Lead-Acid Battery Grid Punching for Paste Adhesion

Solution Overview

Problem

Existing methods for making battery plates for lead-acid batteries require additional equipment and operations to achieve improved paste adhesion, which is not efficiently addressed by the punch/deformation process for punched grids.

Innovation Solution

A method using a die set with male and female components to punch and reform openings in a lead strip, forming grids with non-rectangular cross-sectional wires, enhancing paste adhesion in a single punch operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a second operation is performed to deform the cross-section of the wire after the punch operation, then paste adhesion is improved, but device complexity and process complexity increase

Engineering Contradiction:

Improvepaste adhesionVSAvoidequipment and unit operations

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the punching operation and the wire cross-section deformation operation into a single integrated punch operation. The die set includes both a punch component for removing material and a forming component for shaping the wire cross-section, allowing both operations to occur simultaneously in one step rather than requiring separate operations and equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The punch component is designed to perform multiple functions: it acts as both a cutting tool for removing material to form the grid pattern and as a forming tool for shaping the wire cross-section. This multi-functional design eliminates the need for separate deformation equipment and reduces the number of unit operations required.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If a single punch operation is used to form the grid, then device complexity is reduced, but paste adhesion is insufficient

Engineering Contradiction:

Improveequipment and unit operationsVSAvoidpaste adhesion

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent combines the punching operation and the wire cross-section deformation operation into a single integrated punch operation. The die set includes both a punch component for removing material and a forming component for shaping the wire cross-section, allowing both operations to occur simultaneously in one step rather than requiring separate operations and equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The die set is pre-configured with specific geometric features that automatically deform the wire cross-section during the punching operation itself. The punch component includes forming surfaces that shape the wire as it is being cut, ensuring the desired non-rectangular cross-section is achieved without requiring subsequent deformation steps.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If material is punched from a strip to form a grid with rectangular cross-section wires, then the process is simple, but paste adhesion is insufficient

Engineering Contradiction:

Improveprocess simplicityVSAvoidpaste adhesion

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies a localized deformation to the wire cross-section at specific locations where paste adhesion is critical. The forming component of the die set creates non-rectangular cross-sections (such as oval or rounded shapes) only in the regions that will contact the paste, while maintaining the overall grid structure and rectangular features where mechanical strength is prioritized.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The die set is pre-configured with specific geometric features that automatically deform the wire cross-section during the punching operation itself. The punch component includes forming surfaces that shape the wire as it is being cut, ensuring the desired non-rectangular cross-section is achieved without requiring subsequent deformation steps.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10601025B2Single punch method of making battery plates for lead-acid batteries

Publication Date: 2020.03.24 STRYTEN ENERGY LLC

AI summary

A method of making battery plates for lead-acid batteries includes providing a strip of material comprising lead; and punching material out of the strip to form a grid comprising wires having a non-rectangular cross-sectional shape by utilizing a die set comprising a plurality of male die components and female die components, wherein each of the male die components comprises a first portion having a first cross-sectional shape and a second portion having a second-cross sectional shape. A single punch of the material creates a hole in the material and also forms the periphery of the hole.