Battery Electrode Plug Retention via Deformable Projections
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Solution Overview
Problem
Existing lead-acid battery tubular electrodes face challenges in securely retaining the plug member within the sleeve, often requiring specialist equipment or an inconvenient long conductive spine, which is inefficient and uses excess lead.
Innovation Solution
The electrode design incorporates a plug with deformable projections that engage with the sleeve, forming a seal to prevent egress of active material, and a base for handling and secure packaging, utilizing multiple plug members with varied projection shapes to inhibit removal and reduce shrinkage during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug member is melted onto the sleeve by ultrasound or hot plates, then the plug is securely retained within the sleeve, but specialist welding tooling and equipment are required
Solution Approach 1:
The patent replaces the thermal/ultrasonic welding system with a mechanical interference fit system. The conical projection on the plug member engages with a corresponding conical recess in the sleeve, creating a secure mechanical retention that eliminates the need for specialized welding equipment while maintaining reliable plug retention.
2Reliability
If an aperture is provided in the top of the plug member for the receipt of the end of the conductive spine with an interference fit, then the plug is retained, but the spine must be long and uses more lead than desired
Solution Approach 1:
The patent transitions from vertical retention (long spine extending through the plug) to angular retention (conical projection engaging at an angle). The conical projection engages with the sleeve wall rather than requiring the spine to extend vertically through the entire plug, thereby reducing the required spine length and lead usage while maintaining secure retention.
3Reliability
If deformable projections are provided on adjacent plug members, then attempted withdrawal causes deformation and interference between projections to inhibit removal, but the structure becomes more complex
Solution Approach 1:
The patent utilizes a change in the physical state of the projection material under stress. The projections are made from a deformable material that undergoes plastic deformation when force is applied during withdrawal attempts. This parameter change (from elastic to plastic state) allows the projections to permanently deform and interfere with each other, providing irreversible retention without requiring complex structural features.
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 secures the plug within the sleeve, prevents active material egress, simplifies handling and packaging, and reduces material usage by eliminating the need for excessive lead, enhancing the efficiency and practicality of lead-acid battery production.
Implementation Method 1
the adjacent deformable projections being deformable so that attempted withdrawal of the plug members from the respective sleeves causes deformation of the adjacent deformable projections so that the adjacent deformable projections interfere with one another
Data Source
Figure 1~2d
Figure 2(a)~2(c)
Figure 3~5
AI summary
An electrode (10) for a battery, the electrode comprising: (a) an electrode portion comprising: (i) a sleeve (12a, b, c) and (ii) active material (13a, b, c) disposed within the region bounded by the sleeve; and (b) a plug comprising a plug member (1a, 1b; 101a, 101b; 201; 301a, 301b) disposed within the region bounded by the sleeve, the plug member being provided with one or more projections (4a', 4a'', 4a''', 4b', 4b'', 4b'''; 104a, 104b, 104c; 204a, 204b; 304a, 304b, 304c) which engage with the sleeve to inhibit removal of the plug from the sleeve, wherein the plug forms a seal with the sleeve so to inhibit egress of active material from the electrode portion. A plug suitable for use in such an electrode is also disclosed, as is a battery comprising such an electrode or plug.