Lead Acid Battery Electrode Casting and Expanded Metal Process
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Solution Overview
Problem
Existing methods for manufacturing lead-acid battery electrodes are complex and costly, particularly due to the need for extrusion presses and subsequent punching processes, which result in material waste and inefficiencies.
Innovation Solution
A method combining a casting process to produce a profiled strip blank with thicker frame elements and a subsequent expanded metal process to create a meshed region, eliminating the need for extrusion and punching, thereby reducing costs and increasing mechanical robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an extrusion press machine is used to continuously manufacture lead alloy strip, then the electrode can be produced continuously, but the manufacturing process becomes complex and requires additional equipment
Solution Approach 1:
The patent extracts and eliminates the extrusion press step from the manufacturing process. Instead of using an extrusion press to create the lead alloy strip with frame elements, the invention directly casts the strip in a single continuous operation, removing the complex extrusion equipment while maintaining continuous production capability
Solution Approach 2:
The casting process is designed to perform multiple functions simultaneously: it creates the lead alloy strip, forms the frame elements with appropriate thickness, and produces the meshed region structure all in one operation, replacing what previously required separate extrusion and forming steps
2Shape
If a punching process is used to create openings in the electrode, then the meshed region can be formed, but material waste is generated requiring collection and recycling
Solution Approach 1:
The patent applies preliminary action by forming the meshed region structure directly during the casting process before any punching operation. The strip is cast with the desired meshed pattern already integrated, eliminating the need for subsequent punching operations that would generate waste material
Solution Approach 2:
The invention changes the manufacturing parameter approach from mechanical removal (punching) to direct formation (casting). By controlling the casting parameters, the meshed region is created with appropriate geometry and opening patterns without material removal, thus preventing waste generation at the source
3Strength
If the frame element is made thicker to increase mechanical robustness, then the electrode becomes more robust, but more material is consumed increasing manufacturing cost
Solution Approach 1:
The patent applies local quality by making the frame elements thicker only in the specific regions where mechanical support is needed, while keeping the meshed region thinner. The casting process creates variable thickness within the single strip structure, providing enhanced strength where required without unnecessarily increasing material consumption across the entire electrode
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 approach allows for the economical production of robust lead-acid battery electrodes with reduced material waste, lower manufacturing costs, and increased efficiency, even with higher raw material costs, by integrating frame elements and contact tabs without an extruder, enabling high-speed and high-quantity production.
Implementation Method 1
a) producing a profiled strip blank in a casting process, wherein only by means of the casting process is the strip blank formed to be thicker on one side in at least one of the regions which will ultimately form the upper or lower frame element than in the regions which are to ultimately form the meshed region
Implementation Method 2
b) producing the meshed region having the openings in a subsequent expanded metal process
Data Source
AI summary
A system for producing electrodes for lead-acid batteries is disclosed. An electrode that has been produced comprises at least one upper and/or one lower frame element as well as a lattice-shaped region that extends away from said upper or lower frame element and has a plurality of openings, the upper and/or lower frame element being of a greater thickness than the lattice-shaped region. Said system comprises the steps of: a) producing a profiled strip-shaped blank using a casting method in which the strip-shaped blank is formed, solely by means of said casting method, to have a greater thickness on one side in at least one of the regions which should eventually form the upper or lower frame element, than the thickness in regions which should eventually form the lattice-shaped region, and b) producing said lattice-shaped region with the openings in a subsequent expanded metal process.