Integrated Acid Pump Structure for Lead-Acid Battery
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Solution Overview
Problem
Existing lead-acid batteries suffer from acid stratification, which leads to increased corrosion of electrode plates and reduced cycle life, and require manual insertion of acid pumps that can interfere with manufacturing processes and seal integrity.
Innovation Solution
The design incorporates an acid pump structure with a base having ridges and trenches, and straps or bands to secure battery elements and the acid pump together, allowing for easy installation and integration with the battery housing without damaging other components, and preventing acid stratification by promoting uniform electrolyte distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual insertion of acid pumps is used, then acid destratification is improved, but manufacturing complexity and seal integrity are worsened
Solution Approach 1:
The acid pump is integrated with the battery housing to form a unified structure. The housing serves dual purposes as both containment and acid pump mechanism, eliminating the need for separate manual installation of acid pumps while maintaining acid destratification functionality.
Solution Approach 2:
The battery housing is designed to perform multiple functions: it serves as the structural container for battery elements and simultaneously functions as an acid pump mechanism. This multi-functionality reduces manufacturing steps and eliminates the need for separate acid pump components.
2Reliability
If acid pumps are manually inserted, then acid stratification is reduced, but manufacturing time and production speed are worsened
Solution Approach 1:
The acid pump structure is pre-integrated into the battery housing during the molding process. This preliminary integration ensures that acid stratification reduction is built-in from the start, eliminating the need for subsequent manual installation steps and enabling high-speed production.
Solution Approach 2:
The battery housing automatically performs the acid pump function through its integrated design. The housing structure itself provides the acid circulation mechanism without requiring external intervention or manual assembly, enabling seamless high-speed manufacturing.
3Reliability
If separate acid pump components are used, then acid circulation is improved, but manufacturing cost and material usage are worsened
Solution Approach 1:
The acid pump functionality is merged with the battery housing structure. This consolidation reduces the total number of components, decreases material usage, and lowers manufacturing costs while maintaining effective acid circulation through the integrated housing design.
4Reliability
If acid pumps are installed separately, then acid destratification is achieved, but heat seal operation and seal integrity are worsened
Solution Approach 1:
The acid pump structure is merged with the battery housing to form a single integrated component. This integration eliminates separate sealing interfaces between the housing and acid pump, thereby maintaining seal integrity and allowing heat seal operations to proceed without interference.
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 solution reduces acid stratification, lowers manufacturing costs, and enables high-speed production using conventional equipment, ensuring the acid pump does not interfere with the seal or heat operation, thereby extending battery life and simplifying the manufacturing process.
Implementation Method 1
an acid pump structure comprising a base with a bottom surface comprising one or more ridges and/or trenches and at least one acid pump attached to the bottom surface
Implementation Method 2
the one or more straps bind the one or more battery elements and the acid pump structure together
Data Source
Figure 1~2
Figure 3~5
Figure 6~8C
AI summary
The present disclosure relates to lead-acid batteries and the manufacture of lead-acid batteries containing acid pump devices to promote the circulation of electrolyte within the battery and/or battery cells to reduce acid stratification and improve battery performance. In various embodiments, battery cell components are assembled within an acid pump assembly that encloses the battery cell components on at least the bottom and ends. In various embodiments, at least a portion of the acid pumps may be integrally molded with or secured to various parts of the battery housing including the cover, side walls, and cell walls. In various embodiments, space for the acid pumps is created by varying the shape of the battery housing (e.g., the side walls or cell walls) and/or by modifying the shape, size, and or position of one or more of the battery electrodes or separators.