Accumulator Wall Elements Prevent Sludge Circulation
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Solution Overview
Problem
Existing rechargeable lead-acid batteries face issues with acid stratification during operation, leading to reduced storage capacity and increased risk of short-circuiting due to sludge and particles being circulated from the lower area to the upper area by hydrostatic pumps.
Innovation Solution
The battery design incorporates wall elements that extend upward to prevent electrolyte overflow and uses communicating tubes to ensure electrolyte movement only between volume areas, preventing sludge circulation while maintaining sufficient mixing to counteract acid stratification, with pressure equalization connections to maintain equal air pressure across areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a hydrostatic pump is used to mix electrolyte during battery movement, then acid stratification is counteracted, but sludge and particles are circulated from the lower area to the upper area increasing short-circuit risk
Solution Approach 1:
The cell area is divided into multiple volume areas by wall elements, creating separate compartments. The electrolyte circulation is segmented to flow through specific paths (communicating connections) rather than free circulation, allowing mixing while containing sludge in the lower areas.
Solution Approach 2:
Communicating connections act as intermediaries between volume areas, controlling the electrolyte flow path. These controlled passages allow electrolyte mixing while preventing direct circulation that would lift sludge to the upper areas where separators are located.
2Stability of the object's composition
If wall elements are used to create volume areas for electrolyte circulation, then acid stratification is prevented, but device complexity increases
Solution Approach 1:
The wall elements serve multiple functions: they subdivide the cell area into volume areas, create communicating connections for controlled electrolyte flow, and provide structural support. The communicating connections simultaneously act as flow channels and pressure equalization paths.
Solution Approach 2:
The wall elements and communicating connections are integrated into a single structural component system. The same wall elements that create volume separation also provide the communicating connections, merging the separation function and circulation function into one element.
3Stability of the object's composition
If the battery housing is tilted or moved during operation, then electrolyte mixing occurs to prevent stratification, but electrolyte may overflow from one volume area to another
Solution Approach 1:
The wall elements extend sufficiently high above the electrolyte level to create a safety margin that prevents overflow during normal battery tilting and movement. This pre-designed height buffer accommodates expected movement without allowing electrolyte to escape.
Solution Approach 2:
Pressure equalizing connections are provided in the upper area of volume areas to maintain equal air pressure. This hydraulic balance prevents pressure-driven electrolyte overflow when the battery is tilted, allowing controlled movement while preventing uncontrolled flow.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively prevents sludge and particle circulation, overcoming acid stratification and maintaining battery performance without electrolyte overflow, ensuring reliable operation even when the battery is tilted or moved, thus enhancing storage capacity and reducing the risk of short-circuiting.
Implementation Method 1
When the rechargeable battery moves, electrolyte sloshes over the upper edge of the walls into the volume area bounded by a wall, as a result of which the electrolyte level in this volume area is higher than in the adjacent volume area. During movement, electrolyte additionally flows through an opening in the lower area into the volume area bounded by the wall elements.
Implementation Method 2
there is a pressure equalizing connection in the upper area of the volume areas between the volume areas in order to ensure that the air pressure is the same in the volume areas which communicate with one another
Data Source
AI summary
An accumulator with an accumulator housing, having at least one cell changer, with several electrodes and liquid electrolyte in each cell chamber with at least one wall element in the cell chambers to divide the cell chambers into at least two intercommunicating volume chambers. In the lower region of the volume chambers is a communicating connection for the liquid electrolyte between the volume chambers and a pressure equalization connection between the volume chambers is arranged in the upper region of the volume chambers to assure an equivalent air pressure in the intercommunicating volume chambers. The wall elements extend at least far upwards such that on movement of the accumulator firstly electrolyte in at least one volume chamber flows through the intercommunicating connection in the lower region and secondly electrolyte again flows through the intercommunicating connection in the lower region out of said at least one volume region without an overflow of liquid electrolyte from one volume chamber to the adjacent volume chamber over the upper edge of the wall elements.