Inclined Intermixing Plates for Battery Electrode Alignment
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Solution Overview
Problem
Conventional lead-acid battery manufacturing processes face challenges in accurately positioning electrode plates without damaging the sensitive electrode bags, leading to inefficiencies in electrolyte intermixing and increased battery weight due to large terminal sizes required for alignment.
Innovation Solution
A method involving the use of inclined intermixing plates and a bridging plate to auto-center and align electrode plates during assembly, preventing damage and allowing for smaller terminal sizes, with the intermixing plates inserted before the electrodes to ensure precise positioning and efficient intermixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual insertion of electrodes is used to position them precisely, then alignment accuracy is improved, but the risk of damaging electrode bags increases and manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by inserting the intermixing plates into the battery case before inserting the electrode plates. The intermixing plates are positioned first to create guiding structures, and then the electrode plates are inserted and automatically centered by these pre-positioned intermixing plates. This sequence prevents damage to the electrode bags while achieving precise alignment.
Solution Approach 2:
The patent uses intermixing plates as intermediary elements that facilitate the precise positioning of electrode plates without direct manual handling. The intermixing plates act as mediators that the electrode plates interact with during insertion, enabling automatic centering and alignment while protecting the fragile electrode bags from damage.
2Reliability
If larger terminal sizes are used to ensure alignment, then positioning reliability is improved, but battery weight increases
Solution Approach 1:
The intermixing plates serve as intermediary positioning elements that enable reliable electrode alignment without requiring oversized terminals. By providing a mechanical guiding structure through the intermixing plates, the system achieves accurate positioning using smaller, lighter terminals, thereby reducing overall battery weight while maintaining positioning reliability.
3Productivity
If complex circulation devices with pressure-gas sources are used to intermix electrolyte, then intermixing efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the complex pressure-gas circulation devices from the battery system. Instead, it uses simple passive intermixing plates with channel structures that enable electrolyte intermixing through natural convection and vehicle movement, achieving effective electrolyte circulation without complex active components.
Solution Approach 2:
The intermixing plates are designed to enable self-service electrolyte intermixing through the battery's normal operation. The channel structures in the intermixing plates allow electrolyte to flow and mix automatically during vehicle acceleration, deceleration, and normal operation, eliminating the need for external power sources or complex control 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
This method prevents electrode bag damage, ensures precise electrode alignment, reduces terminal size and weight, and maintains high intermixing efficiency, resulting in lighter and more reliable batteries with reduced manufacturing costs.
Implementation Method 1
When a vehicle is moved at an even speed, i.e., when it is whether accelerated nor decelerated, the surface of liquid electrolyte in the battery is smooth and leveled. When a car is accelerated or decelerated, the electrolyte is pushed back and forth, due to its mass moment of inertia.
Implementation Method 2
When a car is accelerated or decelerated, the electrolyte is pushed back and forth, due to its mass moment of inertia.
Data Source
AI summary
The invention relates to a method for making an electrolytic battery which is preferably used in movable facilities such as cars, boats and planes. The method comprises the following steps: inserting of intermixing plates 5a′ into the battery case 1, one each at two sides thereof which are opposite to each other, inserting of the set of electrodes 2 between the two intermixing plates 5a′ positioned in the battery case 1 and connecting of the two intermixing plates 5a′ straightened out vertically with the bridging plate 5b′ comprising a drain surface, which is slightly inclined towards the center thereof, and an opening provided approximately in the center thereof to enable electrolyte to flow back into the batter case.