Horizontal VRLA AGM Battery Layout to Reduce Electrolyte Stratification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lead acid batteries with vertical electrode orientation suffer from electrolyte stratification and non-uniform utilization of plate surface area due to gravity, leading to battery degradation and loss of performance, especially in high discharge cycles.
Innovation Solution
A horizontal plate arrangement within the battery monobloc, combined with compression baskets and inter-plate connections, maintains homogeneous electrolyte density and reduces mechanical deformations, enhancing cyclic life and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vertical electrode orientation is used, then ease of manufacture is improved, but electrolyte stratification occurs leading to non-uniform utilization of plate surface area
Solution Approach 1:
The patent inverts the conventional vertical orientation of electrodes to a horizontal orientation. This inversion eliminates the harmful effect of gravity-induced electrolyte stratification, ensuring uniform electrolyte distribution across the plate surface area while maintaining manufacturability through standardized horizontal stacking processes.
2Reliability
If horizontal plate arrangement is used, then electrolyte stratification is reduced, but device complexity increases
Solution Approach 1:
The patent divides the battery into multiple horizontal compartments or layers, each containing stacked plate groups. This segmentation allows independent optimization of each layer's electrolyte distribution while simplifying the overall structure through modular design, thereby reducing the complexity burden of the horizontal arrangement.
Solution Approach 2:
The patent implements local compression mechanisms tailored to specific regions of the horizontal plate arrangement. By applying compression locally rather than uniformly, the system maintains electrolyte homogeneity in critical areas while simplifying the overall structural design and reducing manufacturing complexity.
3Stability of the object's composition
If compression system is applied, then mechanical deformations are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the compression function with the existing battery structure by integrating compression elements into the plate group assembly process. This combination eliminates the need for separate complex compression systems, as the compression is achieved through the natural stacking and bonding of horizontally arranged plates during manufacturing.
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 horizontal plate orientation and compression system improve battery performance and durability by minimizing electrolyte stratification and mechanical stress, extending the battery's life and reducing production costs.
Implementation Method 1
Conventional lead acid batteries with vertical electrode orientation suffer from electrolyte stratification and non-uniform utilization of plate surface area due to gravity
Implementation Method 2
A horizontal plate arrangement within the battery monobloc, combined with compression baskets and inter-plate connections, maintains homogeneous electrolyte density and reduces mechanical deformations
Implementation Method 3
During charge and discharge cycles, however, the active masses are subject to high volume changes due to chemical transformations of the reagents
Data Source
AI summary
A 12 V lead acid battery (100) with VRLA AGM technology. according to the 6×1 configuration and with front terminal connections, provides a monobloc consisting of—a container (10), with support base and retaining sides, of the known type—plate groups (12)—compression baskets (14) of the plate groups (12)—inter-plate connections or CoS (16)—relief valves (18)—inter-cell connections (20)—a lid (22) closing the container (10), also of the known type; said monobloc have an internal layout configured to house the plate groups (12) in a horizontal position, parallel to the lid (22).