Battery Strap Structure With Bridging Lines for Low Resistance
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Solution Overview
Problem
Current lead acid batteries have low specific energy and short cycle life, limiting their use in electric vehicles, hybrid electric vehicles, and plug-in hybrid electric vehicles due to high costs and recycling challenges, while alternative batteries like lithium-ion and nickel-metal hydride face similar issues.
Innovation Solution
A unique strap structure for lead acid batteries comprising a housing with cells and strap structures made from lead or lead alloys, featuring parallel strap lines and bridging lines that connect electrode plates without welding, reducing internal resistance and improving corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lead acid battery strap structures are used, then manufacturing simplicity is maintained, but internal resistance is high and corrosion resistance is poor
Solution Approach 1:
The strap structure is divided into multiple parallel strap lines (positive and negative) with multiple bridging lines connecting them, creating a segmented network that distributes current and corrosion exposure across multiple pathways, thereby reducing internal resistance and improving corrosion resistance
Solution Approach 2:
Multiple bridging lines are nested between the parallel strap lines, creating a layered configuration where bridging lines connect the positive and negative strap lines at different positions, forming a compact multi-dimensional connection structure
2Strength
If welding is used to connect strap structures, then connection strength is achieved, but welding defects occur and increase complexity
Solution Approach 1:
The welding process is replaced with a mechanical connection system where strap lines and bridging lines are physically connected through formed connections or mechanical fastening, eliminating welding defects while maintaining connection strength
Solution Approach 2:
Multiple strap lines and bridging lines are merged into a single integrated strap structure assembly that functions as a unified current collector system, simplifying the overall connection architecture while maintaining strength
3Reliability
If more lead is used in strap structures, then connection reliability is improved, but battery weight and cost increase
Solution Approach 1:
The strap structure design changes the geometric parameters (number of parallel lines, bridging positions, line thickness) to optimize the balance between lead usage and connection reliability, achieving sufficient reliability with reduced material quantity
Solution Approach 2:
The strap structure may incorporate composite material configurations or alternative alloys in the lead-based material to reduce density while maintaining mechanical and electrical properties
4Reliability
If parallel strap lines with bridging lines are implemented, then internal resistance is reduced, but manufacturing complexity increases
Solution Approach 1:
The parallel strap lines and bridging lines are pre-formed and pre-assembled into a complete strap structure assembly before installation into the battery, simplifying the final manufacturing step while achieving the low internal resistance design
Data Source
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AI summary
A battery includes a housing, a plurality of cells disposed inside the housing, and a set of strap structures. Each cell comprises a plurality of positive electrode plates and a plurality of negative electrode plates, and each respective electrode plate has a respective tip. The set of strap structures includes one or more of a first strap structure, which includes a positive strap line, a negative strap line, and at least two bridging lines disposed between and connected with the positive strap line and the negative strap line. The negative strap line is connected with respective tips of a plurality of negative electrode plates in a cell. The positive strap line is connected with respective tips of a plurality of positive electrode plates in a different cell. The first strap structure, the set of strap structure, and a method of making the battery are also provided.