AGM Battery Plate Assembly With Stamped Grids for Lead Utilization
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Solution Overview
Problem
Existing lead-acid batteries with absorbed glass mat (AGM) technology are costly and inefficient due to the use of expanded metal grids, which result in low lead utilization and increased manufacturing costs, and require additional tooling for production.
Innovation Solution
A battery plate assembly using stamped electrically conductive grids with a grid pattern and highly absorbent separators, where the electrolyte is absorbed by the separators or active material, optimizing lead usage and reducing manufacturing costs by eliminating the need for concast or book mold cast grids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expanded metal grids are used in AGM batteries, then the battery can retain electrolyte effectively, but the lead utilization efficiency decreases and manufacturing costs increase
Solution Approach 1:
The patent changes the grid structure from expanded metal to stamped grid with modified parameters including grid wire diameter, spacing, and pattern configuration. This allows optimization of lead usage while maintaining electrolyte retention through the AGM separator, resolving the contradiction between reliability and productivity
Solution Approach 2:
The patent replaces expensive expanded metal grids with cheaper stamped grid structures that can be manufactured more efficiently. The stamped grids achieve the necessary mechanical and electrical functions at lower cost and with better lead utilization, effectively substituting a premium component with a more economical alternative
2Stability of the object's composition
If expanded metal grids are used in AGM batteries, then the battery structure is stable, but the manufacturing complexity and tooling requirements increase
Solution Approach 1:
The patent replaces the complex expanded metal grid manufacturing process with a simpler stamped grid process. The stamped grids are formed using standard stamping equipment rather than specialized expanded metal tooling, reducing manufacturing complexity while maintaining structural stability through optimized grid design
Solution Approach 2:
The stamped grid design serves multiple functions including electrical conduction, mechanical support, and electrolyte distribution without requiring separate components. This multi-functionality reduces the number of manufacturing steps and tooling requirements compared to expanded metal grids which require additional assembly operations
3Productivity
If AGM technology with absorbed electrolyte is used, then the battery operates efficiently on oxygen cycle, but the manufacturing cost increases
Solution Approach 1:
The patent modifies the AGM separator parameters including thickness, density, and glass fiber composition to optimize oxygen recombination efficiency while controlling manufacturing cost. The parameter optimization allows achieving high oxygen cycle efficiency without the premium costs associated with traditional AGM construction
Solution Approach 2:
The patent applies different grid patterns and separator densities in different regions of the battery to optimize local oxygen recombination efficiency. This localized optimization achieves high overall efficiency while using materials and processes more economically than uniform AGM construction, reducing total manufacturing cost
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
The solution enhances lead-acid battery performance by improving lead utilization, reducing material costs, and simplifying manufacturing, while maintaining high specific power and discharge efficiency, with reduced internal resistance and electrolyte retention.
Implementation Method 1
These starved electrolyte batteries, or absorbed glass mat (AGM) batteries employ an absorptive separator mat preferably of micro-fine glass fibers having a large surface area per unit of volume and a large porosity, enabling retention of the bulk of the acid electrolyte (capacity determining) of the cell in the separator(s)
Data Source
AI summary
A battery plate assembly for a lead-acid battery is disclosed. The assembly includes a plates of opposing polarity each formed by an electrically conductive grid body having opposed top and bottom frame elements and opposed first and second side frame elements, the top frame element having a lug and an opposing enlarged conductive section extending toward the bottom frame element; a plurality of interconnecting electrically conductive grid elements defining a grid pattern defining a plurality of open areas, the grid elements including a plurality of radially extending vertical grid wire elements connected to the top frame element, and a plurality of horizontally extending grid wire elements, the grid body having an active material provided thereon. A highly absorbent separator is wrapped around at least a portion of the plate of a first polarity and extends to opposing plate faces. An electrolyte is provided, wherein substantially all of the electrolyte is absorbed by the separator or active material. A method for assembling a battery is also disclosed.