Battery Connecting Lug Block Assembly for Lower-Lead High-Current Cells
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Solution Overview
Problem
Lead-acid batteries face challenges in manufacturing due to the high cost and weight of traditional battery cell connectors made from lead, which are required for high current applications, necessitating a more cost-effective and lighter solution.
Innovation Solution
The solution involves forming a connecting lug block by welding or soldering adjacent connecting lugs of the same polarity into a solid block, eliminating the need for external connectors and reducing lead usage, while using spacer shims or thickening the connecting lugs to fill gaps and ensure a strong, lightweight structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional battery cell connector is used to connect connecting lugs, then the battery can handle high currents, but the battery becomes heavier and more expensive due to substantial lead usage
Solution Approach 1:
The patent merges the battery cell connector with the connecting lugs by welding or soldering them directly together to form an integrated connecting lug block. This eliminates the separate connector component and reduces lead usage while maintaining current-carrying capacity through direct material bonding of the lugs themselves
Solution Approach 2:
The patent extracts and eliminates the traditional battery cell connector from the system by directly welding or soldering the connecting lugs together. The connector function is taken out and replaced by the material bonding process, reducing overall lead consumption and battery weight
2Power
If a traditional battery cell connector is used to connect connecting lugs, then the battery can handle high currents, but the manufacturing cost increases due to expensive lead material
Solution Approach 1:
The patent combines the connecting lugs directly through welding or soldering to form an integrated block, eliminating the need for a separate battery cell connector. This reduces material costs while maintaining the current-carrying capacity through direct material bonding
Solution Approach 2:
The patent removes the expensive traditional battery cell connector from the design and replaces it with a more cost-effective direct welding or soldering process between connecting lugs, reducing overall manufacturing cost while preserving electrical performance
3Weight of moving object
If connecting lugs are welded or soldered together to form a connecting lug block, then lead usage is reduced and weight decreases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces the mechanical assembly process of attaching a separate battery cell connector with a thermal joining process (welding or soldering) that directly bonds the connecting lugs together. This substitution simplifies the overall manufacturing process by eliminating multiple assembly steps while achieving the same structural and electrical connection
4Ease of manufacture
If connecting lugs are welded or soldered together to form a connecting lug block, then manufacturing cost is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces costlier mechanical assembly operations with a more efficient welding or soldering process that directly joins connecting lugs. Although welding/soldering equipment is required, the overall process becomes more cost-effective by eliminating the need for separate connector components and reducing assembly steps, thereby lowering total manufacturing cost despite the thermal joining complexity
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 method reduces manufacturing costs and weight, enhances the accumulator's current-carrying capacity, and makes the production process more efficient and reliable, resulting in a sturdier and vibration-resistant battery with minimized lead usage.
Implementation Method 1
the connecting lugs arranged adjacent each another in a row are materially bonded together electrically and mechanically into a connecting lug block by at least one weld or solder point arranged between the connecting lugs
Implementation Method 2
the connecting lugs arranged adjacent each another in a row are materially bonded together electrically and mechanically into a connecting lug block by at least one weld or solder point arranged between the connecting lugs
Data Source
AI summary
An accumulator having a plurality of electrode plates which are adjacently arranged and form at least one electrode plate stack in the form of a block, wherein each electrode plate comprises a frame having a grid arranged therein and wherein at least the grid is filled with an active mass, and wherein each electrode plate comprises at least one connecting lug protruding beyond the frame, wherein the connecting lugs of same-polarity electrode plates are arranged adjacent to one another in a row, wherein the connecting lugs adjacently arranged in a row are materially bonded together electrically and mechanically into a connecting lug block by at least one weld or solder point arranged between the connecting lugs. Further described is a method for manufacturing an accumulator.