Fibre Electrode Lug Connection via Pressure Injection Pulses
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Solution Overview
Problem
Existing methods for forming connections between conductive fibre electrodes and external circuits in batteries, such as lead-acid batteries, face challenges in achieving low electrical resistance and mechanical durability, particularly in high-volume manufacturing scenarios.
Innovation Solution
A method involving pressure injection pulses to impregnate a lug material into a fibre material, forming a continuous lug strip along the fibre material, which surrounds and penetrates the fibres to create a strong and durable electrical connection, allowing for efficient manufacturing of multiple electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure impregnation is used to form lug connections on fibre electrodes, then mechanical strength and electrical connection quality improve, but manufacturing speed and productivity deteriorate due to the sequential nature of the process
Solution Approach 1:
The pressure impregnation process is divided into multiple sequential pulses rather than a single continuous operation. Each pulse creates a discrete impregnation event that penetrates the fibre material, and multiple pulses work together to form the complete lug connection. This segmentation allows the process to maintain mechanical strength while enabling faster cycle times between productions.
Solution Approach 2:
The patent employs periodic pressure injection pulses to impregnate the lug material into the fibre electrode. Instead of continuous pressure application, the process uses repeated cycles of pressure application and release, allowing the material to penetrate and set in controlled intervals. This periodic action maintains connection quality while improving manufacturing throughput.
2Reliability
If lug material is pressure impregnated into fibre material to form connections, then electrical resistance decreases and connection quality improves, but process complexity and device complexity increase
Solution Approach 1:
The pressure impregnation process utilizes the natural capillary action and pressure differential to draw lug material into the fibre electrode structure. The system self-regulates the impregnation depth and distribution through the applied pressure cycles, reducing the need for complex control mechanisms while ensuring consistent electrical connection quality.
Solution Approach 2:
The patent controls the impregnation process by varying key parameters such as pressure magnitude, pulse duration, and number of pulses. By adjusting these parameters, the process achieves reliable electrical connections without requiring complex equipment, as the same basic pressure injection mechanism can be tuned for different fibre types and lug material properties.
3Productivity
If continuous pressure injection is used to form lug strips on moving fibre material, then manufacturing efficiency improves, but control precision and manufacturing precision deteriorate
Solution Approach 1:
The continuous pressure injection process is segmented into discrete pulses synchronized with the movement of the fibre material through the injection stage. Each pulse corresponds to a specific position in the fibre travel path, allowing precise control over where lug material is deposited while maintaining continuous production flow. This segmentation enables both high efficiency and precise lug strip formation.
Solution Approach 2:
The pressure injection system is designed to dynamically adjust its operation based on the real-time position and speed of the moving fibre material. The pulse timing, duration, and intensity are modulated to match the fibre's movement, ensuring precise lug strip formation even at high manufacturing speeds. This dynamic control maintains precision without sacrificing productivity.
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 method enhances the mechanical strength of fibre materials and facilitates high-volume production by creating a continuous lug strip that strengthens the fibre material during manufacturing and handling, while ensuring a low electrical resistance connection, thus improving the durability and efficiency of electrode connections.
Implementation Method 1
pressure impregnating by a series of pressure injection pulses a lug material into a lug zone part of the fibre material to surround and/or penetrate fibres
Data Source
AI summary
A method for forming a connection such as an electrical connection, to a fibre material electrode element comprises moving a length of the fibre material relative to a pressure injection stage and pressure impregnating by a series of pressure injection pulses a lug material into a lug zone part of the fibre material to surround and/or penetrate fibres of the fibre material and form a lug strip in the lug zone. The fibre material may be a carbon fibre material and the lug material a metal such as Pb or a Pb alloy. Apparatus for forming an electrical connection to a fibre material electrode element is also disclosed.