Lead Alloy Electrode Foil for Thin Battery Layer Stability
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Solution Overview
Problem
Reducing the thickness of the electrode lead layer in lead storage batteries while preventing foil extension, positional deviation, wrinkles, or breakage during manufacturing, which decreases productivity.
Innovation Solution
A lead alloy with a half-width ratio of the (311) diffraction peak in X-ray diffraction analysis 1.4 or more times that of pure lead, maintaining high dislocation density to resist extension and deformation, allowing for thinner electrode lead layers without wrinkles or breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the electrode lead layer is reduced to efficiently use internal battery volume, then the battery energy density is improved, but the foil extends and deforms during manufacturing causing positional deviation and wrinkles
Solution Approach 1:
The patent changes the material parameters of the lead alloy by controlling the crystal grain size to 5 μm or less and adjusting the alloy composition (Sn: 0.03-3 mass%, Ca: 0.003-0.03 mass%, Al: 0.003-0.03 mass%). These parameter changes increase the strength and reduce the延展性 of the foil, preventing extension and deformation during manufacturing while enabling thinner designs.
Solution Approach 2:
The patent creates a composite lead alloy material combining multiple elements (Pb-Sn-Ca-Al) with specific compositional ratios. This composite material achieves both the required mechanical strength to prevent foil deformation and the electrical conductivity needed for battery operation, resolving the contradiction between thinness and manufacturability.
2Weight of moving object
If the thickness of the electrode lead layer is reduced, then the battery weight is decreased, but the foil becomes more susceptible to breakage and wrinkles during rolling
Solution Approach 1:
The patent changes the microstructural parameters of the lead alloy by controlling crystal grain size to 5 μm or less through specific alloying and processing. This fine-grain structure increases the strength and ductility of the foil, enabling it to maintain integrity at reduced thicknesses and weights while resisting breakage during manufacturing.
Solution Approach 2:
The patent applies local quality control by optimizing the alloy composition and crystal grain structure specifically in the electrode lead layer foil. The controlled distribution of alloying elements (Sn, Ca, Al) creates localized strengthening that prevents breakage and wrinkles in critical areas while maintaining overall foil flexibility and electrical performance.
3Ease of manufacture
If conventional lead alloy compositions are used, then the manufacturing process is simple, but the foil extends and deforms when force is applied during electrode manufacturing
Solution Approach 1:
The patent modifies the compositional parameters of the lead alloy by adding controlled amounts of Sn (0.03-3 mass%), Ca (0.003-0.03 mass%), and Al (0.003-0.03 mass%). These parameter changes fundamentally alter the material's dimensional stability and resistance to extension, while the manufacturing process remains relatively simple through conventional casting and rolling techniques.
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
Enables the manufacture of lead storage battery electrodes and batteries with high productivity by preventing foil extension and deformation, efficiently using internal battery volume and maintaining structural integrity.
Implementation Method 1
maintaining high dislocation density to resist extension and deformation
Implementation Method 2
a half-width ratio of the (311) diffraction peak in X-ray diffraction analysis
Implementation Method 3
the half width of a (311) diffraction peak in a diffraction chart obtained by analyzing the lead alloy by an X-ray diffraction method
Data Source
AI summary
A lead alloy that is difficult to cause extension even when force is applied to the lead alloy is described. The half width of a (311) diffraction peak in a diffraction chart obtained by analyzing the lead alloy using an X-ray diffraction method is 1.4 or more times the half width of a (311) diffraction peak in a diffraction chart obtained by analyzing powder of pure lead using the X-ray diffraction method.