Battery Grid Coined Edges Prevent Separator Stress
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Solution Overview
Problem
Lead-acid battery grids with surface imperfections, such as burrs and cupping effects, lead to separator failure and short circuits due to excessive pressure and corrosion, resulting in battery failure over time.
Innovation Solution
A battery grid with coined edges and corners is developed, reducing surface imperfections and stress on separators by deforming the frame elements to prevent cupping and corrosion, thereby enhancing stability and reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stamping methods are used to manufacture battery grids, then production efficiency is maintained, but surface imperfections such as burrs and cupping effects occur leading to separator failure and short circuits
Solution Approach 1:
The coining process is performed in advance during grid manufacturing to pre-deform the frame elements and eliminate surface imperfections such as burrs and cupping effects before the grids are assembled into batteries. This preliminary action prevents separator failure and short circuits that would otherwise occur during battery operation.
Solution Approach 2:
The coining process changes the physical parameters of the frame elements by applying controlled deformation to modify the surface geometry. This deformation eliminates sharp edges and cupping effects, transforming the surface quality from defective to smooth and uniform, thereby preventing separator damage.
2Reliability
If grid material is deformed to prevent cupping, then separator stress is reduced, but additional manufacturing steps are required
Solution Approach 1:
The coining process is merged with the existing grid manufacturing workflow by integrating it as a standard step in the production line. This combines the defect prevention function with the existing manufacturing capabilities, reducing separator stress and improving battery longevity without requiring entirely new manufacturing systems.
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 coined edges and corners minimize the incidence of battery failure by reducing stress on separators and preventing short circuits, improving the longevity and reliability of lead-acid batteries.
Implementation Method 1
coining at least one frame element on the battery grids from the strip of interconnected battery grids to form deformed edges on the cross-section of the frame element
Data Source
AI summary
A grid for a battery is disclosed. The battery grid includes an electrically conductive grid body having opposed top and bottom frame elements. At least one of the frame elements has a cross section with coined edges. The battery grid also includes a plurality of interconnecting electrically conductive grid elements spanning between the opposed top and bottom frame elements defining a grid pattern. Methods of forming a battery grid are also disclosed.