Continuous Lead Foil Casting for Bipolar Battery Current Collectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The commercial mass production of thin foils for use as current collectors in bipolar batteries is inefficient, and the manufacturing of lead grids with desired mechanical strength, corrosion resistance, and paste adhesion remains a challenge.
Innovation Solution
A machine and method for continuously casting strips of connected bipolar battery foils or grids using a mold ring with a runner system and a movable belt, which facilitates the delivery and solidification of liquid lead, allowing for the production of foils and grids with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to manufacture thin foils for current collectors, then production efficiency is low, but the complexity of the casting system is increased by continuous casting equipment
Solution Approach 1:
The mold ring is divided into multiple independent foil molds arranged circumferentially, each capable of forming individual foils. This segmentation allows parallel production of multiple foils simultaneously, dramatically increasing productivity while maintaining a compact system structure.
Solution Approach 2:
The continuous casting process enables uninterrupted production of battery foils through continuous movement of the mold ring and belt system. Liquid lead is continuously supplied, cast, and solidified in a continuous manner, eliminating batch processing interruptions and maximizing production efficiency.
2Loss of time
If conventional batch casting is used, then equipment simplicity is maintained, but production time is increased
Solution Approach 1:
The system maintains continuous operation with the mold ring rotating constantly, liquid lead flowing continuously through the runner system, and the belt moving uninterrupted. This eliminates the start-stop cycles of batch processing, reducing production time while increasing throughput.
Solution Approach 2:
The runner system is designed to pre-position and distribute liquid lead to multiple mold cavities simultaneously before casting begins. This preliminary distribution ensures all molds are ready for continuous casting, minimizing preparation time and maximizing production speed.
3Strength
If standard casting methods are used for battery grids, then manufacturing simplicity is maintained, but mechanical strength and corrosion resistance are insufficient
Solution Approach 1:
The foil molds incorporate specific design features such as protrusions and depression molds that create localized structural variations in the cast foils. These local quality modifications enhance mechanical strength and corrosion resistance in critical areas without requiring complex overall manufacturing processes.
Solution Approach 2:
The casting process controls parameters such as cooling rate, mold temperature, and lead alloy composition to optimize the microstructure of the cast foils and grids. By adjusting these parameters, the system achieves superior mechanical properties and corrosion resistance while maintaining manufacturing efficiency.
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
The solution enables the efficient production of bipolar battery foils and grids with improved mechanical strength, corrosion resistance, and uniform grain size, addressing the challenges of existing manufacturing methods.
Implementation Method 1
Liquid lead delivered to the mold cavity by way of the runner system flows between the face of the movable belt and the mold cavity of the mold ring
Implementation Method 2
The mold ring has a mold cavity that resides at a cylindrical outer surface of the mold ring. The movable belt has a face that is situated in general confrontation with a circumferential region of the mold cavity
Data Source
AI summary
Equipment and a machine and a process for continuously casting strips of battery foils and/or strips of battery grids. The battery foils and grids are composed of lead or a lead alloy material. The foils, in particular, can be employed as current collectors in bipolar batteries. The machine, per an implementation, has a mold ring, a movable belt, one or more rollers, and one or more shoes. The mold ring rotates and has a mold cavity. The mold cavity can establish foil molds or grid molds. The movable belt moves about the roller(s) with a face in confrontation with the mold ring. The shoe(s) urges the movable belt into engagement with the mold ring. Liquid lead is delivered to the mold cavity adjacent the location in which the movable belt engages the mold ring amid use of the machine.