larger windows as compared to FIG. 17.

[0058] FIGS. 19-22 disclose additional tessellated grid patterns 455-470, respectively. Grid pattern 455 has a tessellated pattern of one big window and one small window similar to the grid pattern of FIG. 18. This allows for the most amount of growth of the grid patterns 455-470. Grid pattern 460 has a tessellated pattern of two big windows and one small window. As compared to grid pattern 455, grid pattern 460 has more open window space, but has longer grid wires that can grow (e.g. wire 475 vs. wire 480) Grid pattern 460 uses less lead than grid pattern 455. Grid pattern 465 has a tessellated pattern of four big windows and one small window. As compared to grid pattern 460, grid pattern 465 has more open window space, but has longer grid wires that can grow (e.g. wire 485 vs. wire 490) Grid pattern 460 uses less lead than grid pattern 455. Grid pattern 470 has a tessellated pattern of two big windows stacked vertically (as compared to the horizontal stacking of grid pattern 460) and one small window. One skilled in the art afterDocket No. 57501-3120 reading this specification will realize that the size, location, number of spaces, shape of wire (e g., linear, non-linear), angles, etc. can be modified to effect balancing lead usage (and weight), current flow efficiency (and power output), manufacturability, and life expectancy (due to absorbing more growth).

[0059] FIG. 23 shows a grid pattern 495 having a primarily radial design but includes discrete offsets amongst the primarily radial design. The discrete offsets allow for some absorption of growth, while the primarily radial design allows for improved current and power output over the grid patterns 455-470 (for example).

[0060] Accordingly, this disclosure provides a new and useful battery grid for use with a lead-acid battery, a new and useful battery plate including the battery grid, a new and useful lead-acid battery having the battery plate, and a new and useful method of manufacturing the same.

[0061] It is important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a finite numbers embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited.

[0062] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.Docket No. 57501-3120

[0063] It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

[0064] For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

[0065] The terms fixedly, non-fixedly, and removably, and variations thereof, may be used herein. The term fix, and variations thereof, refer to making firm, stable, or stationary. It should be understood, though, that fixed does not necessarily mean permanent — rather, only that a significant or abnormal amount of work needs to be used to make unfixed. The term removably, and variations thereof, refer to readily changing the location, position, station. Removably is meant to be the antonym of fixedly herein. Alternatively, the term non-fixedly can be used to be the antonym of fixedly.

[0066] Elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the invention.Docket No. 57501-3120

[0067] While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and / or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and / or substantial equivalents.

[0068] The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

[0069] The terms “a” and “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and / or “having,” as used herein, are defined as comprising (i.e., open language). The phrase “at least one of . .. and . . . .” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. As an example, the phrase “at least one of A, B, and C” includes A only, B only, C only, or any combination thereof (e g., AB, AC, BC, or ABC).

[0070] It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

[0071] Preferences and options for a given aspect, feature or parameter of the disclosure should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features, and parameters of the disclosure.Docket No. 57501-3120

[0072] Aspects herein can be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope hereof.

Claims

Docket No. 57501-3120CLAIMSWhat is claimed is:

1. A battery grid for use in a lead-acid battery, the battery grid comprising: a first grid wire; a second grid wire coupling with the first grid wire at a node, the first grid wire and the second grid wire defining a plane; and a battery grid window formed by at least the first grid wire, the battery grid window to absorb growth stress of the second grid wire in the plane.

2. The battery grid of claim 1, wherein the first grid wire and the second grid wire form a linear grid wire arrangement.

3. The battery grid of claim 1 or 2, wherein the first grid wire and the second grid wire form a nonlinear grid arrangement.

4. The battery grid of one of claims 1 to 3, wherein the first grid wire and the second grid wire form a combined segmented and nonlinear grid wire arrangement.

5. The battery grid of one of claims 1 to 4, wherein the first grid wire and the second grid wire form at least a portion of a tessellated grid pattern.

6. The battery grid of claim 5, wherein the battery grid window is a first grid window of the tessellated grid pattern, and the tessellated grid pattern includes a second grid window.

7. The battery grid of claim 6, wherein the first grid window is larger than the second grid window.

8. The battery grid of claim 6, wherein the first grid window is the same size as the second grid window.Docket No. 57501-31209. The battery grid of one of claims 5 to 8, wherein the battery grid has a vertical axis, and the first grid wire comprises a substantially vertical grid wire.

10. The battery grid of one of claims 5 to 9, further comprising a third grid wire and a fourth grid wire which form at least a portion of a second tessellated grid pattern, and wherein the second tessellated grid pattern intersects the tessellated grid pattern at an offset.

11. The battery grid of one of claims 1 to 10, wherein the second grid wire segments the first grid wire at the node, and wherein the growth stress of the second grid wire moves the node toward the battery grid window.

12. The battery grid of one of claims 1 to 11, wherein the second grid wire includes a nonlinear grid wire portion, and wherein the growth stress of the second grid wire moves the nonlinear grid wire portion toward the battery grid window.

13. The battery grid of one of claims 1 to 12, wherein the second grid wire includes a nonlinear grid wire portion which segments the first grid wire at the node, and wherein the growth stress of the second grid wire moves the node and the nonlinear grid wire portion toward the battery grid window.

14. A battery plate comprising the battery grid of any of claims 1-13 and a paste supported by the battery grid.

15. A lead-acid battery comprising the battery plate of claim 14.

16. A battery grid for use in a lead-acid battery, the battery grid comprising: a first grid wire; a second grid wire segmenting the first grid wire at a node, the first grid wire and the second grid wire defining a plane; and the first grid wire configured to bend at the node to absorb growth stress of the second grid wire in the plane.Docket No. 57501-312017. The battery grid of claim 16, wherein the first grid wire and the second grid wire form at least a portion of a battery grid window, and wherein the growth stress of the second grid wire is absorbed by the battery grid window in the plane.

18. The battery grid of claim 16, wherein the first grid wire and the second grid wire form at least a portion of a tessellated grid pattern.

19. A battery plate comprising the battery grid of any of claims 16-18 and a paste supported by the battery grid.

20. A lead-acid battery comprising the battery plate of claim 19.

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