Lead Battery Case with Horizontal Cell Orientation
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Solution Overview
Problem
Conventional lead battery case systems with a 2x3 compartment arrangement lead to acid stratification, reduced capacity, and shorter service life due to vertical cell orientation, increased material costs for thicker sidewalls, and complex cabling issues prone to short circuits.
Innovation Solution
A one-piece, box-shaped cell housing with parallel sidewalls and internal division planes forming compartments for horizontal cell orientation, reducing acid stratification, minimizing material usage, and simplifying cabling with terminal feed-throughs and gas vents for improved safety and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cells are arranged vertically with terminals on the same side, then terminal access is simplified, but acid stratification occurs leading to reduced capacity and service life
Solution Approach 1:
The patent transitions from vertical cell arrangement to horizontal cell arrangement, fundamentally changing the spatial dimension of battery construction. This dimensional shift allows terminals to be positioned at opposite ends of the battery while maintaining easy accessibility, and eliminates acid stratification by preventing vertical acid migration, thus resolving the contradiction between operational ease and reliability.
2Volume of stationary object
If a 2x3 compartment arrangement is used, then all cells can be housed in a compact case, but thicker sidewalls are required increasing material costs
Solution Approach 1:
By arranging cells horizontally instead of vertically in a 2x3 grid, the patent redistributes the spatial requirements of battery components. This allows for a more efficient use of case volume with reduced wall thickness requirements, as the horizontal layout naturally provides better structural support distribution, thereby reducing material costs while maintaining compact form factor.
3Reliability
If cells are arranged horizontally with terminals at opposite ends, then acid stratification is minimized improving capacity, but cabling becomes more complex
Solution Approach 1:
The patent merges the positive and negative terminals of adjacent cells into common terminal groups positioned at opposite ends of the battery. This consolidation reduces the number of individual connections required, simplifying the cabling system while maintaining the horizontal cell arrangement that prevents acid stratification and maximizes battery capacity.
Data Source
Figure 1a~1b
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AI summary
The present invention relates to a case System for lead batteries. The case System comprises of a one piece, essentially box shaped cell -housing part with at least 4 sidewalls enclosing an interior volume. At least one division plane divides said interior volume, such as to form a plurality of compartments. Each of the compartments is adapted for storing an electrical cell. The case System further comprises an access wall part with electrical conductor openings or terminal feed throughs and at least one fluid Channel opening. Furthermore the case System comprises a closure wall part for sealing off said casing System. Each of the at least one division planes is essentially perpendicular to the same two opposite side walls of the essentially box shaped cell housing. The present invention further relates to a lead battery and a battery rack incorporating the above described advantageous case System. The electrode plates may have a horizontal orientation.